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6-Level Measurement

matt

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100% found this document useful (2 votes)

350 views76 pages

6-Level Measurement

matt

Uploaded by

Nathali Salinas

We take content rights seriously. If you suspect this is your content, claim it here.

Available Formats

Download as PDF, TXT or read online on Scribd

PROCESS

CONTROL
LEARNING

SYSTEMS ACTIVITY
PACKET

LEVEL MEASUREMENT

BB270-XD06XEN
LEARNING ACTIVITY PACKET 6

LEVEL MEASUREMENT

INTRODUCTION
Level is one of the most commonly measured process variables. Some processes
require precise measurement and control of level. One example is a chemical process
which requires that the level in the reaction tank be maintained at a specific level so the
chemicals are properly mixed.
This LAP covers how a number of level sensing devices operate and how to interpret
their electrical signals in physical units of the level, such as feet or meters.
The last segment covers how to use a process meter to display the output of a level
sensor. Process meters are commonly used to provide a visual indication of the status of a
process variable.

ITEMS NEEDED
Amatrol Supplied
1 T5552 Process Control Learning System

School Supplied
1 Water (10 gallons)
1 Compressed Air Supply
1 Digital Multimeter

FIRST EDITION, LAP 6, REV. A

Amatrol, AMNET, CIMSOFT, MCL, MINI-CIM, IST, ITC, VEST, and Technovate are trademarks or registered trademarks of Amatrol,
Inc. All other brand and product names are trademarks or registered trademarks of their respective companies.
Copyright © 2011 by AMATROL, INC.
All rights Reserved. No part of this publication may be reproduced, translated, or transmitted in any form or by any means, electronic,
optical, mechanical, or magnetic, including but not limited to photographing, photocopying, recording or any information storage and
retrieval system, without written permission of the copyright owner.
Amatrol,Inc., 2400 Centennial Blvd., Jeffersonville, IN 47130 USA, Ph 812-288-8285, FAX 812-283-1584 [Link]

BB270-XD06XEN LEVEL MEASUREMENT 2

SEGMENT 1 LEVEL SENSOR OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

OBJECTIVE 1 Describe the functions of two parts of a sensor: the transducer and the transmitter
OBJECTIVE 2 Describe two types of analog transmitter signal outputs
OBJECTIVE 3 Describe four methods of sensing level and give an application of each
OBJECTIVE 4 Describe how to measure liquid level using a pressure sensor and give an application
OBJECTIVE 5 Describe how to measure liquid level using a bubbler and give an application
OBJECTIVE 6 Describe the operation of a variable capacitance pressure sensor
OBJECTIVE 7 Describe how to use a multimeter to measure a pressure sensor output signal
SKILL 1 Connect and operate a variable capacitance pressure sensor

SEGMENT 2 LEVEL SENSOR SIGNAL MEASUREMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

OBJECTIVE 8 Define specific gravity and describe its affect on level measurement
OBJECTIVE 9 Describe how to convert liquid level units to fluid pressure units
SKILL 2 Convert liquid level units to fluid pressure units
OBJECTIVE 10 Define sensitivity and explain its importance
OBJECTIVE 11 Describe how to convert pressure sensor output signals to pressure units
SKILL 3 Convert pressure sensor output signals to pressure units
OBJECTIVE 12 Describe how to convert liquid level units to sensor output signal units
SKILL 4 Convert liquid level units to sensor output signal units
SKILL 5 Use a multimeter to test pressure sensor operation

SEGMENT 3 DISPLAY SCALING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

OBJECTIVE 13 Define display scaling
OBJECTIVE 14 Describe the function of a process meter
OBJECTIVE 15 Describe the operation of a process meter
OBJECTIVE 16 Describe how to configure a Honeywell UDI 1700 process meter to display a process variable
SKILL 6 Configure a Honeywell UDI 1700 process meter to display a process variable

APPENDIX A SPECIFIC GRAVITY OF VARIOUS LIQUIDS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

BB270-XD06XEN LEVEL MEASUREMENT 3

OBJECTIVE 1 DESCRIBE THE FUNCTIONS OF THE TWO PARTS OF A SENSOR:

THE TRANSDUCER AND THE TRANSMITTER

A sensor is a device that responds to some type of physical input (e.g. pressure,
thermal energy, magnetism, motion, etc.) by producing an output signal, usually
electrical, as shown in figure 1.

PHYSICAL ELECTRICAL
INPUT OUTPUT
SENSOR

Figure 1. General Sensor Function

The two main parts of a sensor are the transducer and the transmitter, as figure
2 shows. The transducer converts the physical input into a variable electrical
measurement (e.g. variable resistance, variable capacitance, etc.). The transmitter
then creates an electrical output signal that is sent to a controller or some other
device.

SENSOR

VARIABLE
PHYSICAL ELECTRICAL ELECTRICAL
INPUT MEASUREMENT OUTPUT
TRANSDUCER TRANSMITTER

Figure 2. Two Main Parts of a Sensor

BB270-XD06XEN LEVEL MEASUREMENT 4

Copyright © 2011 Amatrol, Inc.
Some sensors, like the pressure sensor in figure 3, are made with the transmitter
and transducer built into the sensor housing. The sensor receives a pressure input
signal and produces an electrical output signal that is proportional to the pressure.

ELECTRONICS
FOR TRANSMITTER

TRANSDUCER

INPUT
PRESSURE

Figure 3. Pressure Sensor with an Internal Transmitter and Transducer

In other cases, the transducer and transmitter are packaged separately. Figure 4
shows an example of a flow transducer with an external transmitter. As liquid flows
over the blades, the paddle wheel rotates. This generates a frequency output that is
sent to an external transmitter and converted to an analog output.

ANALOG CURRENT
OUTPUT 4-20 mA

TRANSMITTER

PULSE
FLOW
FLOW
TRANSDUCER

FLOW

Figure 4. Flow Transducer with External Transmitter

BB270-XD06XEN LEVEL MEASUREMENT 5

Transmitters are designed to provide two types of analog signal outputs:

• DC Voltage
• DC Current

Voltage producing transmitters most often produce a 0 volt output when the
physical input signal (i.e. pressure, temperature, etc.) is also at zero. As the phys-
ical input signal increases, the voltage also increases in a proportional or straight
line manner. For example, the graph in figure 5 shows the output of a 0-10 V pres-
sure transmitter. The transmitter produces 0 volts at 0 psi and 10 volts at 1 psi.

8
(OUTPUT)

6
VOLTS

0
0 0.5 1
PRESSURE (psi)
(INPUT)

Figure 5. Pressure Input/Voltage Output Chart for a Transmitter

BB270-XD06XEN LEVEL MEASUREMENT 6

Copyright © 2011 Amatrol, Inc.
Transmitter outputs can have a minimum value other than zero. The current
producing transmitter represented in figure 6 has a range of 4 to 20 milliamps
(mA), where an output of 4 mA actually represents a zero physical input signal and
20 mA represents the output at maximum input, or full range. The output graph is
still proportional but shifted up, or offset, as shown in figure 6. Manufacturers state
the range for a transmitter in their specifications.

CURRENT (mA)
(OUTPUT)
12

OFFSET 0
0 0.5 1
PRESSURE (psi)
(INPUT)

Figure 6. Pressure Input/Current Output Chart for a Transmitter

BB270-XD06XEN LEVEL MEASUREMENT 7

There are a variety of sensors used to measure level. The type used depends on
the application. Four methods of sensing level are:
• Pressure
• Electrical Resistance
• Electrical Capacitance
• Ultrasonic

Pressure
Pressure-type level sensors measure level by measuring the pressure of the
liquid at the bottom of a container. This pressure is then converted to an analog
electrical signal that is proportional to the liquid level in the tank. Figure 7 shows
an example of a pressure-type level sensor. This type of level sensor has an internal
transmitter that produces a 4-20 mA electrical current output.

PRESSURE-TYPE 4-20mA
LEVEL SENSOR
W/ INTERNAL TRANSMITTER

Figure 7. Pressure-Type Level Sensor Application

Pressure-type level sensors are often used in wastewater treatment tanks,

chemicals, and fuel manufacturing. Common types of pressure-type level sensors
include strain-gage pressure sensors, bubbler systems, and variable capacitance
pressure sensors.

BB270-XD06XEN LEVEL MEASUREMENT 8

Copyright © 2011 Amatrol, Inc.
Electrical Resistance
A resistance level sensor measures liquid level by changing its resistance as
the level changes. This resistance is then converted to an analog electrical signal
that is proportional to the liquid level in the tank. An example of this type of sensor
is a resistance tape level sensor, as shown in figure 8. It consists of a metal base
strip and a wire winding.
When the sensor is placed in a liquid, the pressure causes the winding to
contact the base strip. This contact creates a change in the resistance of the wire
that is proportional to the change in level. An internal transmitter converts the
resistance measurement to a 4-20 mA output.

INTERNAL 4-20mA OUTPUT

TRANSMITTER
RESISTANCE
MEASUREMENT

WIRE WINDING

BASE STRIP

LIQUID PRESSURE

Figure 8. Submersion (Resistance Tape) Level Sensor

Resistance tape level sensors are often used to measure raw sewage, sludge,
and gasoline levels.

BB270-XD06XEN LEVEL MEASUREMENT 9

Copyright © 2011 Amatrol, Inc.
Electrical Capacitance
A capacitive sensor measures level by measuring the change in capacitance
caused by a change in level. This change in capacitance is then converted to an
analog electrical signal that is proportional to the material level in the tank.
A capacitive sensor, as shown in figure 9, forms a capacitor using a sensor
probe as one of the plates, the vessel wall as the other plate, and the material in the
container as the dielectric material. As the material level changes, the capacitance
also changes. The sensor contains electronic circuitry that senses the change in
capacitance and produces a proportional electrical output that is usually a 4-20 mA
current.

4-20 mA
OUTPUT
CAPACITANCE
PROBE

PROBE
TIP
(PLATE)
TANK
WALL
LIQUID (PLATE)
(DIELECTRIC)

Figure 9. Capacitive Level Sensor

Capacitive sensors are generally used with non-conductive, non-corrosive

materials. A common application of capacitive level sensors is to measure refrig-
erant liquid level.

BB270-XD06XEN LEVEL MEASUREMENT 10

Copyright © 2011 Amatrol, Inc.
Ultrasonic
Ultrasonic level sensors measure the level in the tank by transmitting ultra-
sonic waves and measuring the time it takes for the reflected waves to return to the
sensor. The sensor converts this time measurement into an analog electrical signal
that is proportional to the liquid level in the tank. An internal transmitter produces
a 4-20 mA output, which can be sent to a controller or some other device.

