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 proportional–integral–derivative (PID) controllers, supervisory control and data acquisition (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" Highway Addressable Remote Transducer (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.
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.
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.
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An industrial control system (ICS) is an electronic control system and associated instrumentation used for industrial process control. Control systems can range in size from a few modular panel-mounted controllers to large interconnected and interactive distributed control systems (DCSs) with many thousands of field connections. Control systems receive data from remote sensors measuring process variables (PVs), compare the collected data with desired setpoints (SPs), and derive command functions that are used to control a process through the final control elements (FCEs), such as control valves.
An industrial process control or simply process control in continuous production processes is a discipline that uses industrial control systems and control theory to achieve a production level of consistency, economy and safety which could not be achieved purely by human manual control. It is implemented widely in industries such as automotive, mining, dredging, oil refining, pulp and paper manufacturing, chemical processing and power generating plants.
A distributed control system (DCS) is a computerised control system for a process or plant usually with many control loops, in which autonomous controllers are distributed throughout the system, but there is no central operator supervisory control. This is in contrast to systems that use centralized controllers; either discrete controllers located at a central control room or within a central computer. The DCS concept increases reliability and reduces installation costs by localising control functions near the process plant, with remote monitoring and supervision.
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