Module 1

1. Objective
1.1 To known the components or devices in this Process Instrumentation Trainer.
1.2 To understand 4-20 mA current loops.
1.3 To become familiar with the programming and operation of the display devices
provided with this trainer.
1.4 To become familiar with the manual set up of the level sensor and calibrate the
sensor.
1.5 To became familiar with temperature sensor and their application.

2. Theory

2.1 Introduction components and devices.

38-541-MV – Manual Valve

A multi turn manual valve with approximately 8 turns from fully open to fully closed. It is
used for manually setting the flow. This type of valve is a Bonnet needle valve and has a
fairly linear relationship between orifice opening and flow.

38-541-PFS – Pulse Flow Sensor

A transducer, which consists of a turbine in the water flow, whose rotational speed is
converted into a pulse train. The frequency of the pulse train is approximately proportional
to the flow rate.
38-541-OB – Orifice Block

The Orifice block provides an aperture of exact dimensions for the water to flow through. It
is used to investigate the relationship between the flow rate and the pressure difference in
the fluid the orifice.

38-541-PT – Pressure Transmitter

This device is constructed of two pressure transmitters that can be used independently, or
to measures the difference in pressure between its two apertures. It provides, after
calculation, a method of measuring fluid flow without interfering with the flow.
38-541-CPC – Current/Pressure Converter

The Current to Pressure converter (I/P) is an electro-pneumatic transducer that converts an

electrical signal to a proportional pressure output. The controlled pressure is set by a 4-20
mA input source. It must be supplied with a pressurized air supply of at least 20 psi or 5 psi
more than the maximum controlled pressure it is require to deliver. It is used to control
valves, such as the Control Valve 38-541-CV, which rely on air pressure to control the
passage of process fluid through the valve.

38-541-TT – Temperature Transmitter (SMART)

The temperature transmitter is used to accurately measure temperature. The unit normally
receives input from a Resistance Temperature Detector (RTD) or a thermocouple. It is
configured by the use of software from the Programming Equipment 38-541-PE. The
relationship between the output from resistance temperature detectors and thermocouples
and temperature is well documented and measured according to International Standards.
38-541-PD – Programmable Display – (3 supplied)

This universal display may be programmed manually to show data in any desired units of
measurements and to set the span and zero over which the quantity is to vary.
The expected input is a current source of 4-20 mA. To relate this to a measurable quantity
the display must be set up by the use of three pushbuttons on the reverse side of the
display. At the simplest level I can for example, be programmed to convert 4-20 mA input to
display flow rates in litres/minute, degrees C, or volume in the process tank in litres.

38-541-FT – Frequency Transmitter (SMART)

This display shows the frequency of the dc pulses from the pulse flow sensor. It may be set
by software in the PC to show frequency, and with the use of the Programmable Display,
litres per minute. If the output from a pulse sensor is not linear with respect to flow, then a
series of measurements can be taken calibrating the pulse flow sensor against known flow
rates, so that the displayed flow rate shows the actual flow.
38-541-CLR – Current Loop Resistors

24 V dc voltage sources are provided for devices that require a current source to operate. To
provide this current source the voltage must be connected to the device in series with a
250R resistor, which is the Industry Standard. Generally this configuration is used for
devices, which provide a 4-20 mA output – for example the 38-541-LP Level Probe.
There are two additional 250R resistors that are located on the controls section of the
training unit.

38-541-FM – Flow meter (2 supplied)

A visual gauge for measuring flow rates from about 0.4 to 4.4 litres/min. The water flow
displaces a metal marker whose position in the glass column indicates the flow rate. The
direction of low is always from bottom to top and the higher the marker rises in the column
the greater the rate of water flow.
38-541-LP – Level Probe

A level indicator positioned in the process tank which produces a 4-20 mA current
proportional to the level of water in the tank. It may be calibrated so that 4 mA and 20 mA
represent water depths corresponding to 0 litres and 8 litres respectively, on the volumetric
scale on the front of the process tank.

38-541-CV – Control Valve

This valve uses Air pressure To Open and a spring to close (ATO), air being fed to the
underside of the diaphragm, The unit requires 3 to 15 psi, which corresponds to the valve
being fully closed at 3 psi, and fully open at 15 psi with a linear range in between.
Note. There are alternative forms of operation, Air To Close spring open (ATC), and air to
open and close.
38-541-PG – Pressure Gauge 0-2 bar (0-30 psi)

The pressure gauge 38-541-PG is a general purpose industrial Bourdon tube pressure gauge,
displaying pressure in the range 0-2 bar. It is suitable for use with water or air systems with
pipe adaptors as supplied.

38-541-TP – Temperature Probes

These devices are usually inserted into the top of the process tank. They can also be
inserted into the sump tank for alternative temperature measurement.

