Signal Conditioning & Process Control Equipment

A brief introduction to common applications.

There are four very broad applications of signal conditioning:

Elimination of Ground Loops and AC Electrical Noise

Ground loops can occur where there are multiple current return paths or multiple connections to earth
ground. Ground loops cause problems by adding or subtracting a noise current or voltage from the
process signal. The measuring system only sees the effected signal and so returns an inaccurate or
unstable reading.
Putting a signal isolator between the earthed devices breaks the galvanic path (dc continuity) between the grounds but
allows the analogue signal through. |In addition common mode voltages (ac continuity) generated by ac noise can also be
rejected leading to an electrically clean, accurate signal being sent to the measuring instrument.

Non-Isolated
Transmitter

Receiver

Ground Loop
____
__

____
__

Earth loops can occur where more than earth ground exists, causing inaccurate signals

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Signal Conversion
As well as providing isolation between input and output signal conditioners are used to change an
incoming signal into the form required by the control or monitoring system. For example a PLC may
require 0-10Vdc input from a field instrument which generates a 4-20mA signal. An isolating signal
converter can be used to both maintain and integrity of the 4-20mA signal whilst also providing an
isolated 0-10Vdc output for the PLC. As well as changing the signal type some conditioners can
linearise the incoming signal from, say a thermocouple and provide an output which is proportional to
temperature. Other linearising functions available are square-root extraction for how measurements
using a pressure drop and linearisation for tank contents where the tank content is not linear with tank
level.

4-WIRE
XMITTER

+
Isolated
4-20mA

0-10v

RECEIVER

____
__

POWER
SUPPLY

____
__

Controller

To change signal levels to those required by control systems

Transmitter Sharing and Signal Boosting

It is quite common for one process transmitter, say a fluid temperature transmitter to be connected to
several different instruments, such as a temperature controller a chart recorder and a DCS. Signal
isolators can be used to generate extra drive capability for an existing loop or to generate an extra
loop, which can be adjusted using zero, and span potentiometers without affecting the existing loop.

Isolated

pH METER

4-20mA

RECORDER
two isolated loops operated from one
transmitter

4-20mA
Isolated
4-20mA

____
__

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DCS

4-WIRE
XMITTER
(into 600
max)

INTEGRATOR
(250)

PID
(250)

4-20mA

____
__
4-20mA
into 583

RECORDER
(250)

220V ac

boosts signal in an existing loop

Bucking Power Supplies

This occurs when an existing loop and the measuring instrument are both attempting to power the
same loop. A suitable isolator will accept power on both input and output and provide isolation
between the two. A typical example would be where a PLC with 24Vdc transmitter excitation needs
to be connected to a transmitter, which is line powered.

4-WIRE
XMITTER

+24

+24
DCS

PROBLEM

____
__

SOLUTION

4-WIRE
XMITTER

24V

24V

4-20mA

____
__

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DCS

4-20mA

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__

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SPECIFYING ISOLATORS
To specify an isolator the following features need to be considered and the appropriate option selected:

Power Source
Choose between a loop powered (2-wire) or line powered (4-wire) instrument. For line powered
instruments select an ac or dc voltage and for loop powered units specify whether the instrument is
input loop powered or output loop powered.

Input Signal Type

The input type is usually pre-determined by plant design and instruments are available for virtually all
process signals, ranging from mA, voltage high level signals through thermocouple and RTD
temperature sensors. A selection guide showing the types of input each device can handle is located
at the front of the product catalogue.

Input Signal Range

For mA and voltage inputs 4-20mA and 0-10V inputs respectively are the most common type.
Thermocouples tend to be used for measuring higher temperatures, in applications where a faster
response is required and, being less expensive than RTD' where sensor economy is of prime
importance. RTDs have a higher accuracy specification and are more stable than thermocouples.
Typical input types are as follows:
4-20mA
0-10Vdc
Type K thermocouple 0-5000C
Pt100 RTD sensor 30
+300C

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SPECIFYING ISOLATORS
Continued

Output Signal Type

The output signal type depends on the final measuring device and its input circuit. The most common
types are 4-20mA current loop and 0-10Vdc voltage outputs.
4-20mA loops provide higher noise immunity and are independent of wire resistance (up to the limit
of loop voltage available).
Voltage outputs can be easier in control panel applications because that can be calibrated without
disconnecting the loop.
Some units feature more than one output. The DUALCON has two, isolated analogue outputs
allowing an instrumentation loop to be easily monitored by two separate measuring devices.
Other units have optional alarm relay outputs for indication of high/low and other alarm conditions.

Isolation Voltage
All Industrial Interface units are isolated to a minimum of 1KV. Typically maximum common mode
voltages on most sites reach a maximum of 120V peak-to-peak.

Accuracy
Typical accuracy requirements are 0.15% greater accuracy devices are available up to the UNICON
with an input accuracy of 0.005%, and a typical overall accuracy (input to analogue output) of 0.04%.

Options
The options available vary from instrument to instrument but the most common one is for an isolated
transmitter supply on 4-wire isolators. This allows a large number of loops to be powered from a
single auxiliary supply but provides input/output and chanel-to-chanel isolation.
Please see individual data sheets for further options.

