A Transmitter is a device that converts the signal produced by a

sensor into a standardized instrumentation signal such as 3-15

PSI air pressure, 4-20 mA DC electric current, Fieldbus digital
signal etc., which may then be conveyed to an indicating device, a
controlling device, or both.

What is a Pressure Transmitter ?

A pressure transmitter is a transducer that converts pressure into

an electrical signal.

It outputs both analog and digital signals corresponding to the

pressure.

A pressure transmitter measure three phenomena : Differential

Pressure,Gauge Pressure,Absolute Pressure.

The most common and useful industrial pressure measuring

instrument is the differential pressure transmitter.

This instrument senses the difference in pressure between two

ports and produces an output signal with reference to a calibrated
pressure range.

Pressure Transmitter Applications

Pressure transmitters are commonly used to measure the pressure

inside of industrial machinery or in industrial processes.They are
used in various industries such as oil and
gas,refining,chemical,pharmacy and so on.

Pressure transmitters are widely used in industry to measure

flow,level and pressure.
It can monitor pressure drop across valves and can be used to
monitor pump control.

DP flow measurement is one the most common applications for

differential pressure transmitter.

By measuring the difference in fluid pressure while the fluid flows

through a pipe,it is possible to calculate the flow rate.For differential
pressure flow measurement,a primary and secondary element are
used.The primary element is designed to produce a difference in
pressure as the flow increases.There are many different types of
primary element.The most common being the orifice
plate,venturi,flow nozzle,and pitot tube.

The secondary element is the differential pressure transmitter.It is

designed to measure the differential pressure produced by the
primary element as accurately as possible.In particular,it is
important that the differential pressure measurement is not affected
by changes in the fluid line pressure,temperature or other
properties such as ambient temperature.

A good DP transmitter will ensure that the differential pressure is

measured accurately,regardless of other changing parameters and
will reliably transmit signal to represent the differential pressure.

The DP flow transmitter output signal may also include square root
extraction for flow calculation,although it is common for this
function to be handled in control system.

In a typical control loop,the transmitter signal is fed to the controller

where output is used to regulate the flow rate through a control
valve.

Differential Pressure transmitter can also be used for measuring

tank level by measuring the pressure.

The transmitter is installed at the bottom of the tank whose level is

to be detected.

In case of a sealed tank,a transmitter with capillaries measures the

differential pressure between the upper side and the bottom side.
The liquid inside the tank at the bottom creates pressure which is
higher than the pressure at the top.The difference in
these pressures can be used to calculate the level.

In case of an open tank,the transmitter measure the differential

pressure between the liquid inside the tank and reference
atmospheric pressure.

In typical control loop,the transmitter signal is fed to the controller

whose output is used to regulate the tank level through a control
valve.

4-20 mA Transmitter Wiring Types

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.

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.
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.
How does adding a 250-ohm resistor make
HART work?
Sometimes there’s a problem getting a loop powered HART instrument to communicate when it’s on the
bench top, but it communicated fine when wired in the field. Why is that? It’s probably because when it’s
on the test bench, the loop doesn’t have enough resistance for the HART signal to be ‘seen’ by the HART
handheld or HART modem.

In a bench test situation, power is applied to the transmitter, so it fires up and runs fine. But there’s
no analog input in the loop as there is when the transmitter is wired in the field. What’s missing is the
dropping resistor on the analog input that supplies the loop resistance needed for the HART signal to
develop.

4-20mA loops transmit the signal as electrical current (milliamps), but the receiver device with the analog
input ‘reads’ the signal as a voltage, whether the signal to be read is analog or HART. The current signal
becomes a voltage drop when the current passes through a resistor (Ohms Law).

The HART signal is a 1200 baud signal superimposed on the loop’s 4-20mA DC signal. 1200 baud is a
relatively high frequency signal compared to the 4-20mA DC current signal.

Some minimum loop impedance is needed so that the HART signal can be ‘seen’ or ‘read’ by a HART
master, like a HART communicator or HART modem. The analog inputs on the receiver device (DCS,
PLC, RTU, PAC, controller, recorder, or indicator) have a precision shunt resistor installed at each analog
input. It is usually 250 ohms, but not always.

The voltage (IR) drop needed for HART communications is produced by the resistance at the loop
receiver’s analog input. The loop’s wire resistance contributes very little resistance. When a transmitter
is powered up with just a DC power supply there isn’t enough voltage from the 1200 baud HART signal
for the for the HART master (handheld communicator or a HART modem) to ‘see’ the signal. The
internal resistance of a DC power supply is insufficient to develop a HART voltage drop, and its filter
capacitors act as a low pass filter to squelch the relatively high frequency 1200 baud HART signal.

In the absence of a receiver device with its analog input resistance being part of the loop, there is
insufficient loop resistance for a HART master device to ‘see’ the FSK HART signal and HART
communications fails.
The good news is that a resistor can be inserted into the loop and the HART signal will develop a voltage
drop and the HART master can ‘see’ the HART signal.

The HART Foundation’s website has a technical specification that states that the minimum loop
resistance needed is 230 ohms. A 250 ohm resistor is commonly used because 250 ohm resistors work
for that purpose and are typically available in the instrument shops where these types of bench tests are
done. The resistor need not be a precision resistor.

Connect a 250 ohm resistor with alligator clips, like this one, to a wiring terminal and a loose wire in a
loop circuit to test HART communications at the benchtop.

HART handheld communicators (275/375/475, Meriam 5150) usually have a pair of banana jacks on the
handheld for the purpose of connecting a plug adapter with a 249 or 250 ohm resistor to provide the
needed loop resistance. If a HART communicator or HART modem fails to establish communications, it is
advisable to insert a 250 ohm resistor in series in the loop (or use the banana plug adapter with a
communicator).