4-20mA ULTRASONIC
OUTPUT LEVEL SENSOR
TRANSMITTED
WAVES

REFLECTED
WAVES

Figure 10. Ultrasonic Level Sensor

Applications for ultrasonic level sensors include measuring the level of chemi-
cals that can become contaminated through any type of contact. Ultrasonic sensors
are also used to measure the level of combustible fluids.

BB270-XD06XEN LEVEL MEASUREMENT 11

Copyright © 2011 Amatrol, Inc.
OBJECTIVE 4 DESCRIBE HOW TO MEASURE LIQUID LEVEL USING A PRESSURE
SENSOR AND GIVE AN APPLICATION

A volume of liquid in a tank exerts pressure on the bottom of the tank due to
its weight. This pressure is referred to as hydrostatic pressure, which is commonly
measured in pounds per square inch (psi).
Pressure can also be expressed in terms of the height of the liquid. In this
case, it is referred to as hydrostatic head and is measured in feet/inches or meters/
centimeters.
Figure 11 shows an example of the pressure on the bottom of a tank expressed
in terms of hydrostatic pressure and hydrostatic head. The amount of pressure or
head depends on the height and the density of the liquid. Increasing the liquid level
in the tank increases the pressure at the bottom of the liquid column. Decreasing
the liquid level in the tank decreases the pressure.

HYDROSTATIC HYDROSTATIC
PRESSURE HEAD
5 psi 11.6 ft

5 lbs
WATER

11.6 ft

1 SQUARE
INCH SURFACE

5 POUNDS
PRESSURE =
1 SQ. IN.

Figure 11. Hydrostatic Pressure Vs. Hydrostatic Head

BB270-XD06XEN LEVEL MEASUREMENT 12

Copyright © 2011 Amatrol, Inc.
Level Measurement in an Open Container
Hydrostatic head, or head, can be measured in an open container by placing an
analog pressure sensor at the bottom of the tank. Since the pressure at the bottom
of the tank is equal to the sum of the atmospheric pressure (P1) and the hydrostatic
pressure, a pressure sensor that measures gage pressure is used. Gauge pressure
indicates the amount of pressure above atmospheric pressure. This type of sensor
subtracts the effect of the atmospheric pressure (Pabs) so that the signal measured is
only the hydrostatic pressure.

OPEN
CONTAINER
ATMOSPHERIC
PRESSURE
P1 = 14.7 psia

ABSOLUTE
PRESSURE
HYDROSTATIC HEAD Pabs = 16.86 +14.7
5 FEET = 16.86 psia CONTROLLER
= 31.56 psia

5.00

GAUGE PRESSURE
Pgage = 31.56 - 14.7 = 16.86 psia

Figure 12. Open Tank Level Measurement Using Pressure-Type Level Sensor

BB270-XD06XEN LEVEL MEASUREMENT 13

Copyright © 2011 Amatrol, Inc.
Level Measurement in a Closed Container
If the liquid is held in a pressurized tank, standard head pressure measurement
is not accurate because the pressure at the bottom of the tank is greater than the
sum of atmospheric pressure and hydrostatic pressure.
For example, in figure 13, the pressure measured by the sensor is 46.86 psia,
which is the sum of the air pressure in the tank (30 psia) and the liquid or hydro-
static pressure (16.86 psia). Therefore, the controller indicates a level of 74.44 ft
even though the actual liquid level is only 5 ft.

AIR PRESSURE=
30 psia

HYDROSTATIC HEAD
5ft = 16.86 psia

CONTROLLER

74.44

TOTAL PRESSURE = 30 + 16.86

= 46.86 psia
= 74.44 ft.

Figure 13. Level Measurement in Pressurized Tank

BB270-XD06XEN LEVEL MEASUREMENT 14

Copyright © 2011 Amatrol, Inc.
The solution to this problem is to use a differential pressure sensor to monitor
the level in the tank. This method uses two taps in the tank, one at the top and one
at the bottom, as figure 14 shows.
The differential pressure transmitter subtracts the air pressure at the top of the
tank from the pressure at the bottom, leaving only the differential pressure, which
represents the hydrostatic pressure.

PRESSURE
TAP
P1 = 30 psia

NET (DIFFERENTIAL)
PRESSURE SIGNAL
16.86 psia

5ft = 16.86 psi CONTROLLER

5.00

DIFFERENTIAL
PRESSURE
TRANSMITTER
PRESSURE
TAP
P2 = 46.86 psia

Figure 14. Differential Pressure Measurement

Pressure type level sensors are used in various industries including oil and gas,
marine, medical, and space. Differential pressure measurement is commonly used
when measuring the level of potentially volatile liquids such as liquid oxygen or
hydrogen.

BB270-XD06XEN LEVEL MEASUREMENT 15

A bubbler system is a type of level measuring device that determines the level
of a liquid by measuring the pressure of a gas that is forced out of a tube into the
liquid in the tank. This type of system is often used for measurement but seldom
for control because its accuracy is not as high as other methods.
Bubbler systems consist of a tube, regulator, gas supply (usually air or
nitrogen), and pressure gauge, as shown in figure 15. The tube is placed inside the
tank or vessel so that it extends near the bottom of the tank or just below the lowest
point of desired level measurement. The gas supply and regulator force a regulated
volume of air or nitrogen through the tube until it bubbles out the open end. The
pressure gauge measures the pressure required to force the gas out of the tube.

PRESSURE
GAUGE

REGULATOR
0
PSIG

GAS BUBBLER
SUPPLY TUBE

Figure 15. Bubbler System

BB270-XD06XEN LEVEL MEASUREMENT 16

Copyright © 2011 Amatrol, Inc.
The pressure required to force the gas out of the tube is approximately equal to
the hydrostatic pressure at the bottom of the tank. The hydrostatic pressure can be
expressed in terms of height of a liquid column (e.g. inches of water, millimeters
of mercury, etc.). Therefore, the operator is able to determine the level. As the level
in the tank increases and decreases, the pressure to force the gas out of the tube
increases and decreases, respectively.
Bubbler systems are often used in combustible fluid applications. They prevent
having an electrical signal in the tank, thereby reducing the risk of fire or an explo-
sion due to a spark. Also, the only wetted part of the bubbler system is the tube,
which costs less than a typical pressure sensor. Therefore, the components in a
bubbler system should last longer than a system that places a pressure sensor in the
bottom of the tank.
Bubbler systems do have some limitations. For instance, a bubbler cannot be
used in a sealed tank unless a differential pressure measurement is used or the tank
is vented, as figure 16 shows. If the tank is not vented, gas flow stops when the
pressure in the open area of the tank equals the hydrostatic pressure. In addition,
if the material in the tank has sensitive chemical properties, the introduction of
another gas can upset the balance of the materials in the tank.

PRESSURE
GAUGE

REGULATOR VENT
0

GAS
PSIG

SUPPLY BUBBLER
PIPE

Figure 16. Bubbler in a Sealed Vessel

BB270-XD06XEN LEVEL MEASUREMENT 17

One type of electrical pressure sensor is a variable capacitance pressure sensor.

This sensor uses a change in capacitance to create an electrical output signal that is
proportional to pressure. Figure 17 shows an example of a typical variable capaci-
tance pressure sensor. Common features of variable capacitance pressure sensors
include a round or tubular body, a pipe fitting on one end of the sensor, and an
electrical connection on the other end of the sensor, as figure 17 also shows.

PIPE FITTING

TUBULAR BODY

ELECTRICAL
CONNECTION

+ -

Figure 17. Construction of a Typical Pressure Sensor

BB270-XD06XEN LEVEL MEASUREMENT 18

Copyright © 2011 Amatrol, Inc.
Figure 18 shows the internal components of a variable capacitance pressure
sensor. It contains a stationary electrode and a flexible diaphragm, usually made
of stainless steel. Together they form a capacitor, which is the transducer portion
of the sensor. This assembly is connected to electronic circuitry that acts as the
transmitter.

PICTORIAL BLOCK DIAGRAM

FLEXIBLE FLEXIBLE
DIAPHRAGM DIAPHRAGM

STATIONARY STATIONARY
ELECTRODE OSCILLATOR OSCILLATOR ELECTRODE
CIRCUIT WITH CIRCUIT WITH
VARIABLE FIXED
CAPACITANCE CAPACITANCE
TRANSMITTER

COMPARATOR
TRANSMITTER
CIRCUIT
COMPONENTS
GENERATES
4-20mA OUTPUT

4 - 20 mA

- +

Figure 18. Construction of a Variable Capacitance Pressure Sensor

When fluid pressure acts on the diaphragm, it flexes causing the capacitance
to change.
To detect the change in capacitance, this sensor uses two oscillator circuits one
connected to a fixed capacitance and the other connected to available capacitance
created by the diaphragm. When pressure increases, the frequency of the oscil-
lator circuit connected to the flexible diaphragm changes. A comparator circuit
compares the difference in frequency between the oscillator circuit connected to
the flexible diaphragm to the frequency of a fixed capacitor oscillation circuit and
produces a proportional analog output signal, usually 4-20 mA.

BB270-XD06XEN LEVEL MEASUREMENT 19

Copyright © 2011 Amatrol, Inc.
The 4-20 mA analog output signal of a variable capacitance pressure sensor
varies linearly with the input pressure, as figure 19 shows.

CURRENT (mA)
(OUTPUT)
12

OFFSET 0
0 0.5 1
PRESSURE (psi)
(INPUT)

Figure 19. Linear Current Input-Pressure Output Relationship of a Variable Ca-

pacitance Pressure Sensor

BB270-XD06XEN LEVEL MEASUREMENT 20

A sensor’s output can be tested by using a multimeter to measure the output

signals of both voltage and current-producing sensors.
To measure current from a sensor, the leads of a multimeter are connected in
series with the sensor output, as shown in figure 20.

MULTIMETER
7mA

+ -
-
+ CONTROLLER
INPUT
+ -

DC POWER
SUPPLY
2-WIRE + -
PRESSURE SENSOR

Figure 20. Output from a Pressure Sensor Measured as a Current

The output of a current-producing sensor can also be measured as a voltage by

placing a resistor across the input terminals of the controller and connecting the
leads of a multimeter across the controller input terminals, as shown in figure 21.
This method is also commonly used with digital display meters because they are
sometimes designed only to receive voltage input signals.

MULTIMETER
3V

+ -

-
+ CONTROLLER
INPUT
+ -

DC POWER
2-WIRE SUPPLY
PRESSURE SENSOR + -

Figure 21. Output from a 2-Wire Pressure Sensor Measured as a Voltage

BB270-XD06XEN LEVEL MEASUREMENT 21

Copyright © 2011 Amatrol, Inc.
Many voltage-producing pressure sensors use a 3-wire design. The output
voltage can be measured by placing a multimeter across the input terminals of the
controller, as shown in figure 22.

