wp_EDDL loop check

2015-08-22 19:18:00

Intelligent Device Management Tutorial: Loop Check

The term loop can refer to the entire control loop from primary element (sensor) through the
transmitter, and controller, to the valve positioner, and the final control element (valve). The term
loop can also refer to a current loop which is the 4-20 mA circuit in series from the current
generator through the loads and back. Loop check (a.k.a. loop test 1 ) refers to checking of a 4-
20 mA loop to ensure it functions correctly.

Electronic Device Description Language (EDDL) is the technology used by device manufacturers to
define how the system shall display the device information and functions to the technician. EDDL
makes loop check of smart transmitters and other intelligent devices easier thanks to user guidance
such as wizards and help, and unparalleled consistency of use.

This tutorial explains the common principles of loop checking as they apply to various kinds of
intelligent devices. The detail procedure varies slightly depending on the manufacturer. Refer to the
device instruction manual. But once the common principles in this tutorial are understood, the
product manual becomes easier to understand.

1 Loop Check
The major commissioning difference between 4-20 mA/HART and Fieldbus is that 4-20 mA/HART
requires five point loop check, but Fieldbus, PROFIBUS, and WirelessHART do not.

1.1 Analog Loop Check

Distortion of analog signals is not detected; known as covert failure meaning the error is
undetected and goes unnoticed. For this reason a loop check is done at commissioning to verify the
integrity of the 4-20 mA current loop. The loop check is typically done in 5 points to verify
linearity; at 4 mA, 8 mA, 12 mA, 16 mA, and 20 mA. Indeed it may also be a good idea to test <
3.6 mA and >21 mA to verify correct NAMUR NE43 failure alarm indication in the control system.
The loop check verifies multiple aspects of the 4-20 mA current loop:
Current signal is not limited (e.g. due to excessive load / insufficient voltage)
Current signal is not biased (e.g. due to ground loop)
Range mismatch (transmitter range and system range)
Non-linearity (intermediate signal conditioners)

It may be good practice to periodically perform loop check to verify the integrity of the current loop
has not degraded over time or range mismatch as a result of device replacement etc. has been
introduced. Additionally, take the opportunity to perform loop check whenever a 4-20 mA/HART
device is installed, replaced, repaired, calibrated, or otherwise worked on.

Many 4-20 mA/HART devices have multiple analog signals such as a Coriolis mass flow
transmitter may have as many as three current loops that should be checked. A 4-20 mA/HART
control valve positioner will have one current loop for the valve setpoint and may also have a
second current loop for actual position feedback. All signal loops should be checked.

1.2 Digital Loop Check

A fundamental property of digital technology is that digital signals can be transmitted perfectly,
without error and that digital signals can be replicated infinitely. FOUNDATION fieldbus,
PROFIBUS-PA, and WirelessHART devices are completely digital signals. There is no analog 4-20
mA and therefore a traditional loop check need not be made for digital communication. That is, for

1
In this tutorial the terms loop check and loop test are used interchangeably
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Fieldbus, PROFIBUS, and WirelessHART no 5-point loop check is required because distortion of a
digital signal is detected thanks to the error checking which is part of digital communication. The
digital signal is rejected if it has been distorted. This is known as an overt failure meaning the
error is detected and annunciated. As a result, if the signal is received, it is received correctly, if not,
somebody is notified. So if a transmitter using only digital communication measures 123.45 degrees
C, the exact same number is received in the control system end. This is why a loop check is not
required for digital communication. It should be noted that there is no ranging in the transmitter
when only digital communication is used, so there is no chance of range mismatch between a bus
device or wireless transmitter and system causing an error (refer to calibration tutorial for details on
this). Therefore physical input need not be injected, a simple plausibility check based on the
prevailing condition is made; such as ambient temperature, atmospheric pressure, empty tank, or no
flow etc. Check the measurement status to confirm that it is Good meaning the sensor is healthy.