38-541-UT – Universal Transmitter (SMART)

This is an extremely versatile transmitter that can be programmed to perform numerous
tasks with inputs from different types of temperature sensors and also 4-20 mA signals. The
device can be set to perform mathematical operations.
It has two input channels and two output channels that can be configured to cover the
majority of the requirements for processing and displaying the process variables.

38-541-SV – Solenoid Valve

The solenoid valve provides a means of opening and closing fluid flow by using a 24 V
voltage signal. The valve can be switched manually, permanently on or pulsed, or through
the use of a external contact closure such as that provided on the Frequency Transmitter
38-541-FT. In application the solenoid may be used to stop process fluid flow, provide a
secondary flow or to bypass an existing flow route.

Locking Tool
2.2 4-20 mA Current Loops

Signalling is necessary in controlled installations.

Consider, for example, that a controller is situated in a control room and a control valve and
its transmitter are mounted locally to a tank. In order for the controller to send new
instructions to the control valve (to alter the flow rate or the level in the tank for example),
it is necessary to be able to signal to the device.
A great advantage with signalling is that standard signals can be used, which means that
instruments can be bought from different suppliers and still remain compatible.
Electrical signals in a control system are usually direct current (dc) and can be divided into
current and voltage.
Current is used for signalling over long distances and voltage is used for shorter distances.
One great advantage of current over voltage is that the current in a circuit is constant
throughout its length, whereas voltage will vary depending on any resistance it my
encounter.
Nowadays. Computers are increasingly taking over control room instrumentation and there
has been a corresponding drop in the use of voltage signalling.
Current signalling is very often used between transmitters, controllers and signal
transducers.

This shows a simple signaling arrangement between a control room and a transmitter.
From an electrical point of view, a transmitter can be regarded as a current generator
situated in a remote control room, which in our case is powered by the services section of
the 38-023 Training Unit. This means that it is the transmitter that determines the current
independently of the line resistance.

However, Ohm’s law still applies :

𝐸
Imax =
R
Where E is the voltage supplied by the services panel (in the control room) and R is the line
resistance.
Industry standard current signals are 4-20 mA and 0-20 mA.
A transmitter for a 4-20 mA signaling loop works as follows: The transmitter draws about 3
mA in order to work itself. The voltage required at the transmitter’s terminals is usually of
the order of 12-15 Vdc
The diagram in Figure 2.2.1 shows a typical transmitter arrangement.

Figure 2.2.1

The sensing device converts a physical quantity (eg, level, flow rate, pressure, etc.) into a
current signal. The current sensor compares this with the outgoing current. The difference is
amplified and is used to alter the setting of the current generator.
The current signal changes in proportion to the output from the sensing device.
Signalling between the transmitter and a number of instruments sited in the control room
often requires a current-to-voltage conversion. This takes place in the instruments by
passing the current through their resistors.

This multiple instrument signaling is shown below.

Figure 2.2.2
The voltage levels obtained are then used internally by the instruments, which are based on
analogue electronics.

Voltage signals also occur in computer equipment, where analogue signals are processed
firstly using current-to-voltage conversion and then Analogue-to-Digital (A/D) conversion.

The most common signal range is 0-10 V, but 1-5 V and 2-10 V are also used. Voltage
signaling is uncommon between transmitters and controllers within the process industries.
There are exceptions however, particularly in rotational speed control motors, where the
output signal from the tacho-generator is a dc voltage.

The most commonly used current signals are 4-20 mA.

Advantages
- 2-wire connection system; ie, signaling and power supply in the same leads maybe
used.
- The floating zero point (4 mA) means :
◦ Simple to calibrate zero point because the lowest current can be
reduced below 0%
◦ Simple to provide transmitter fail-safe system.
𝐸
◦Current signal is independent of line resistance, however, Imax = still
R
applies.
◦ Good noise immunity as a current loop circuit has low resistance.
Disadvantages
- Resolution of only 16 mA.

Considering the above points, the 4-20 mA current loop is used in the experiments you will
be going in this assignment.

2.3 4-20 mA Loop Programmable Display

The ‘DM700/I’ is a loop-powered process indicator with a 4-digit 7-segment red LED display.
The ‘DM700/I’ accepts a 4-20 mA input signal and displays the associated process variable.

The instrument configuration setting are selectable via a simple to use menu system, which
is navigated by the use of three push-button keys located on the rear of the display. This is
described in detail later.

IMPORTANT:
The maximum current rating for this device is 90 mA for 1 minute. Exceeding
this value will destroy the device. Fuse protection of the current loop to which
this device is connected is highly recommended.
Note:
The two 4-20 mA loop power sources fitted to the 38-540-PIS have a
maximum output 70 mA each (sufficient to run 3 loop powered circuits each).
Some of the considerations that must be given when installing this piece of equipment are:
a. This unit must only be series connected into a 4 to 20 mA current loop.
b. Ensure the instrument is installed with adequate protection against the environment.
IP67 rating must be maintained.
c. Avoid installing the equipment close to sources of extreme temperature and electrical or
electromagnetic interference.