MULTIMETER
3V

+ -

CONTROLLER
INPUT INPUT
+ -
COMMON
EXCITATION +

DC POWER
SUPPLY
+ -
3-WIRE
PRESSURE SENSOR

Figure 22. Output from a 3-Wire Pressure Sensor Measured as a Voltage

BB270-XD06XEN LEVEL MEASUREMENT 22

Procedure Overview
In this procedure, you will connect a 2-wire variable capacitance pressure
sensor to an external power supply on the T5552 process control system. You
will then place a digital multimeter (DMM) in the circuit to determine if the
sensor produces an output signal.

 1. Perform a lockout/tagout.
 2. Perform the following substeps to set up the T5552, as shown in figure 23.

NOTE
The appearance of the electrical outlet will differ based on the electrical
power supplied at your location.

ELECTRICAL
PID CONTROLLER FLOW TRANSMITTER
FT1

4-20mA
FLOW SENSORS

FT2

4-20mA TEST
FLOWPVALVE

FV1

4-20mA
PL1 PL2 PL3 PL4

ALM1

ALM2

ALM3
PROCESS METER

UDI1700

MAX
MIN
OUTLET
SS1 SS2 SS3 SS4
ALM4
ALM5
ALM 1234 MAN FC
LEVEL SENSORS
0
DI 1234 SET SETUP
PV LT1 LT2
OUT 1234

-sp 0.0
OUTPUT RELAY 1
CURRENT INPUT
SP NO COM NC
mA

4-20mA 4-20mA 24VDC

Func. Lower Man SP LS1 LS2 OUTPUT RELAY 2

Loop 1/2 Display Auto Select VOLTAGE INPUT NO COM NC
mV/V
Setup Run
Hold

CONTROL RELAYS ALARMPHORN [Link] PLC DISCRETE I/O

24VDC
INPUTS OUTPUTS OUTPUTS AH1 P1

ANALOG ANALOG CR1

ANALOG
AL1 AO1
1 2 3 4 5 6 7 8

CR2
4-20mA
AL2
DISCRETE
9 10 11 12 13 14 15 16
DL1
AUX. POWER
ALARM
AL1 CR3
DISCRETE
DC POWER SUPPLY PLC ANALOG I/O
DL2 4-20mA
24 VDC 24 VDC 24VDC 24VDC 24VDC
AL2 OPEN COLLECTOR
SOLENOID VALVES
1 2 3 4 5 6 7 8
SV1 SV2 SV3

GND
9 10 11 12 13 14 15 16

PRESSURE
REGULATOR
HV2 SET TO ZERO

MANUAL DRAIN
VALVES CLOSED

AIR SUPPLY
CONNECTION
HAND VALVES HV1
OPEN MANUAL FLOW
CONTROL VALVE
OPEN

Figure 23. T5552 Setup

BB270-XD06XEN LEVEL MEASUREMENT 23

Copyright © 2011 Amatrol, Inc.
A. Connect the air supply line to the T5552.
B. Set the pressure regulator to 0 psi.
You will not control flow with the diaphragm actuator valve in this skill.
C. Fill the reservoir tank with water.
D. Close (turn fully clockwise) the two process tank manual drain valves.
E. Open the manual flow control valve.
F. Locate a digital multimeter (DMM) and set it to measure milliamps (mA).
G. Make sure that the DMM test probes are connected to the appropriate
jacks (COM and mA) and the selector switch is set to DC mA.
 3. Locate the pressure sensor attached to the bottom of the tank, as shown in
figure 24.
The pressure sensor on the process tank of the T5552 is a variable capacitance
type sensor. It has a current producing output with a 4-20 mA range. This
sensor’s leads are pre-wired to the output jacks on the control panel labeled
LT1, as shown in figure 24.
 4. Connect the circuit shown in figure 24.
This circuit allows you to control the flow into the process tank using the
hand valves or by turning the pump on and off. It also allows you to measure
the output of the pressure sensor (LT1) using the DMM.

FLOW SENSORS FLOW VALVE DISCRETE I/O

FT1 FT2 FV1 PL1 PL2 PL3 PL4

4-20mA 4-20mA TEST 4-20mA

SS1 SS2 SS3 SS4

LEVEL SENSORS
LT1 LT2

4-20mA 4-20mA 24VDC

LS1 LS2

LT1
10
9
CONTROL RELAYS ALARM HORN CIRC. PUMP
8
AH1 P1

7 CR1

5 CR2

4
CR3
3
DC POWER SUPPLY
2
24VDC 24VDC 24VDC
1
SOLENOID VALVES
0 SV1 SV2 SV3

GND

SET TO MEASURE DC
TO LT1 mA mA (TEST PROBES
WAVETEK

CONNECTED TO
DM15XL

V 1000 OFF 750 V

200 200
20

PRESSURE
20
2 2

COM AND mA JACKS)

200m 200m
LOGIC 200
2m

SENSOR 2000
M
20M
20m
200m
A
2000k 10A
200k 10A
20k 200m
2k 20m
200 200 2m
l A

V COM mA 10A
FUSED
MAX
1000V FUSED
750V

DMM

Figure 24. Circuit to Measure Pressure Sensor Output

BB270-XD06XEN LEVEL MEASUREMENT 24

Copyright © 2011 Amatrol, Inc.
 5. Remove the lockout/tagout.
 6. Turn on the main circuit breaker.
 7. Perform the following substeps to fill the process tank and determine the
effects on the output of the sensor.
A. With the process tank empty, observe the display of the DMM and record
the reading.
Pressure Sensor Output __________________________________ (mA)
This represents the minimum value of the sensor output for this application.
B. Start the circulation pump by placing selector switch SS1 in the ON
position.
Water should begin to flow into and fill the process tank.
C. Allow the tank to fill for approximately 30 seconds and determine the
effect of filling the process tank on the sensor output by watching the
DMM display. After 30 seconds, turn off the circulation pump (SS1 off).
Pressure Sensor Output _____________________ (Increases/Decreases)
You should find that the sensor output increases as the tank fills because
the sensor measures more pressure on the diaphragm.
D. Fully open (counterclockwise) the two process tank manual drain valves
and determine the effect of draining the process tank on the sensor output
by watching the DMM display.
Pressure Sensor Output _____________________ (Increases/Decreases)
You should find that the sensor output decreases as the tank drains because
the sensor measures less pressure on the diaphragm.
 8. Perform the following substeps to shut down the T5552.
A. When the process tank is empty, close the manual drain valves by turning
them clockwise.
B. Turn off the main circuit breaker.
C. Disconnect the control circuit.
D. Return the DMM to its proper storage location.

BB270-XD06XEN LEVEL MEASUREMENT 25

1. A ____________ is a device that responds to some type of physical

input by producing an output signal.

2. A ____________ converts the input energy of a device to the desired

output energy.

3. A ____________ creates and sends the output signal to a controller or

some other device.

4. Two types of analog transmitter output signals are DC current and

____________.

5. Four methods of sensing liquid level are electrical capacitance,

pressure, ultrasonic, and electrical __________.

6. The pressure that a liquid exerts on the bottom of a tank is called

____________ pressure or head pressure.

7. The pressure exerted on the bottom of a tank depends on the height and
__________ of the liquid in the tank.

8. A system that uses a tube through which a gas is forced as a method of

sensing pressure is called a ___________.

9. A variable _______________ sensor contains a stationary electrode

and a flexible diaphragm.

10. To measure current from a sensor, the leads of a multimeter are

connected in _______ with the sensor output.

BB270-XD06XEN LEVEL MEASUREMENT 26

OBJECTIVE 8 DEFINE SPECIFIC GRAVITY AND DESCRIBE ITS EFFECT ON

LEVEL MEASUREMENT

Specific Gravity (SG) is the ratio of the weight of a liquid to an equal amount
of water. There is no unit of measure for specific gravity because it is a ratio.
The formula below shows how to calculate the specific gravity of a material.

FORMULA: SPECIFIC GRAVITY

Mmaterial
SG 
Mwater

Where:
SG = Specific Gravity
Mmaterial = Mass of the material
Mwater = Mass of an equal volume of water

BB270-XD06XEN LEVEL MEASUREMENT 27

Copyright © 2011 Amatrol, Inc.
The specific gravity of a liquid must be known to convert a hydrostatic pres-
sure value into a liquid level. Figure 25 shows that the same level of three liquids
with different specific gravities produces a different hydrostatic pressure (in psi).

HEAD = 231 ft.

WATER GASOLINE ACETONE

231 ft. SG SG SG
1.0 0.74 0.79

100 74 79
psi psi psi

Figure 25. Relationship Between Specific Gravity, Pressure, and Head

The specific gravity of various liquids are shown in figure 26.

LIQUID SPECIFIC
GRAVITY
Acetone 0.79
Corn Oil 0.92
Crude Oil 0.85
Gasoline 0.74
Glucose 1.35 - 1.42
Glycol 101
Molasses 1.45
Soy bean oil 0.93
Tar 1.2
Water (fresh) 1.00
Water (sea) 1.03

Figure 26. Specific Gravity of Various Liquids

A liquid that has a specific gravity greater than 1 (the specific gravity of fresh
water) exerts more pressure on the bottom of a tank than water, or any fluid with a
specific gravity less than 1.

BB270-XD06XEN LEVEL MEASUREMENT 28

Liquid level units can be converted to fluid pressure units if the level in the
tank and the specific gravity of the liquid in the tank are known. Converting liquid
level units to pressure units is useful in determining the proper components for the
system.
The following formula converts liquid level units to pressure units.

FORMULA: LIQUID LEVEL TO PRESSURE

P = L × SG × k
Where:
P = Pressure (psi, kPa)
L = Level (inches, feet, meters)
SG = Specific Gravity
k = Conversion Factor = 0.036 psi/in
= 0.432 psi/ft
= 9.772 kPa/m

Example: Determine the range needed for a pressure sensor for a tank. The
maximum level is 25 feet of water, as shown in figure 27.

LEVEL = 25 ft.

PRESSURE = ?

Figure 27. Level Measuring System

BB270-XD06XEN LEVEL MEASUREMENT 29

Copyright © 2011 Amatrol, Inc.
The maximum pressure exerted by the water is determined using the level to
pressure formula as follows:
P = L × SG × 0.432
P = 25 × 1 × 0.432
P = 25 × 0.432
P = 10.80 psi
In this case, the pressure sensor must have a wide enough range to handle the
10.8 psi maximum pressure.

SKILL 2 CONVERT LIQUID LEVEL UNITS TO FLUID PRESSURE UNITS

Procedure Overview
In this procedure, you will be given the height of a liquid and asked to
calculate the pressure that will be detected by the level sensor. Or, you may
be given the pressure and asked to calculate the height of the liquid. This
information would then be used to select a level sensor for that application.