Figure 1 Status associated with each measurement confirms sensor is healthy

Therefore, for pure digital communication, to simulate 0%, 25%, 50%, 75%, and 100% as a kind of
digital loop check is not necessary. It is the nature of digital signals that if one value comes through
correctly, then other values will also work.

Discrete devices using digital communication such as a FOUNDATION fieldbus on-off valve,
electric actuator / Motor Operated Valve (MOV), or a PROFIBUS-PA level switch also do not
require a traditional loop check.

Lastly, it should be noted that although HART is digital, 4-20 mA is not. In most plants the system
is using the real-time 4-20 mA signal, and therefore analog loop check should be carried out to
ensure the 4-20 mA is functioning properly since it is the 4-20 mA signal which the control system
actually uses for control, not the digital HART signal. It is possible for the digital HART signal to
give a correct indication while the analog 4-20 mA signal is in error due to excessive load or ground
loop etc. In some applications such as remote wellhead monitoring where fast updates are not
required, HART devices may be used in a pure digital multi-drop topology using only the digital
HART communication, no analog 4-20 mA. In such applications, a 4-20 mA loop check is not
required since the current signal is not used.

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2 Loop Checking 4-20 mA/HART Transmitter Signals
There are two ways to loop check a 4-20 mA/HART transmitter current loop:
Inject physical sensor input
Force output current

A third way would be to use a loop checker tool in place of the 4-20 mA/HART transmitter to inject
a current from the field-end to verify the reading in the control system end. However, the voltage
drop of a loop checker is different from that of a 4-20 mA/HART transmitter so the result may be
misleading.

2.1 Inject Physical Sensor Input

Inject the actual physical input on the 4-20 mA/HART transmitter such as pumping up physical
pressure on a pressure transmitter, inject a simulated temperature sensor signal from a calibrator on
a temperature transmitter, or put the temperature sensor in a temperature bath. As this is done in 5
points; first at 0%, then 25%, 50%, 75%, and 100% in each step of the test, the engineering unit
reading in the control system end is verified. This is very time consuming as the sensor has to be
disconnected or isolated and the signal injection connected. This requires one person in the field
with a calibrator to inject the input and a second person in the control room to verify the reading on
the control system screen. Ideally also simulate a sensor failure, such as by disconnecting the sensor
cable (not the transmitter wires), to verify correct NAMUR NE43 failure alarm indication in the
control system.

This loop check method has the advantage that it verifies that sensor is working, that the transmitter
signal is marshaled to the correct input card channel, and that the 4-20 mA range setting in the
transmitter is matching control system range setting which is critical.

A multi-meter can also be inserted in the loop as an additional check

If the 4-20 mA transmitter or system does not support HART, this is the only way

2.2 Force Output Current

Another way is to force the output current of the 4-20 mA/HART transmitter irrespective of applied
input. This HART function is known as loop test. A person in the field can use a handheld field
communicator to force the current first to 4 mA, then 8 mA, 12 mA, 16 mA, and 20 mA in each
step of the test. Ideally also test < 3.6 mA and >21 mA to verify correct NAMUR NE43 failure
alarm indication in the control system. If the 4-20 mA/HART transmitter has a local display it may
be possible to force the output current from the local operator interface without using a handheld
field communicator. By loop checking from the field it is verified that the transmitter signal is
marshaled to the correct input card channel.

If the plant has an Intelligent Device Management (IDM) software part of the Asset Management
System (AMS) the technician can instead force the output from an indoor workstation without
having to go to the field. A second technician verifies the reading on the control system is correct.
Note that the reading cannot be verified from the IDM software because the IDM software looks at
the reading from the transmitter-end, not the 4-20 mA current received in the controller which is
what matters in a current loop check. By loop checking from the IDM software, a transmitter signal
marshaled to the wrong input card channel may not be detected. Therefore the correct device type
should be verified separately.