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INPUTS
dc voltage
ac voltage
dc current
ac current
Potentiometer
Strain gauge
Thermocouple/mV
RTD
Frequency
Multiple I/O
OUTPUTS
dc voltage
dc current source
dc current sink
mV Output
Dual outputs
Relay contacts
Frequency
FEATURES AND OPTIONS
Loop powered
dc powered
ac powered
Isolated I/O
User-Configurable
PC Configurable
Square-Root Extract
T/C Linearisation
RTD Linearisation
Custom Linearisation
Full Maths/Logic
LED Display
Tx Supply Option
Integration
Intelligent Trip
RS232/485 Comms
PID / Timers
Steam Tables
Flow Computing
True RMS
OEM Solution

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FREQCON

MATHSCON

UNICON

INTELLIGENT
PRODUCTS
CHAMELEON

RTD-HEAD

INHEAD

TC-HEAD

4002-ALM

2002-ALM

20-ALM

TRIP
AMPLIFIERS

RMSCON

STRAIN

TWINCON

DAULCON-6,3

TC-TC

ISOCON-3

ISOCON-6

420 SERIES
Loop Powered

ISOCON FAMILY
Isolating Signal Converters

POWER SUPPLIES

Product Selection Guide

TYPICAL APPLICATIONS
420i / V Series of Loop-Powered Isolating Converters
+24Vdc
3

Temp Tx

Isolated
4-20mA

420I
LoopPowered
Isolator

240Vac
Chart Recorder with
Transmitter Supply

240Vac
Telemetry System to
Remote SCADA Package

420i Used to Provide a Second Isolated 4-20mA from A Single Transmitter

Non-Isolated
Temperature
Transmitters

12

10
9

2
6

5
1&4

+24Vdc
Isolated 4-20mA Signal

Isolated 4-20mA Signal

Optional 0V Connection

0V

422Tx Dual Isolating

Transmitter Supply
422Tx Used to Provide 2 Isolated 4-20mA Signals from 2 Non-Isolated Transmitters

420-TW / In-Head Series of Transmitter Isolating Terminal Blocks

4-20mA Source output
from a pH Meter

+24V

4-20mA

4-20mA

Alg I/P 1

420-TW-HL
0-10Vdc signal from a
Valve Positioner

+24V

0-10V

4-20mA

Alg I/P 2

420-TW-HL
+24V

K-Type Thermocouple

4-20mA

Alg I/P 3

420-TW-TC
+24V

High Alarm Pressure Switch

420-DIG-IN
The use of the 420-TW Series eliminates any possibility of stray
earth loops and gives RFI protection

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Dig I/P 1
PLC / DCS
System

TYPICAL APPLICATIONS
ISOCON-6

+24Vdc

Isolated
4-20mA

Temp Tx

+24Vdc

240Vac
Telemetry System to
Remote SCADA Package

240Vac
Chart Recorder with
Transmitter Supply

VCON-HL used to provide an isolated 4-20mA signal from an existing instrumentation loop
Telemetry System

DUALCON-6

Level Transmitter
+24Vdc
PLC

123.4

Input

Isolated 4-20mA
Signals

+24Vdc

DUALCON used to provide complete isolation between 3 devices using the same transmitter

+24Vdc

ISOCON-3
Isolated
4-20mA

Temp Tx

PLC

110 / 240V ac
MVCON-HL used to provide an isolated power supply for a 2 wire transmitter

Excitation

STRAIN-AC
Isolated
4-20mA

Input

PLC

110 / 240V ac

Load Cell

STRAIN-AC used to provide excitation for a 4-wire load cell and an isolated 4-20mA output

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Panel Meter

TYPICAL APPLICATIONS
Digital Comms
+24Vdc

Type K
Thermocouple

PLC

Isolated 4-20mA Sink

High Temp Alarm
Sensor Fail Alarm

+24Vdc

UNICON-TRIP used to linearise and isolate the signal from a K Type Thermocouple and provide an isolated
4-20mA output with High Temperature and Sensor Fail trip outputs

Digital Comms
Isolated 4-20mA Source
PLC
10Hz - 1MHz

+24Vdc
FREQCON used to convert 10Hz to 1MHz Frequency signal from an inductive pick up and provide an
isolated 4-20mA output

Digital Comms

Loop-Powered
Panel Meter
4-20mA

Flow Meter
1

12.5

Flow Meter
2

(Flow1-Flow2)>SP
Integrate (Flow1-Flow2)

+24Vdc

MATHSCON-TRIP used to provide an isolated 4-20mA signal of the difference between flow and return
meters on a burners oil line. The unit also gives a pulse totalised output of net usage and a high alarm of
net usage.

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TYPICAL APPLICATIONS
Chart Recorder

+24Vdc
3
Temp Tx
4

1
High Alarm
Indicator

20-ALM
240Vac
20-ALM used to provide a High Alarm output from an existing 4-20mA Temperature Loop

High Alarm

Type K
Thermocouple

Low Alarm
24Vdc
2002-TC
2002-ALM-TC used to provide High and Low Alarm relay outputs from a type K Thermocouple

Ultrasonic Level
Transmitter

High Alarm

To Pump Starter
Contact

Low Alarm

056

Retransmitted 420mA Signal

110Vac
4002-ALM-HL-LED
4002-ALM-HL-LED used in latching mode to start pump when high level is reached and stop pump when the low
level is reached. The LED display indicates the actual level in the tank and the two setpoints

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TYPICAL APPLICATIONS
Panel Meter
+24Vdc 1

124.3C

10

L
240Vac

Temp Tx
3

4-20mA

12

PSU-3

PSU-3 used to power a Temperature Transmitter Loop from a 240Vac Supply

+
Clean Isolated 24Vdc
Supply at 625mA for
Instrumentation Bus

Existing 24Vdc
Supply
-

DC-15
DC-15 used to provide a clean isolated 24Vdc for the Instrumentation side of a Motor Control
Centre

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