 1. Determine the maximum pressure exerted by a column of liquid given the

following scenario.
 Scenario: You have a tank that contains glucose at a maximum height of
18.35 ft (5.59 m), as shown in figure 28 and you want to select the proper
level sensor for this tank.
Maximum Pressure = __________________________________ (psi/kPa)

GLUCOSE

MAXIMUM HEIGHT =
18.35 ft (5.59m)

Figure 28. Tank Containing Glucose

BB270-XD06XEN LEVEL MEASUREMENT 30

Copyright © 2011 Amatrol, Inc.
 Your answer should be 10.70 psi (73.74 kPa) to 11.26 psi (77.57 kPa).
 For this application, you would need to select a sensor with an upper range
value greater than 11.26 psi (77.57 kPa).
 2. Determine the maximum pressure exerted by a column of liquid given the
following scenario.
 Scenario: You have a tank that contains tar at a maximum height of 43 ft
(13.11 m) and you want to select the proper level sensor for this tank.
Maximum Pressure = ___________________________________ (psi/kPa)

You should find that the maximum pressure is 22.29 psi (153.69 kPa).
 3. Determine the maximum pressure exerted by a column of liquid given the
following scenario.
 Scenario: You have a tank that contains seawater at a maximum height of
98.5 in (2.5 m) and you want to select the proper level sensor for this tank.
Maximum Pressure = ___________________________________ (psi/kPa)

You should find that the maximum pressure is 3.65 psi (25.16 kPa).
 4. Determine the height of the column of liquid given the following scenario.
 Scenario: You have a tank that contains molasses exerting a pressure of 32.80
psi (226.15 kPa) as shown in figure 29 and you want to determine the column
height (level) of the molasses.
Column Height (Level) = __________________________________ (ft/m)

MOLASSES

COLUMN
HEIGHT
(LEVEL)=?

PRESSURE = 32.8 psi

(226.15 kPa)

Figure 29. Tank Containing Molasses

You should find that the column height (level) is 52.36 ft (15.96 m).

BB270-XD06XEN LEVEL MEASUREMENT 31

Copyright © 2011 Amatrol, Inc.
 5. Determine the height of the column of liquid given the following scenario.
 Scenario: You have a tank that contains soybean oil exerting a pressure of
4.82 psi (33.23 kPa) and you want to determine the column height (level) of
the soybean oil.
Column Height (Level) = ___________________________________(in/m)
 You should find that the column height (level) is 144 in (3.66 m).

OBJECTIVE 10 DEFINE SENSITIVITY AND EXPLAIN ITS IMPORTANCE

The sensitivity of a sensor is the amount of change in the electrical signal

(output) that occurs for a given amount of change in the physical quantity being
sensed (input). This relationship is shown in the following formula:

SENSITIVITY FORMULA
 OElec
S
 I Phys
where
S = Sensitivity
D = Amount of Change
OElec = Electrical Output Signal
IPhys = Physical Input Signal

Example: If a pressure sensor increases its electrical signal 0.001 volt for
every 1 psi increase in pressure, as shown in figure 30, its sensitivity is 0.001 volts
per 1 psi (0.001 volt/1 psi).

phys = 1 psi Oelec = 0.001V

SENSOR
INPUT OUTPUT

Figure 30. Sensitivity of a Pressure Sensor

Sensitivity is important in process control systems because the end result of

the data collection process is not an electrical signal in units of volts or amps but
data in units of the quantity being sensed. The sensitivity can be used to calculate
the sensor’s output in the physical units sensed by the sensor.

BB270-XD06XEN LEVEL MEASUREMENT 32

The sensitivity formula is modified as follows to calculate the signal values

in physical units, in this case pressure, for a given current or voltage signal that
ranges from zero to some number (e.g. 0-10 V, 0-20 mA).

FORMULA: ELECTRIC SIGNAL TO PRESSURE CONVERSION

(Minimum Output Signal = 0)

Om
Pm 
S
Where:
Pm = Measured Pressure
Om = Measured Output Signal Value
S = Sensitivity

Example: Determine the actual pressure exerted on the pressure sensor in

figure 31 if the output range of the sensor is 0-5 V and the input range is 0-20 psi.

PRESSURE =

0.5V

Figure 31. Pressure Sensor Signal to a Electronic Controller

BB270-XD06XEN LEVEL MEASUREMENT 33

Copyright © 2011 Amatrol, Inc.
First, determine the sensitivity.
5
S  0.25 volts/psi
20
Then, calculate the actual pressure.
0.5
Pm   2.0 psi
0.25
To calculate signal values for current or voltage producing sensor signals that
do not have zero as the minimum output value (i.e. 4-20 mA), the formula must
include a deduction for the offset from zero. This is shown as follows:

FORMULA: ELECTRIC SIGNAL TO PRESSURE CONVERSION

(Minimum Output Signal ≠ 0)

( Om  Omin )
Pm 
S
Where:
Pm = Measured Pressure
Om = Measured Output Signal Value
Omin = Minimum Output Signal Value
S = Sensitivity

Example: Calculate the pressure that the sensor in figure 32 senses using the
following information:
Electrical Output Signal Range = 1-5 V
Pressure Input Signal Range = 0-20 psi
Measured Output = 1.5 V

CONTROLLER

PRESSURE =

1.5V

Figure 32. Pressure Sensor with an Output Signal of 1.5 V

BB270-XD06XEN LEVEL MEASUREMENT 34

Copyright © 2011 Amatrol, Inc.
To solve the problem, first determine the sensitivity. Then use the sensitivity to
determine the measured pressure.
Determine the sensitivity:
OElec
S
I Phys
5V  1V

20 psi  0 psi
4V

20 psi
 0.2 V/psi

Determine the measured pressure:

( 1.5  1)
Pm 
0.2
0.5

0.2
 2.5 psi

To calculate the pressure sensor output signal value given the measured pres-
sure input signal value, the previous formula can be rearranged as follows:

FORMULA: PRESSURE TO ELECTRICAL SIGNAL VALUES

Om = (Pm × S) + Omin
Where:
Om = Measured Output Signal Value
Pm = Measured Pressure
S = Sensitivity
Omin = Minimum Output Signal Value

BB270-XD06XEN LEVEL MEASUREMENT 35

Copyright © 2011 Amatrol, Inc.
Example: Determine the value of the measured output signal for the pressure
sensor in figure 33 using the following information:
Electrical Output Signal Range = 1-5 V
Pressure Input Signal Range = 0-20 psi
Measured Pressure = 2.5 psi

PRESSURE = 2.5 psi

Figure 33. Pressure Sensor Measuring a Pressure of 2.5 psi

To solve the problem, first determine the sensitivity. Then use the sensitivity to
determine the measured output.
Determine the sensitivity:
5V  1V
S
20 psi  0 psi
4V

20 psi
 0.2 V/psi

Determine the measured output:

Om = (2.5 × 0.2) +1
Om = 0.5 +1
Om = 1.5V

BB270-XD06XEN LEVEL MEASUREMENT 36

Procedure Overview
In this procedure, you will convert pressure sensor output signals to
pressure units and vice versa given the pressure and output ranges of the sensor
and either the measured output signal or the measured input pressure.

 1. Calculate the pressure sensed by the pressure-type level sensor shown in

figure 34. It has a 0-5 psi (0-34.47 kPa) input range and a 4-20 mA output
range. The measured output from the sensor is 15 mA.
Pressure _____________________________________________ psi (kPa)

15 mA

Figure 34. Pressure Sensor with a 15 mA Output

 You should find that the pressure is approximately 3.44 psi (23.72 kPa).
 2. Calculate the pressure sensed by a pressure-type level sensor that has a 0-3
psi (0-20.68 kPa) input range and a 1-5 V output range if the measured output
is 3.5 V.
Pressure _____________________________________________ psi (kPa)
 You should find that the pressure is approximately 1.88 psi (12.96 kPa).

BB270-XD06XEN LEVEL MEASUREMENT 37

Copyright © 2011 Amatrol, Inc.
 3. Calculate the pressure sensed by a pressure-type level sensor that has a 0-7
psi (0-48.26 kPa) input range and a 4-20 mA output range if the measured
output is 16 mA.
Pressure _____________________________________________ psi (kPa)
 You should find that the pressure is approximately 5.25 psi (36.20 kPa).
 4. Calculate the measured output of a pressure-type level sensor shown in figure
35 that has a 0-4 psi (0-27.58 kPa) input range and a 0-20 mA output range if
the pressure sensed is 3 psi (20.68 kPa).
Electrical Output _________________________________________ (mA)

PRESSURE = 3 psi
(20.68 kPa)

Figure 35. Pressure Sensor Measuring a Pressure of 3 psi

 You should find that the electrical output is approximately 15 mA.
 5. Calculate the pressure sensed by the pressure-type level sensor that has a 0-1
psi (0-6.89 kPa) input range and a 1-5 V output range if the measured output
is 2 V.
Pressure _____________________________________________ psi (kPa)
 You should find that the pressure is 0.25 psi (1.72 kPa).
 6. Calculate the pressure sensed by a pressure-type level sensor that has a 0-15
psi (0-103.42 kPa) input range and a 0-10 V output range if the measured
output 8 V.
Pressure _____________________________________________ psi (kPa)
 You should find that the pressure is 12 psi (82.74 kPa).

BB270-XD06XEN LEVEL MEASUREMENT 38

Copyright © 2011 Amatrol, Inc.
 7. Calculate the measured output of a pressure-type level sensor that has a 0-9
psi (0-62.05 kPa) input range and a 4-20 mA output range if the pressure
sensed is 5 psi (34.47 kPa).
Electrical Output _________________________________________ (mA)
 You should find that the electrical output is approximately 12.9 mA.
 8. Calculate the measured output of a pressure-type level sensor that has a 0-12
psi (0-82.74 kPa) input range and a 1-5 V output range if the pressure sensed
is 10 psi (68.95 kPa).
Electrical Output __________________________________________ (V)
 You should find that the electrical output is approximately 4.33 V.

BB270-XD06XEN LEVEL MEASUREMENT 39

Liquid level units are converted to sensor output signal units by first converting
the liquid level units to pressure units and then converting the pressure units to
sensor output signal units. This calculation is useful in troubleshooting and allows
the technician to determine if the pressure sensor is providing the correct output.
Substituting the expression relating liquid level to pressure into the equa-
tion that converts pressure units to sensor output signal units gives the following
equation:

LIQUID LEVEL TO SENSOR OUTPUT CONVERSION

Om = (S × L × SG × k) + Omin
Where:
Om = Measured Output Signal
S = Sensitivity
L = Level (inches, feet, meters)
SG = Specific Gravity
Omin = Minimum Output Signal Value
k = Conversion Factor
= 0.036 psi/in
= 0.432 psi/ft
= 9.772 kPa/m

Example: Calculate the measured output of a pressure sensor with a 0-3 psi
range and a 1-5 V output signal range if the level of crude oil (SG = 0.85) in the
tank is 26 inches. Figure 36 shows this system.