The advantage of the current forcing method is that it does not require physical sensor input to be
injected and which therefore is much faster. However, it does not verify that the range in the 4-20
mA/HART transmitter matches the range in the control system. Therefore the range should be
verified separately.
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 WARNING: Exit Loop Test

It is absolutely critical to properly exit the loop test function in the 4-20 mA/HART transmitter after
the loop check is completed. If the 4-20 mA/HART transmitter is left with a forced current output
the control system will not be receiving the actual measurement signal and therefore alarms,
trending, control, and interlocks will not be working.

After the loop check has been completed a plausibility check based on the prevailing condition
should be made; such as ambient temperature, atmospheric pressure, empty tank, or no flow etc.
This verifies the sensor is working and also verifies that the loop test function has been exited
properly and that the reading in the control system reflects actual physical input.

A multi-meter can also be inserted in the loop as an additional check

EDDL plays an important role in loop checking 4-20 mA current loops because a wizard created
by the device manufacturer guides the user step by step through the process.

Note that the value in the display of the device is the measured process value, not the value
corresponding to the forced current output.

3 Loop Checking 4-20 mA/HART Positioner Setpoint Signal

There are three ways to loop check a 4-20 mA/HART positioner current loop:
Watch the valve move
Read position feedback
Read-back loop current

In all of these approaches the control loop is put in manual and the control system output set to first
0%, then 25%, 50%, 75%, and 100% in each step of the test. The difference is in how the
instrument technician verifies that the correct signal has been received in the 4-20 mA/HART valve
positioner.

A fourth way would be to use a multi-meter in place of the 4-20 mA/HART valve positioner to
measure the current in the field-end to verify it matches what is sent from the control system end.
However, the voltage drop of a multimeter is much lower than a 4-20 mA/HART valve positioner
so the result may be misleading.

3.1 Observe Valve Movement

The operator at the control system puts the control loop in manual and sets the control system
output first to 0%, then 25%, 50%, 75%, and 100% for each step of test, a second person in the field
observes the actual valve movement. This loop check method has the advantage that it verifies that
the valve strokes over the full range and its movement is not limited.

A multi-meter can also be inserted in the loop as an additional check

If the 4-20 mA positioner or system does not support HART, this is the only way

3.2 Read Position Feedback

The operator at the control system puts the control loop in manual and sets the control system
output first to 0%, then 25%, 50%, 75%, and 100% for each step of test, a second person uses the
IDM software to read the valve position feedback from the valve positioner. This loop check
method has the advantage that there is no need for a person to go to the field.

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Figure 2 IDM software renders bargraph graphics with setpoint and actual valve position as
defined in EDDL file

3.3 Read-back Loop Current

The operator at the control system puts the control loop in manual and sets the control system
output first to 0%, then 25%, 50%, 75%, and 100% for each step of test, a second person uses the
IDM software to read the loop current as received by the 4-20 mA/HART valve positioner. This
loop check method also does not require a person to go to the field. However, there is no indication
if the valve is actually moving.

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Figure 3 IDM software displays analog loop current

4 Poor Hosts
The original DD technology from 1992 made it possible to loop check all 4-20 mA/HART devices
using the same handheld field communicator or laptop software. Before DD only proprietary
solutions existed.

The most basic content of a DD file is the Device Definition describing the blocks and the
parameters in the device, including limits, options, and help etc. The original DD technology from
1992 already included Business Logic as well, such as "wizards" (aka "methods") which is a kind of
script created by the device manufacturer to guide the technician through the analog loop checking
procedure. Wizards thus make loop checking easy. Wizards, conditionals, and help are explained
further in the section on EDDL. However, not all devices provided wizards in their DD file and not
all intelligent device management software supported wizards. That is, on many systems and for
many types of devices, loop check in the past was not so easy. For instance, the field technician
may forget to return the 4-20 mA/HART transmitter to normal operation after loop checking is
completed. At the same time the technician also had to remember to inform operations. All of this
in addition to actual loop check task itself such as applying input, or working the manifold etc. Lack
of wizards was not a problem with the DD technology itself; it was poor implementation in many
early products.

