Current output type transmitter signal wiring method - Database & Sql Blog Articles

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Currently, current-output transmitters used in power systems come in four-wire, three-wire, and two-wire signal wiring configurations, as illustrated in the figure.

Signal wiring diagram

Signal wiring diagram

The current-output transmitter converts a physical quantity into a 4–20 mA current output, which requires an external power supply. The most common configuration is a four-wire system, where the transmitter uses two separate lines for power and two for the current output.

In a three-wire system, one of the power lines (either VCC or GND) can be shared with the current output, reducing the total number of wires to three.

A two-wire transmitter, on the other hand, uses the 4–20 mA current itself to power the device. This means only two wires are needed, making it highly efficient. The industrial standard sets a minimum current of 4 mA, ensuring that the transmitter always has enough power to operate within its range. This design makes two-wire transmitters both practical and reliable.

Two-wire transmitters offer several significant advantages:

1) They are less affected by parasitic thermocouples, voltage drops, and temperature drift along the wire. Thin and low-cost wires can be used, significantly reducing cabling and installation costs.

2) When the current source has a high output resistance, magnetic field coupling-induced voltage in the wire loop has minimal impact because the interference current is very small. Twisted pair cables can further reduce this effect. For three-wire systems, shielded cables must be used, and the shielding should be properly grounded.

3) Capacitive interference can cause errors in the receiver’s resistance. In a 4–20 mA two-wire loop, the receiver resistance is typically 250 ohms (producing a voltage output of 1–5V). This low resistance minimizes error, allowing for longer wire lengths compared to voltage-based telemetry systems.

4) Each reading or recording device can switch between different channels with varying wire lengths without affecting accuracy, enabling decentralized data acquisition and centralized control.

5) Using 4 mA as the zero level allows for easy detection of open circuits, short circuits, or sensor failures (when the current drops to 0 mA).

6) It is simple to add surge protection devices at the two-wire output port, enhancing safety against lightning strikes and electrical surges.

Compared to three-wire and four-wire transmitters, two-wire systems offer better performance and reliability, and they are gradually replacing older technologies. In the global industry, there's a growing trend toward using two-wire transmitters, especially in applications where the monitoring system is located far from the field equipment—often tens or even hundreds of meters away. These environments are often harsh, with strong electrical signals and potential electromagnetic interference, as well as lightning-induced surges.

One of the major challenges in single-chip-based systems is reliably transmitting small signals over long distances in such conditions. Two-wire transmitters have effectively addressed this issue, making them a preferred choice in modern industrial automation and control systems.

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