26 INCHES
CRUDE OIL

OUTPUT = ?V
PRESSURE
SENSOR
(0-3 psi)

Figure 36. System Measuring Crude Oil Level

BB270-XD06XEN LEVEL MEASUREMENT 40

Copyright © 2011 Amatrol, Inc.
Using the equation:
 4  
Om   26  0.85  0.036  1
 3  
Om = (1.33 × 26 × 0.85 × 0.036) + 1
Om = 1.06 + 1
Om = 2.06 V
To determine liquid level when given the electrical output, the equation above
can be rewritten as follows:

SENSOR OUTPUT SIGNAL TO LIQUID LEVEL

CONVERSION

L = ( Om − Omin )
( S × SG × k)
Where:
L = Level (inches, feet, meters)
Om = Measured Output Signal
Omin = Minimum Output Signal Value
S = Sensitivity
SG = Specific Gravity
k = Conversion Factor
= 0.036 psi/in
= 0.432 psi/ft
= 9.772 kPa/m

Example: Calculate the level (in inches) of soybean oil (SG = 0.93) in a tank
if the measured output from a 6 psi sensor with a pressure range of 0-5 psi is 8 mA.
The sensor has a 0-20 mA output signal range.
Using the equation:
(8 − 0)
L=
( ( )
20
5
× 0.93 × 0.036)

8
L=
( 4 × 0.93 × 0.036)

8
L=
0.134

L = 59.74 inches

BB270-XD06XEN LEVEL MEASUREMENT 41

Procedure Overview
In this procedure, you will convert liquid level units to sensor output signal
units using the equations to convert liquid level to pressure and pressure to
sensor output signal. Refer to Appendix A for the specific gravity of the liquids.

 1. Calculate the current output signal from a pressure-type sensor that has a 0-2
psi (0-13.79 kPa) input signal range if it measures a water level of 21 inches
(0.53 m).
 The sensor has a 4-20mA output signal range.
Electrical Output Signal ____________________________________ (mA)

21 INCHES
(0.53m)
WATER

OUTPUT = ?mA
PRESSURE
SENSOR

Figure 37. System Measuring Water Level

 You should find that the electrical output signal is approximately 10.05 mA.
 2. Calculate the measured output signal from a pressure-type sensor that has a
0-4 psi (0-27.5 kPa) input signal range measuring a water level of 72 inches
(1.83 m). The sensor has a 4-20mA output signal range.
Electrical Output Signal ____________________________________ (mA)
 You should find that the electrical output signal is approximately 14.37 mA.

BB270-XD06XEN LEVEL MEASUREMENT 42

Copyright © 2011 Amatrol, Inc.
 3. Calculate the measured output signal from a pressure-type sensor that has
a 0-1 psi (0-6.89 kPa) input signal range measuring an acetone level of 18
inches (0.46 m). The sensor has a 1-5 V output signal range.
Electrical Output Signal _____________________________________ (V)
 You should find that the electrical output signal is approximately 3.05 V.
 4. Calculate the measured output signal from a pressure-type sensor that has a
0-5 psi (0-34.47 kPa) input signal range measuring a crude oil level of 100
inches (2.53 m). The sensor has a 0-20 mA output signal range.
Electrical Output Signal ___________________________________ (mA)
 You should find that the electrical output signal is approximately 12.24 mA.
 5. Calculate the measured output signal from a pressure-type sensor that has a
0-2 psi (0-13.79 kPa) input signal range measuring a glycol level of 21 inches
(0.53 m). The sensor has a 0-10 V output signal range.
Electrical Output Signal _____________________________________ (V)
 You should find that the electrical output signal approximately 4.16 V.
 6. Calculate the level of tar in a tank if the measured output from a pressure-type
sensor that has a 0-3 psi (0-20.68 kPa) input signal range is 7 mA. The sensor
has a 4-20 mA output signal range.
Level in __________________________________________________ (m)
 You should find that the level is approximately 13.02 inches (0.33 m).
 7. Calculate the level of gasoline in a tank if the measured output from a
pressure-type sensor that has a 0-7 psi (0-48.26 kPa) is 16 mA. The sensor
has a 0-20 mA output signal range.
Level in __________________________________________________ (m)
 You should find that the level is approximately 210.53 inches (5.38 m).
 8. Calculate the level of tar in a tank if the measured output from a pressure-type
sensor that has a 0-3 psi (0-20.68 kPa) input signal range is 7 V. The sensor
has a 0-10 V output signal range.
Level in __________________________________________________ (m)
 You should find that the level is approximately 48.61 inches (1.24 m).

BB270-XD06XEN LEVEL MEASUREMENT 43

Copyright © 2011 Amatrol, Inc.
 9. Determine the measured output signal of the pressure sensor shown in figure
38. The sensor has a 0-3 psi (0-20.68 kPa) input signal range and a 4-20 mA
output signal range.
Electrical Output _________________________________________ (mA)

LEVEL = 70 in
(1.78m)

FRESH
WATER

PRESSURE
SENSOR

Figure 38. Level System

 You should find that the electrical output is 17.44 mA.
 10. Determine the level in the tank shown in figure 39 if the output signal from
the pressure sensor is 4.5 V. The sensor has a 0-7 psi (0-48.26 kPa) input
signal range and a 1-5 V output signal range.
Level in __________________________________________________ (m)

LEVEL = ?

CORN OIL

4.5V
PRESSURE
SENSOR

Figure 39. Level System

 You should find that the level is approximately 184.93 inches (4.7 m).
BB270-XD06XEN LEVEL MEASUREMENT 44
Copyright © 2011 Amatrol, Inc.
SKILL 5 USE A MULTIMETER TO TEST PRESSURE SENSOR OPERATION

Procedure Overview
In this procedure, you will check the output of a pressure sensor using a
digital multimeter (DMM). The sensor should produce an analog electrical
signal (current) that is proportional to the fluid level in the process tank. As the
level in the tank increases, so should the output signal of the sensor. You will
verify this relationship in this procedure.
This is a procedure commonly used to troubleshoot a suspected bad sensor.

 1. Perform a lockout/tagout.
 2. Perform the following substeps to set up the T5552, as shown in figure 40.

NOTE
The appearance of the electrical outlet will differ based on the electrical
power supplied at your location.

ELECTRICAL
PID CONTROLLER FLOW TRANSMITTER
FT1

4-20mA
FLOW SENSORS

FT2

4-20mA TEST
FLOWPVALVE

FV1

4-20mA
PL1 PL2 PL3 PL4

ALM1

ALM2
PROCESS METER

UDI1700

MAX
MIN
OUTLET
SS1 SS2 SS3 SS4 ALM3

ALM4
ALM5
ALM 1234 MAN FC
LEVEL SENSORS
0
DI 1234 SET SETUP
PV LT1 LT2
OUT 1234

-sp 0.0
OUTPUT RELAY 1
SP CURRENT INPUT
mA NO COM NC

4-20mA 4-20mA 24VDC

Func. Lower Man SP LS1 LS2 OUTPUT RELAY 2

Loop 1/2 Display Auto Select VOLTAGE INPUT NO COM NC
mV/V
Setup Run
Hold

CONTROL RELAYS ALARMPHORN [Link] PLC DISCRETE I/O

24VDC
INPUTS OUTPUTS OUTPUTS AH1 P1

ANALOG ANALOG CR1

ANALOG
AL1 AO1
1 2 3 4 5 6 7 8

GND
9 10 11 12 13 14 15 16

PRESSURE
REGULATOR
HV2 SET TO ZERO

MANUAL DRAIN
VALVES CLOSED

AIR SUPPLY
CONNECTION
HAND VALVES HV1
OPEN MANUAL FLOW
CONTROL VALVE
OPEN

Figure 40. T5552 Setup

BB270-XD06XEN LEVEL MEASUREMENT 45

Copyright © 2011 Amatrol, Inc.
A. Connect the air supply line to the T5552.
B. Set the pressure regulator to 0 psi.
You will not be controlling flow with the diaphragm-actuated control
valve in this skill.
C. Fill the reservoir tank with water.
D. Close (fully clockwise) the two manual process tank drain valves.
E. Open the manual flow control valve.
F. Locate a digital multimeter (DMM) and set it to measure DC milliamps
(mA).
When you measure milliamps with a DMM, make sure that the test probes
are connected to the appropriate jacks (COM and mA) of the DMM and
the selector switch is set to DC mA.
G. Connect the circuit shown in figure 41.
This circuit allows you to control the flow into the process tank by turning
the circulation pump on or off. It also allows you to measure the output of
the head pressure sensor (LT1) with the DMM.

FLOW SENSORS FLOW VALVE DISCRETE I/O

FT1 FT2 FV1 PL1 PL2 PL3 PL4

4-20mA 4-20mA TEST 4-20mA

SS1 SS2 SS3 SS4

LEVEL SENSORS
LT1 LT2

4-20mA 4-20mA 24VDC

LS1 LS2

CONTROL RELAYS ALARM HORN CIRC. PUMP

AH1 P1

CR1

CR2

CR3

DC POWER SUPPLY

24VDC 24VDC 24VDC

SOLENOID VALVES
SV1 SV2 SV3

GND

SET TO MEASURE DC
mA mA (TEST PROBES
WAVETEK DM15XL

V
2
20
200
1000 OFF 750
200
20
2
V
CONNECTED TO
200m

COM AND mA JACKS)

200m
LOGIC 200
2m
20m
2000
M
200m
20M A
2000k 10A
200k 10A
20k 200m
2k 20m
200 200 2m
l A

V COM mA 10A
FUSED
MAX
1000V FUSED
750V

DMM

Figure 41. Circuit to Measure Output of Head Pressure Sensor

H. Make sure SS1 is in the OFF (up) position.

BB270-XD06XEN LEVEL MEASUREMENT 46

Copyright © 2011 Amatrol, Inc.
The 2-wire variable capacitance pressure sensor on the T5552 has a pres-
sure range of 0-1 psi. Therefore, it can measure levels from zero to 27.7
inches (1/0.036 = 27.7 inches).
The pressure sensor outputs a 4-20 mA analog signal. Theoretically, a
signal of 4mA represents zero psi (zero inch). A signal of 20 mA repre-
sents 1 psi (27.7 inches). However, the T5552 does not use the full range
of the sensor.
The maximum level in the process tank is 10 inches, which is less than
half of the maximum level (27.7 inches) the sensor can detect. Therefore,
the output of the sensor will never reach the 20 mA maximum.

NOTE
Actual measurements depend on how well the sensor is calibrated.