Wiring and switch location (viewed looking a connector)

Figure 2.3.1

2.4 Capacitor Level Sensor & Transmitter

Capacitance is the ratio of the electric charge on one of a pair of conductors to the potential
difference between the conductors. A capacitance level probe determines the level of liquid
in a column or receiver by measuring the combined capacitance of the liquid and gas (vapor)
in the column. See the figure below. As the liquid level rises in the column, the total
capacitance value increases. This increase is measured by the controlling electronic system
and an output control signal is created. The following simplified formula can be used.

Capacitance = Dielectric constant x (Area of the plates ÷ Distance between plates)

The dielectric constant is the ability of a material to store electrostatic energy for a voltage
potential, or difference. Since it is a constant, it does not change. Liquid refrigerant will
always have one constant, and vapor will always have a different a constant. Looking at the
above formula, the distance between the plates also does not change. This is because the
rod and the column (the plates) do not move. Therefore, the only variable in the above
formula is the area of the plates in the liquid. (The capacitance of vapor is very small
compared to the capacitance of the liquid.) This area changes as the liquid rises or falls in
the column. Therefore, the total capacitance changes approximately proportional to the
liquid rise or fall in the column. The liquid level can then be determined electronically by the
change in capacitance.

Vapour 1.0
Ammonia 15.5
Oil 2.0
R22 6.1
Water 70

The values given are

approximate. Values are for
comparison purposes only
and should not be used for
engineering calculations.

2.5 temperature sensors

A brief description of the two types of temperature sensors supplied with the training unit
follows.

2.5.1 The Platinum Resistance Thermometer Sensor, PT100

Produces a change in resistance of a platinum element when the temperature changes.

When supplied with a constant current, the measured voltage will be proportional to the
resistance by Ohms law.
Resistance Temperature Detectors or RTDs for short, are wire wound and thin film devices
that measure temperature because of the physical principle of the positive temperature
coefficient of electrical resistance of metals. The hotter they become, the higher the value
of their electrical resistance.
They, in the case of Platinum known as PRTs and PRT100s, are the most popular RTD type,
nearly linear over a wide range of temperatures and some small enough to have response
times of a fraction of a second. They are among the most precise temperature sensors
available with resolution and measurement uncertainties of ± 0.1 °C or better is possible,
when used in special designs.

2.5.2 RTD Error Sources

The lead wires used to connect the RTD to a readout device can contribute to their
measurement error, especially when there are long lead lengths involved, as often happens
in remote temperature measurement locations. Those calculations are straight forward and
there exist 3-wire and 4-wire designs to help minimize or limit such errors, when needed.
Often the lead error can be minimized through use of a temperature transmitter mounted
close to the RTD. Transmitters convert the resistance measurement to an analog current or
serial digital signal that can be sent long distances by wire or RF to a data acquisition or
control system and/or indicator.

3. Equipment required
- The Process Instrumentation Services unit 38-540-PIS.
- A general purpose multimeter.
- Connection Leads
- Programmable Loop Display 38-541-PD
- Capacitive Level probe 38-541-LP
- Temperature Transmitter 38-541-TT

4. Practical

Practical 1.1 Measuring Current Source of the Training Unit

Step 1 : Set Multimeter to current range and connect to the training unit (see figure 1.1.1)

Figure 1.1.1
Step 2 : Turn Control knob of current source to anticlockwise until it reach minimum, check the
current. Turn Control knob to the clockwise until reach maximum, check the current. Write results to
Table 1.1.1.1.

Min. Current (mA) Max. Current (mA)

Table 1.1.1

Step 3 : Make connection according to figure 1.1.2. Check the minimum and maximum current in
the loop (repeat step 2 and 3) and write the result on table 1.1.2. Calculate minimum and maximum
voltage through 250 Ω resistor using current result from step 6. Write results on Table 1.1.3

Figure 1.1.2

Step 4 : Connect the current source only with 250 Ω resistor and take off multimeter. Turn the
control knob to minimum and check the voltage of current source. Turn the control knob to
maximum and check the voltage of current source. Write result on table 1.1.3. Compare between
voltage from calculated and measured.
 Figure 1.1.3

Min. Current (mA) Max. Current (mA)

Table 1.1.2

Min. Voltage (V) Max. Voltage

From
calculating
From
measuring
Table 1.1.3

Step 5 : Connect current source to 500 Ω resistor like step 3. Repeat step 3, write current result on
table 1.1.4. and calculated voltage on table 1.1.4.

Step 6 : Plug out multimeter from loop (see figure 1.1.3), then repeat step 4. Write result on table
1.1.5 and compare between voltage calculated and measured.