EDDL

Device Business User

Definition Logic Interface
Description

Blocks Wizards Menus

Parameters Conditionals Graphics

Figure 4 Not all systems supported EDDL Business Logic, and the graphical User Interface
Description was not introduced until 2006.
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The EDDL enhancement done in 2006 is a User Interface Description which includes graphics such
as trend charts, waveform graphs, dial gages, bargraphs, bar charts, and tables etc. Make sure to use
a control system which supports enhanced EDDL.

5 Loop Check Made Easy with EDDL

In the field, loop check is carried out using a small portable field communicator or possibly using
configuration software on a laptop computer with interface. From the control room or equipment
room it may be performed from the intelligent device management software part of the asset
management system. EDDL (IEC 61804-3) is the only device integration technology that supports
all platforms, not just laptop (see separate technical white paper on field work).

5.1 Interactive Wizards

Wizards, also known as EDDL methods, are used by device manufacturers to guide tasks such as
loop check. By creating wizards the device manufacturer's expert embeds their commissioning
know-how in the EDDL file taking the technician through the task step-by-step. This ensures the
correct sequence is followed, thereby simplifying tasks and reducing mistakes. Entries provided by
the technician as part of the procedure, such as applied input, are validated for plausibility before
being accepted by the device avoiding gross errors. This same sequence will be followed regardless
which EDDL software the technician chooses to use.

Steps in a loop check wizard for a 4-20 mA/HART transmitter may include:
Instruct technician to tell operations to put the associated control loop in manual so control
is not upset when PV changes when a new current value is forced
Instruct technician to select a test point
Instruct the technician to tell the person at the control system to note down the system
reading for this test point
Instruct the technician to return the device to normal operation if loop check is completed
Instruct technician to tell operations the associated control loop can be put back in automatic

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Figure 5 A wizard (EDDL method) takes the technician step by step through the loop check
procedure

Because the sequence is driven according to the steps defined by the transmitter manufacturer, all
technicians will follow that same sequence.

5.2 Consistent
EDDL (www.eddl.org) has a multilingual dictionary including standard text for user prompts in the
wizards, error messages, parameter labels, and even help. This dictionary is referenced by device
manufacturers, thus providing consistency making work more intuitive and reducing errors because
devices of different type from different manufacturers will use the same message (refer to separate
white paper on consistent look & feel).

6 Single Solution
Because EDDL is a text file from which the device page graphics is rendered by the device
management software, the loop check wizards and help are rendered the same way for all devices
regardless of manufacturer or type. This consistency achieved thanks to EDDL makes loop check
easier and intuitive (see separate technical white paper on consistency of use). No other
technologies can provide a comparable result.

7 Conclusion
For plants that are looking for an easy solution to loop checking multiple types and versions of 4-20
mA/HART devices, EDDL technology is a perfect match. EDDL meets the need of plants to loop
check all types of 4-20 mA/HART devices from a single software application using a single
technology while at the same time making it fast and easy to keep the system up to date with new
device versions. Plants should upgrade existing DD systems to EDDL with enhancements to enjoy
the greater ease of use afforded by the standard graphical display.

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Loop check is just one of the ways in which intelligent device management software based on
EDDL reduces maintenance & operational cost. Please refer to other technical white papers on
advanced diagnostics, configuration/setup, and system administration etc.

8 Questions
Post your questions on loop checking and intelligent device management with the EDDL group on
Linkedin:
http://www.linkedin.com/groups?gid=3736433

9 References
EDDL Brochure and Technical Description on www.eddl.org site

Jonas Berge, "Fieldbuses for Process Control: Engineering, Operation, and Maintenance", ISA,
2002, ISBN 1-55617-760-7

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