 3. Remove the lockout/tagout.

 4. Turn on the main circuit breaker.
 5. Perform the following substeps to fill the process tank and observe the output
of the pressure sensor as the tank fills.
A. With the process tank empty, observe the display of the DMM and record
the reading.
Pressure Sensor Output _________________________________ (mA)
Theoretically, with no (or very little) water in the process tank, the output
of the sensor should be near its minimum signal, which is approximately
4 mA.
However, because the sensor diaphragm is actually located almost 1.5
inches beneath the bottom of the tank, there will be some offset to the
actual output. You should find that the output of the sensor with the tank
level at zero is between 5.3 and 5.5 mA.
B. Start the circulation pump by placing SS1 in the ON position.
This causes water to begin to flow into the process tank, and the tank to
fill.

BB270-XD06XEN LEVEL MEASUREMENT 47

Copyright © 2011 Amatrol, Inc.
C. When the tank level reads each of the levels listed in the following chart,
read and record the corresponding DMM reading.
LEVEL (inches) SENSOR OUTPUT (mA)
2
4
6
8
10

You should find the readings to be close (typically within ± 0.5 mA) of the
theoretical values (from the graph in figure 43). If your recorded values
vary from theoretical values by more than ±1 mA, inform your instructor.
The sensor may be out of calibration.
D. When the level in the tank reaches 10 inches, turn off the circulation
pump.
 6. Make a plot of the sensor output versus the level using the data you recorded
in substep 5C.

20
19
18
17
16
15
14
13
12
11
OUTPUT
10
(mA)
9
8
7
6
5
4
3
2
1
0
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28
LEVEL
(INCHES)

Figure 42. Graph Sheet

BB270-XD06XEN LEVEL MEASUREMENT 48

20
19
18
17
16
15
14
13
12
11
OUTPUT
10 10" ≈ 10.75mA
(mA)
9
8
7
6
5
4
3
2
1
0
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28
LEVEL
(INCHES)

Figure 43. Level Vs. Current Output

 7. Perform the following substeps to shut down the T5552.
A. Open the process tank manual drain valves until all of the water drains
from the process tank.
B. When the process tank is empty, close the manual drain valves by turning
them clockwise.
C. Turn off the main circuit breaker.
D. Disconnect the control circuit.
E. Return the DMM to its proper storage location.

BB270-XD06XEN LEVEL MEASUREMENT 49

1. To convert liquid level units to pressure units, you need to know the
level and the _______________________ of the fluid.

2. The ratio of the change in electrical output signal to the change in

physical input signal is called _______________.

3. The specific gravity of water is _______.

4. To convert sensor output signals to pressure units, you need to know

the sensitivity, the minimum output signal, and the ____________
output signal value.

5. Water exerts a pressure of ____________ psi per column inch.

6. When converting liquid level units to sensor output signal units, you
should first convert the liquid level units to ___________ units.

BB270-XD06XEN LEVEL MEASUREMENT 50

OBJECTIVE 13 DEFINE DISPLAY SCALING

Display scaling is the process of configuring a display device such as a

controller or a process meter to display the output signal from a sensor in measure-
ment units other than the actual units of the sensor’s signal. Scaling allows the
display to show the sensor’s signal in physical units such as liquid level or pres-
sure. For example, figure 44 shows a controller that is receiving a 5 mA input
signal from a level sensor. The controller is displaying 2.0 to indicate the actual
value of the liquid level in the tank, which is 2 meters.

SCALED
DISPLAY
2.0

5mA
LEVEL
SENSOR

Figure 44. Display Scaled to Show Actual Level Value

In addition to displaying physical units, the sensor signal can be scaled to

display the percentage of the total input range. The scale may also be inverted so
that the maximum value displayed corresponds to the minimum input value and
the minimum display value corresponds to the maximum input value.
Most electronic controllers and some process meters have the ability to scale
the input automatically. This is done when the low and high values for the input
are entered into the device. The controller compares the programmed range for the
display values to the electrical input signal range and calculates the proper scale
factor.

BB270-XD06XEN LEVEL MEASUREMENT 51

A process meter is a versatile measurement instrument that is widely used in

process control applications to provide a visual indication of the value of a process
variable (i.e. level, flow, pressure, temperature, and pH).

UDI1700

ALM1 MAX

ALM2 MIN

ALM3

ALM4
ALM5

SET SETUP

Figure 45. A Process Meter

BB270-XD06XEN LEVEL MEASUREMENT 52

Copyright © 2011 Amatrol, Inc.
Process meters are typically wired directly to sensors that monitor a process
variable. Figure 46 shows a system that connects a level sensor to a process meter
to indicate the level in the tank.

PROCESS
METER
UDI1700

2.0
ALM1 MAX

ALM2 MIN

ALM3

ALM4
ALM5

SET SETUP

5mA

Figure 46. Process Meter Indicating Level

Process meters are often scaled to display the electrical input signal in terms of
the physical units (i.e. display scaling). For example, although the process meter in
figure 46 receives a 5 mA input signal, it displays 2.0 (the level in meters).
Process meters can be mounted almost anywhere. In some applications, it is
necessary to mount the process meter near the actual process. Some applications
require the process meter to be installed in a central location such as a control panel
or a control room.

BB270-XD06XEN LEVEL MEASUREMENT 53

Although process meters vary widely in appearance and functionality, most

process meters have the same basic components shown in figure 47:
• Display
• Programming Keys
• Connection Terminals

DISPLAY
CONNECTION TERMINALS
(ON BACK)

UDI1700

ALM1 MAX

ALM2 MIN

ALM3

ALM4
ALM5

SET SETUP

PROGRAMMING
KEYS

Figure 47. Basic Components of a Process Meter

BB270-XD06XEN LEVEL MEASUREMENT 54

Copyright © 2011 Amatrol, Inc.
Display
While some older process meters have an analog display (scale and pointer),
most of today’s process meters have a digital display, like those in figure 48. The
digital display makes it easier to read and understand the data.
Process meters can be programmed to display either the actual value of the
input signal, a percentage of the input signal, or most commonly, the physical
units of the process variable that the input signal represents. Figure 48 shows
three process meters that all receive the same 12 mA input signal. The process
meter on the left indicates 12.0, the actual value of the input signal (in mA). The
process meter in the center indicates 50.0, the percentage of the input signal range
(assuming a 4-20 mA range), and the process meter on the right indicates 5.0, the
liquid level measured in feet.

ACTUAL UNITS PERCENTAGE OF PHYSICAL UNITS

FULL SCALE
12mA 12mA 12mA

UDI1700 UDI1700 UDI1700

ALM1 MAX ALM1 MAX ALM1 MAX

ALM2 MIN ALM2 MIN ALM2 MIN

ALM3 ALM3 ALM3

ALM4 ALM4 ALM4

ALM5 ALM5 ALM5

SET SETUP SET SETUP SET SETUP

Figure 48. Process Meter Displaying Different Units

BB270-XD06XEN LEVEL MEASUREMENT 55

Copyright © 2011 Amatrol, Inc.
Programming Keys
Most of today’s process meters are microprocessor-based, making them
programmable. Microprocessor-based process meters provide a set of keys that
allow the user to program the meter to display the process variable. Typically, this
requires changing a number of parameters.
For example, the Honeywell UDI 1700 process meter shown in figure 49 allows
the user to select the type of input signal, the range of the input signal, and the high
and low display values that correspond to the upper and lower limits of the input
signal range. It also allows the user to program relays that can be used as alarms.
The SETUP key is used along with the up arrow  key to place the process
meter in the Select Mode. The Select Mode allows the user to select which set of
parameters to edit. The up  and down  arrow keys are used to scroll through the
different programming menus and to change parameter values. When a program-
ming mode is selected, the SETUP key is used to scroll through the parameters in
the selected mode and the up  and down  keys are used to change parameter
values.

UDI1700

ALM1 MAX

ALM2 MIN

ALM3

ALM4
ALM5

SET SETUP

DOWN UP SETUP
ARROW ARROW KEY
KEY KEY

Figure 49. Honeywell UDI1700 Process Meter Programming Keys

BB270-XD06XEN LEVEL MEASUREMENT 56

Copyright © 2011 Amatrol, Inc.
Connection Terminals
The connection terminals provide a means to connect the process devices to
the process meter. Typically, the connection terminals are located on the back of
the process meter, as figure 50 shows, since most process meters are designed to
be panel mounted.

OPTION A

POWER DIGITAL INPUT

INPUT
OPTION 1
DC SUPPLY - + -
+ D
R
RS485 Comms RELAY OUTPUT
UT D B OA
AC SUPPLY L N P
T AR AY
A B
OU BO EL
13 14 15 16 17 18 19 20 21 A A AL R
R Y
NE L
LI RE DU
N/O N/C + 12 22 - N/C N/O

OPTION 3 C C 11 23 C C OPTION 2

N/O N/O - 10 24 + N/O N/O

D D Y
AR AR PPL 9 8 7 6 5 4 3 2 1
BO BO SU
Y Y
LA LA ER
RE RE OW RTD
AL P - +
DU Tx
T/C

- + LINEAR (V/mV)

LINEAR (mA)
+ -

UNIVERSAL INPUT

Figure 50. Connection Terminals on a Process Meter

Terminals 1-4 are input terminals. When connecting an RTD (Resistance

Temperature Detector), terminals 1-3 are used. When using a thermocouple, termi-
nals 2 and 3 are used. Terminals 2 and 3 are also used if the input signal is a
voltage. If the input signal is a current (mA), terminals 1 and 4 are used.
Terminals 5-9 are not typically used. Terminals 10-12 are used for Option 3, if
used. Typically, these terminals are used for relays.
Terminals 13 and 14 are connections for the input power. The input power can
be AC or DC. Terminal 15 is not used.
Terminals 16 and 17 are used for Option A. Typically they can either be used
for a digital (discrete) input or for communications (RS485). Terminal 18 is not
used.
Terminals 19-21 are used for Option 1, which is a relay output. Terminal 19
is the NC contact, terminal 20 is the common, and terminal 21 is the NO contact
connection.

BB270-XD06XEN LEVEL MEASUREMENT 57

Copyright © 2011 Amatrol, Inc.
Terminals 22-24 are used for Option 2. Option 2 can be another relay or termi-
nals 22 and 24 can provide a 4-20mA output.
Figure 51 shows a level sensor wired to the input of a process meter and the
output from the process meter wired to a controller in a remote location. The level
sensor provides a voltage output. The output from the process meter closes the
control loop.

PROCESS METER

13 14 15 16 17 18 19 20 21

12 22
CONTROLLER

11 23
+ -
INPUT
10 24

9 8 7 6 5 4 3 2 1

- +

LEVEL
SENSOR
(1-5VDC)

Figure 51. Process Meter Wired to a Level Sensor and Remotely Located Controller

Since the level sensor outputs a 1-5V DC signal, it is connected to terminals 2

and 3. The positive terminal on the level sensor is connected to terminal 2 and the
negative terminal on the level sensor is connected to terminal 3.
The process meter is equipped with a 4-20mA output that is connected to the
input terminals of the controller. Terminals 22 and 24 provide the output signal.