Min. Current (mA) Max. Current (mA)

Table 1.1.4

Min. Voltage (V) Max. Voltage

 From
calculating
From
measuring
Table 1.1.5

Practical 1.2 Setting DM700/1 Programmer Display

Step 1 : Attach DM700/1 Programmer Display on panel (see Appendix A). Connect it to voltage
source and 250 Ω resistor from training unit (see figure 1.2.1 ). Unscrew DM700/1 Programmer
Display case to configure it .

Figure 1.2.1

Step 2 : To make it to show the mA for electrical value of 4-20mA, the buttons (behind the display
programmer) need to pressed in the following order: ENT (top & bottom right) >> CYC >> LIN >> INC
>> NONE >> ENT >> SCAL >> INC >> StNd >> ENT >> ENLO >> INC >> 0 (zero) >> ENT >> ENHI >> INC
hold to 16 >> ENT >> OFSt >> INC >> hold to 4 >> ENT >> dECP >> INC >> select two decimal places >>
ENT >> PASS >> INC >> 0 (zero) >> ENT >> tOUT >> INC >> 60s (seconds) >> ENT >> LIN (start of cycle)
>> ESC (top left and top right) >> return ‘runtime’. (see figure 1.2.2 for setup buttons)

Figure 1.2.2
Step 3 : Re-work connections shown in figure 1.2.2. Turn the 4-20mA output knob into minimum,
write number shown on display programmer on table 2.1.1. And turn the knob into maximum, write
number shown on display programmer on table 2.1.1.

Figure 1.2.3

Min. scale Max. scale

Table 1.2.1

Step 4 : Re-configure the device as % or oC that can read 0 to 100, then write the order in the blank

………………………………………………………………………………………………………………………………………………………
………………………………………………………………………………………………………………………………………………………
………………………………………………………………………………………………………………………………………………………
………………………………………………………………………………………………………………………………………………………
………………………………………………………………………………………………………………………………………………………

Step 5 : Repeat step 3 , then write the result on table 1.2.2

Min. scale Max. scale

Table 1.2.2

Practical 1.3 Capacitive Level Sensor and Transmitter

Step 1 : Make connection according to figure 1.3.1. Make sure the Programmer Display configure as
mA. Unscrew the blue plastic of the level probe.
 Figure 1.3.1

Figure 1.3.2

Step 2 : Open valve A under the process tank and drain the tank. Close valve A, open valve B. Turn on
the pump power supply, then fill the process tank about 1 litre by turn the pump control clockwise.
Open valve A until the bottom of meniscus is at zero mark on the scale front of the process tank.
Adjust ZO (Zero) pot until the PD (Programmer Display) shows 4 mA.
Step 3 : Open valve B, fill the process tank to level about 8 mm above the 8 litre. Open valve A until
the bottom of meniscus is at 8 litre on the scale, then adjust SP (Span) until the PD shows 20mA.

Step 4 : Open Valve A until the water level in tank is at 7 litre, read number in the PD, write in table
1.3.1. Write number shows on PD after water in process tank decrease 1 liter on table 1.3.1. until the
level become 0. Then draw a graph from data in table 1.3.1 on figure 1.3.2. Correlate between
current from the level probe and the water level.

Level mA Ideal mA

20

18

16

14

12

10

Table 1.3.1

Step 5 : Configure PD to show volume in process tank (show 0 to 8). Configure another PD to show %
(show 0 - 100). Make connection according figure 1.3.3. Fill the process tank to a level about 8 litre.
Write numbers shows on both of PD on table 1.3.2. Compare results from both of PD and scale on
process tank.
 Figure 1.3.3

Level from PD (L) Percentage (%) Level from scale

on process tank
(L)

Table 1.3.2

Practical 1.4 Temperature Sensors and Transmitters

Step 1 : Make connection according figure 1.4.1. Don’t connect the temperature transmitter to the
PC. Insert the temperature probe into process tank.

Process tank temperature = …….. o C

Step 2 : Plug out the temperature from process tank and insert it into sump tank. Configure another
PD to show mA. Connect it with PD that used to show temperature. Write numbers shows on both
PD in table 1.4.1.

Step 3. : Prepare stopwatch. Turn on heater, write numbers shows on both PD every 30 second in
table 1.4.1. Do it 4 times. Corelate between current and temperature based on data from table
1.4.1. If heater works until 120 seconds, you must to turn off the heater.

Temperature (oC) Current (mA) Time (second)

30

60

90

120

Step 4 : After 120 seconds. Read numbers show on PD then write in table 1.4.1. Calculate power
that used to heat the water.

P=Q/t

Q = m . c . ΔT

C = 4200 Joule / kg

Initial water water temperature

temperature in in sump tank after ΔT (oC) Q (Joule) Power (Watt)
sump tank (oC) heated (oC)

Table 1.4.2