BB270-XD06XEN LEVEL MEASUREMENT 58

Copyright © 2011 Amatrol, Inc.
Display Operation
When a process meter receives an analog input signal, the signal is converted
(analog-to-digital) and fed to its microprocessor, as figure 52 shows. The micro-
processor adjusts the input based on the parameters entered into the processor’s
memory and then sends the adjusted data to the display. The microprocessor
constantly monitors the input and updates the display so that the data displayed
remains accurate.

PROCESS METER
DISPLAY
ANALOG
INPUT ANALOG-TO-
DIGITAL (A/D)
CONVERSION

DIGITAL
SIGNAL

MICROPROCESSOR
ADJUSTED
DATA

PARAMETERS

MEMORY

Figure 52. Basic Operation of a Process Meter

BB270-XD06XEN LEVEL MEASUREMENT 59

Configuring a process meter involves programming the meter to accurately

display the process variable in the desired units. To configure a process meter,
the input signal range parameters and the measurement range parameters must be
programmed.
The input signal range represents the minimum and maximum values of the
electrical input signal. Common analog input signals that process meters accept
include 4-20 mA, 0-20 mA, 1-5 V, and 0-10 V. Figure 53 shows a process meter
accepting a 4-20 mA signal.

PROCESS METER

13 14 15 16 17 18 19 20 21

12 22

11 23

10 24

9 8 7 6 5 4 3 2 1

+ -
DC POWER
SUPPLY
LEVEL + -
SENSOR
(4-20mA)

Figure 53. Process Meter Accepts 4-20mA Signal

BB270-XD06XEN LEVEL MEASUREMENT 60

Copyright © 2011 Amatrol, Inc.
Program Input Signal and Range
For the Honeywell UDI 1700 process meter, the input type/range parameter
(inPt) is located in the Configuration Menu. The selections for this parameter
include several types of thermocouples and RTDs. When a thermocouple or RTD
is selected, the range is automatically set. If the input is a voltage or current, the
desired range is selected (i.e. 4_20 for 4-20mA). The table below shows the various
selections for the input (inPt) parameter.

Figure 54 shows the input parameter is set for a 4-20mA signal.

UDI1700

ALM1 MAX

ALM2 MIN

ALM3

ALM4
ALM5

SET SETUP

Figure 54. Input Parameter set to 4-20mA

BB270-XD06XEN LEVEL MEASUREMENT 61

Copyright © 2011 Amatrol, Inc.
Program Scale Range Parameters
The scale range represents the minimum and maximum display values that
correspond to the minimum and maximum values of the input signal range. The
scale range is programmed into the meter so that the display indicates the value of
the process variable in the desired units.
For example, if a process is measuring the level in a tank from 0-10 ft, the scale
range for the meter is 0-10 even though the input signal may be 4-20mA. Entering
the scale range enables the meter to scale the display.
The scale range parameters for the Honeywell UDI 1700 process meter are:
• ruL - Scale Range Upper Limit that corresponds to the maximum value of
the input signal.
• rLL - Scale Range Lower Limit That corresponds to the minimum value of
the input signal.
Figure 55 shows the Scale Range Upper Limit parameter on the Honeywell
UDI 1700 set to 10.0

UDI1700

ALM1 MAX

ALM2 MIN

ALM3

ALM4
ALM5

SET SETUP

Figure 55. Scale Range Upper Limit Parameter Set to 10

BB270-XD06XEN LEVEL MEASUREMENT 62

Copyright © 2011 Amatrol, Inc.
The following steps describe how to program a Honeywell UDI 1700 process
meter to display a process variable:
Step 1: Enter the Select Mode - Pressing and holding the SETUP key and
pressing the up arrow  key enters the select mode.
Step 2: Scroll to the Configuration Menu Selection - Scroll through the
menu selections using the up  and down  arrow keys until ConF (Configura-
tion Menu) is displayed. The Configuration Menu is used to select the input type/
range and the scale range.
Step 3: Enter the Configuration Menu - Pressing the SETUP key enters the
Configuration Menu.
Step 4: Enter the Unlock Code - The unlock code for the Configuration
Menu is 20. The value is set using the up  and down  arrow keys. When 20 is
displayed, pressing the SETUP key accepts the value and opens the Configuration
Menu.
Step 5: Select the Input Type/Range - If the input (inPt) parameter is not
currently displayed, scroll to the input parameter by pressing the SETUP key until
“inPt” appears on the display, as figure 56 shows. After one second, the current
input value should appear. Using the up  and down  arrow keys, scroll until
the desired value appears (i.e. 4-20mA). When the desired value appears, press the
SETUP key. This causes the Yes (YES?) prompt to appear. Accept the new value
by pressing the up  arrow key.

UDI1700

ALM1 MAX

ALM2 MIN

ALM3

ALM4
ALM5

SET SETUP

Figure 56. Input Parameter

BB270-XD06XEN LEVEL MEASUREMENT 63

Copyright © 2011 Amatrol, Inc.
Step 6: Set the Scale Range Upper Limit - Using the SETUP key, scroll to
the Scale Range Upper Limit (ruL) parameter. After a second, the current value of
the parameter is displayed. Change the value using the up  and down  arrow
keys. The longer a key is held, the faster the value changes in the display. When
the desired value appears, select it by pressing the SETUP key. This causes the Yes
(YES?) prompt to appear. Accept the new value by pressing the up  arrow key.
Step 7: Set the Scale Range Lower Limit - Using the SETUP key, scroll to
the Scale Range Lower Limit (rLL) parameter. After a second, the current value of
the parameter is displayed. Change the value using the up  and down  arrow
keys. When the desired value appears, select it by pressing the SETUP key. This
causes the Yes (YES?) prompt to appear. Accept the new value by pressing the up
 arrow key.
Step 8: Exit the Configuration Menu - Pressing and holding the SETUP key
and pressing the up  arrow key exits the Configuration Menu and returns to the
Select Mode.
Step 9: Exit the Select Mode - Scroll the display using the up arrow key until
“OPtr” appears. Then, return to the Operating Mode (OPtr) by pressing the SETUP
key. The display momentarily displays “Proc” and then returns to the Operating
Mode, displaying the current scaled value of the input.

BB270-XD06XEN LEVEL MEASUREMENT 64

Procedure Overview
In this procedure, you will connect and configure the process meter on the
T5552 to measure the level of water in the process tank. To do this, you must
first determine the output of the level sensor/transmitter for a level of zero
inches and a level of 10 inches. You will then use this information to configure
the meter.

 1. Perform a lockout/tagout.
 2. Perform the following substeps to set up the T5552, as shown in figure 57.

NOTE
The appearance of the electrical outlet will differ based on the electrical
power supplied at your location.

ELECTRICAL
PID CONTROLLER FLOW TRANSMITTER
FT1

4-20mA
FLOW SENSORS

FT2

4-20mA TEST
FLOWPVALVE

FV1

4-20mA
PL1 PL2 PL3 PL4

ALM1

ALM2
PROCESS METER

UDI1700

MAX
MIN
OUTLET
SS1 SS2 SS3 SS4 ALM3

ALM4
ALM5
ALM 1234 MAN FC
LEVEL SENSORS
0
DI 1234 SET SETUP
PV LT1 LT2
OUT 1234

-sp 0.0
OUTPUT RELAY 1
SP CURRENT INPUT
mA NO COM NC

4-20mA 4-20mA 24VDC

Func. Lower Man SP LS1 LS2 OUTPUT RELAY 2

Loop 1/2 Display Auto Select VOLTAGE INPUT NO COM NC
mV/V
Setup Run
Hold

CONTROL RELAYS ALARMPHORN [Link] PLC DISCRETE I/O

24VDC
INPUTS OUTPUTS OUTPUTS AH1 P1

ANALOG ANALOG CR1

ANALOG
AL1 AO1
1 2 3 4 5 6 7 8

GND
9 10 11 12 13 14 15 16

PRESSURE
REGULATOR
HV2 SET TO ZERO

MANUAL DRAIN
VALVES CLOSED

AIR SUPPLY
CONNECTION
HAND VALVES HV1
OPEN MANUAL FLOW
CONTROL VALVE
OPEN

Figure 57. T5552 Setup

BB270-XD06XEN LEVEL MEASUREMENT 65

NOTE
You must set several parameters to properly configure the process meter on
the T5552. The relevant parameters will be explained as you progress through
the remaining steps.

 4. Perform the following substeps to set up the process meter on the T5552 for
configuration.
A. Connect the circuit shown in figure 58.
Make sure the current input terminals are used.
This circuit allows you to measure the level of water in the process tank
with the process meter.

FLOW SENSORS FLOW VALVE DISCRETE I/O

PROCESS METER
FT1 FT2 FV1 PL1 PL2 PL3 PL4
UDI1700

ALM1 MAX

4-20mA 4-20mA TEST 4-20mA ALM2 MIN

SS1 SS2 SS3 SS4 ALM3

ALM4
ALM5

LEVEL SENSORS SETUP

SET
LT1 LT2

OUTPUT RELAY 1
CURRENT INPUT
mA NO COM NC

4-20mA 4-20mA 24VDC

LS1 LS2
OUTPUT RELAY 2
VOLTAGE INPUT NO COM NC
mV/V

CONTROL RELAYS ALARM HORN CIRC. PUMP PLC DISCRETE I/O

24VDC
AH1 P1

CR1

1 2 3 4 5 6 7 8

CR2

9 10 11 12 13 14 15 16

CR3

DC POWER SUPPLY PLC ANALOG I/O

4-20mA
24VDC 24VDC 24VDC

SOLENOID VALVES
1 2 3 4 5 6 7 8
SV1 SV2 SV3

GND
9 10 11 12 13 14 15 16

Figure 58. Circuit to Measure Level Using the Process Meter

BB270-XD06XEN LEVEL MEASUREMENT 66

DC POWER
SUPPLY LT1 PROCESS METER
PRESSURE SENSOR CURRENT INPUT
+
+ - + -

-
24
VDC
CIRC. PUMP
P1
SS1
+
-

Figure 59. Wiring Diagram for Level Sensor Connected to the Process Meter

B. Turn on the main circuit breaker.

BB270-XD06XEN LEVEL MEASUREMENT 67

Copyright © 2011 Amatrol, Inc.
 5. Perform the following substeps to enter the Configuration Menu on the
Honeywell UDI 1700 process meter.
A. Press and hold the SETUP key and then press the up  arrow key.
This places the meter in the Select Mode. The letters “SLCt” should
appear on the display briefly, indicating that the meter is now in the Select
Mode. Then, the last selected menu will appear on the display.
From the Select Mode, you can select from the four available menus, as
listed in the table in figure 60. Two of the menus, Set Up and Configura-
tion, require codes to unlock them. The unlock codes are also listed in the
table.
You will be using the Configuration Menu for this skill.
SELECTION MODE MENUS
UNLOCK
MENU DISPLAY DESCRIPTION
CODE
Operator Optr Normal operation - Allows user to view None
process variable or other data
Set Up SetP Allows user to customize settings for spe- 10
cific application. Includes adding an offset
for the PV, adding a filter for the input, and
setting scaling breakpoints.
Configuration ConF Allows user to configure the meter settings 20
including inputs, alarms, and outputs.
Product Infor- InFo Displays product information for meter None
mation including options, firmware information,
manufacture date, and serial number.

Figure 60. Selection Mode Menus

B. Use the up  and down  arrow keys to scroll through the menus until
the Configuration Menu (ConF) appears on the display.
“ConF” should now appear on the display.
C. Press the SETUP key to open the Configuration Menu.
Since the Configuration Menu is locked, “ULoc” appears on the display
briefly, followed by 0. The unlock code must be entered before you can
continue.
D. Use the up  and down  arrow keys to change the displayed value to
20, which is the unlock code for the Configuration Menu.

BB270-XD06XEN LEVEL MEASUREMENT 68

Copyright © 2011 Amatrol, Inc.
E. When 20 is displayed, press the SETUP key to enter the unlock code.
The Configuration Menu should now be unlocked and the first parameter
in the menu should be displayed. The first parameter is the input (inPt)
parameter. The display should briefly show “inPt”, followed by the current
setting for the input parameter, similar to figure 61.
You should also notice that the SET indicator, shown in figure 61, is flashing
to indicate that the meter is in the Configuration Menu. It continues to
flash until the Configuration Menu is closed. When the Set Up Menu is
opened, the SET indicator remains on constantly until the menu is closed.

UDI1700

ALM1 MAX

ALM2 MIN

ALM3

ALM4
ALM5

SET SETUP

Figure 61. Example of Current Input Parameter Value

 6. Perform the following substeps to select the desired input type.
 The output from the level sensor (LT1) is a current with a 4-20mA range.
A. If 4-20mA is not currently displayed, as shown in figure 61, use the up
 and down  arrow keys to scroll through the input selections until it
appears on the display.

NOTE
The longer you hold a key, either up or down, the faster the value scrolls.

If 4_20 mA is currently displayed, skip to Step 7.

BB270-XD06XEN LEVEL MEASUREMENT 69

Copyright © 2011 Amatrol, Inc.
B. When the correct input is displayed, press the SETUP key.
This causes the Yes prompt to appear on the display, as shown in figure
62. This prompt appears any time you change a value in the Configuration
Menu.

UDI1700

ALM1 MAX

ALM2 MIN

ALM3

ALM4
ALM5

SET SETUP

Figure 62. Yes Prompt

C. Press the up  arrow key to accept the new value for the input parameter.

NOTE
If you do not press the up  arrow key in response to a Yes prompt, the
value of the selected parameter reverts to the previous setting.

With the correct input selected, the next step is to set the scale range limits
for the process variable.
 7. Perform the following substeps to set the scale range limit parameters.

NOTE
In order to scroll through the parameters using the SETUP key, the name
of a parameter (i.e. inPt) must appear on the display. If a value is displayed (i.e.
4_20), pressing the SETUP key displays the parameter name. The parameter
name will appear for about one second before returning to the value. You can
only scroll with the SETUP key when a parameter name is displayed.

 The scale range limit parameters are also located in the Configuration Menu.

BB270-XD06XEN LEVEL MEASUREMENT 70

Copyright © 2011 Amatrol, Inc.
A. Using the SETUP key, scroll to the Scale Range Upper Limit (ruL)
parameter. When “ruL” appears on the display, stop scrolling.
After a second, the current value of the parameter should appear.
B. Use the up  and down  arrow keys to change the value to 27.7.
The measurement range for the level sensor is 0 to 27.7 inches.
C. When the correct value is displayed, press the SETUP key.
The Yes prompt again appears on the display.
D. Press the up  arrow key to accept the new value for the parameter.
E. Using the SETUP key, scroll to the Scale Range Lower Limit (rLL)
parameter. When “rLL” appears on the display, stop scrolling.
After a second, the current value of the parameter should appear.
F. Use the up  and down  arrow keys to change the value to 0.0.
G. When the correct value is displayed, press the SETUP key.
The Yes prompt again appears on the display.
H. Press the up  arrow key to accept the new value for the parameter.
I. Using the SETUP key, scroll to the to the Decimal Point Position (dPoS)
parameter. When “dPoS” appears on the display, stop scrolling.
After a second, the current value of the parameter should appear.
J. Use the up  and down  arrow keys to change the value to 1, if
necessary.
A setting of 1 for this parameter indicates that there is one position after the
decimal point (XXX.X). Other settings for this parameter are 0 (XXXX),
2 ([Link]), and 3 ([Link]).
K. When the correct value is displayed, press the SETUP key.
The Yes prompt again appears on the display.
L. Press the up  arrow key to accept the new value for the parameter.
That completes the parameter settings in the Configuration Menu. You can
now exit the Configuration Menu and the Select Mode.

BB270-XD06XEN LEVEL MEASUREMENT 71

Copyright © 2011 Amatrol, Inc.
 8. Perform the following substeps to exit the Configuration Menu and the Select
Mode.
A. Press and hold the SETUP key and press the up  arrow key to return to
the Select Mode.
B. Use the up  arrow key to scroll to the Operator Menu (OPtr). Stop when
the display shows “OPtr”.
C. Press the SETUP key to exit the Select Mode and return the process meter
to normal operation.
“Proc” should appear briefly on the display followed by the process vari-
able value. You should notice that the value shows a level of approxi-
mately 1.6, even though the actual level (according to the sight scale) is
zero.
The reason for this difference is that the level sensor is mounted to the
bottom of the tank, causing the actual sensing element to be below the
zero mark in the process tank. In fact, the sensing element is approxi-
mately 1.6 inches below the zero mark in the tank.
In order to compensate for this difference, you need to set the Process
Variable Offset (OFFS) parameter in the Set Up Menu.
 9. Perform the following substeps to set the Process Variable Offset parameter
in the Set Up Menu.
A. Press and hold the SETUP key and then press the up  arrow key to enter
the Select Mode.
B. Use the up  and down  arrow keys to scroll through the menus until
the Set Up Menu (SEtP) appears on the display.
“SEtP” should now appear on the display.
C. Press the SETUP key to open the Set Up Menu.
Since the Set Up Menu is locked, “ULoc” appears on the display briefly,
followed by 0. The unlock code must be entered before you can continue.
D. Use the up  and down  arrow keys to change the displayed value to
10, which is the unlock code for the Set Up Menu.
E. When 10 is displayed, press the SETUP key to enter the unlock code.
The Set Up Menu should now be unlocked and the first parameter in the
menu should be displayed. The first parameter is the Input Filter Time
Constant (FiLT) parameter.
F. Using the SETUP key, scroll to the Process Variable Offset (OFFS)
parameter. Stop scrolling when “OFFS” appears on the display.
Remember, the name of a parameter (i.e. FiLT) must be displayed before
you can scroll using the SETUP key.
After a second, the current value of the parameter should appear.
G. Use the up  and down  arrow keys to change the value to -1.6.
Setting the Process Variable Offset (OFFS) parameter to -1.6 compensates
for the difference between the sensing element location and the actual
zero mark in the process tank.

BB270-XD06XEN LEVEL MEASUREMENT 72

Copyright © 2011 Amatrol, Inc.
H. Press the SETUP key to accept the new value.
I. Press and hold the SETUP key and press the up  arrow key to return to
the Select Mode.
J. Use the up  arrow key to scroll to the Operator Menu (OPtr). Stop when
the display shows “OPtr”.
K. Press the SETUP key again to exit the Select Mode and return the process
meter to normal operation.
The process value on the display should now be 0.0. If it is not 0.0, you
can go back to the Process Variable Offset parameter and adjust the value
until the meter displays 0.0 when the water level is at the zero mark on the
process tank.
 10. Perform the following substeps to fill the process tank and measure the level
using the process meter.
A. Observe the process meter while the process tank is empty.
You should observe that the process meter display shows 0.0.
B. Start the circulation pump by placing SS1 in the ON position.
The process meter should display the level of water in the tank (in inches)
as it continues to increase.
C. Continue to allow the tank to fill and observe the process meter as the level
increases.
You should find that the indicated level on the process meter continues to
increase as the actual level in the process tank increases.
D. When the process meter indicates 10.0 (10 inches), turn off the circulation
pump.
E. Check the level of water in the tank using the sight level scale on the front
of the process tank.
Is the level close to 10 inches? _________________________ (Yes/No)
You should find that the level according to the sight level scale is close to
10 inches. If not, you may need to reconfigure the process meter.
F. Open the right side process tank manual drain valve and drain the process
tank to the 5-inch mark.
G. When the level reaches the 5-inch mark, close the tank drain valve.
H. Check the level indicated on the process meter.
You should find that the displayed value indicates approximately 5.0
inches.
As you can see, when a process meter is properly configured, it can provide
the operator or technician with valuable data concerning the process. You
can determine whether a process is in control (PV = SP) without physi-
cally observing the process.

BB270-XD06XEN LEVEL MEASUREMENT 73

Copyright © 2011 Amatrol, Inc.
 11. Perform the following substeps to shut down the T5552.
A. Open the process tank manual drain valves until all of the water drains
from the process tank.
B. When the process tank is empty, close the manual drain valves by turning
them clockwise.
C. Turn off the main circuit breaker.
D. Disconnect the control circuit.

BB270-XD06XEN LEVEL MEASUREMENT 74

1. Display _______________ is the process of configuring a device to

display the output signal from a sensor in measurement units other than
the actual units of the sensor’s signal.

2. Most newer process meters have a(n) ________________ display.

3. When a process meter receives an analog input signal, the signal is

converted (analog-to-digital) and sent to its ______________.

4. Process meters can be programmed to display the actual value of the

input signal, a percentage of the input signal, or the ___________ units
of the process variable.

5. To configure a process meter, you must program the input signal range
and the _______________ range parameters.

6. Process meters are typically wired directly to _______ that monitor a

process variable.

BB270-XD06XEN LEVEL MEASUREMENT 75

LIQUID SPECIFIC GRAVITY

Acetone 0.79
Corn Oil 0.92
Crude Oil 0.85
Gasoline 0.74
Glucose 1.35-1.42
Glycol 1.01
Molasses 1.45
Soy bean oil 0.93
Tar 1.2
Water (fresh) 1.00
Water (sea) 1.03

BB270-XD06XEN LEVEL MEASUREMENT 76

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