Today's electricians are often found working in applications outside the realm of what is traditionally considered "electrical." Through new programs sponsored by the IBEW-JATC training schools and others, the skill sets of the electrical union workforce have broadened to include automation and controls.

Nowadays many industrial electricians are just as comfortable troubleshooting a circuit breaker panel as a PLC (Programmable Logic Controller). It is becoming more common for electricians to work in automation applications, where they frequently troubleshoot the inputs and outputs (I/O) of control systems.

Commercial electricians, meanwhile, are rapidly training on building controls, as retrofits and retro-commissioning become larger opportunities. New efficiency upgrades double or triple the demand for low voltage and milliamp troubleshooting.

In 2007, the first clamp meter to accurately measure milliamps without breaking the circuit was introduced. It could simply clamp on and read down to 0 milliamps and up to 100 milliamps. The tool saved so much time that it revolutionized automation and controls troubleshooting. Interestingly, electricians adopted the tool in even greater numbers than industrial technicians.

Now, new versions of this clamp meter have been engineered with controls electricians specifically in mind. By incorporating the functions of a loop calibrator, including low voltage measurement and sourcing, the meters will save electricians even more time and vastly increase their troubleshooting capabilities in both automation and controls.

Measurement Capabilities

Where the original clamp meter measured milliamp signals, one new model adds milliamp sourcing, simulation and 24 V loop power (for testing power supplies to control loops). Another model further adds voltage sourcing and measurements (for low voltage building controls), simultaneous mA sourcing and measurement (for testing I/O) and mA output, to log over time and capture intermittent problems.

Automation Overview

Programmable Logic Controllers (PLCs) are the control system of choice for many industrial applications, ranging from water treatment facilities to high speed automation applications like bottling lines. Most PLC inputs and outputs are "ones and zeros" representing either the status of devices, such as a switch or sensor, or outputting a signal to close a switch or relay, open or close a valve or control a motor in a process.

Many inputs and outputs are analog and represent a measured variable such as temperature, pressure or to what degree a valve is opened or closed. These measured variables are represented as inputs to the PLC using the 4 to 20 mA signal. A good example would be where the control system needed to know the position of a valve (percent open or closed). If the output signal from a normally closed valve is 4 mA, the control system interprets this as the valve being closed. If the valve output signal is 20 mA the control system interprets this as the valve being open. When the electrician is troubleshooting analog I/O, measuring and interpreting the 4 to 20 mA signal is essential.

Building Controls Overview

While control systems are often a jumble of digital, analog and pneumatic controls, the analog component reliably uses either low voltage or milliamp loops, or sometimes both. The purpose is similar to the automation description above-these loops transmit information and instructions from sensors and devices to controllers upstream.

Sensors communicate by converting their output signal to a 4-20 mA dc current, with 4 mA representing the sensor's zero-level output and 20 mA representing the sensor's full-scale output. Other systems use 1-5 V dc or 0-10 V dc circuits in a similar fashion. Occasionally, the 4-20 mA signal is converted to a 2-10 V dc signal by adding a 500 ohm resistor across the load.

Most control systems use fully-electronic, two-way, three-way and Pressure Independently Characterized Control Valves (PICCVs).Variable frequency drives (VFDs) are used as standard equipment on towers, variable air volume (VAV) fans, pumps and chillers.

Typical sensors include humidity and temperature transmitters, CO2 sensors for indoor air quality, power meters, branch circuit monitors and energy meters. Field level controllers talk to sensors and actuators, often using 4-20 mA or 0-10 V dc analog signals.

Troubleshooting 4 to 20 mA Input Output Circuits

Often the first indication of a control loop problem comes from the operator or manufacturing manager: "I think we have a bad valve," or "This control system is not responding the way it used to." In either case, it is the electrician's signal to begin troubleshooting.

The first step is to measure the 4 to 20 mA signal, either by breaking the loop connecting in series with a DMM, or by using a mA clamp meter and verifying the loop current value. If the loop current measured is not as expected, there are three likely causes: broken/disconnected/shorted wires, a bad loop power supply or faulty instrumentation.

If no problem is found in the wires, use a DMM (or the voltage measurement function on specific clamp meters) to check the loop power supply. If the power supply shows no output, use the 24 V loop power function of the clamp meter to substitute for it; if the loop then works properly the source of the problem is obvious.

If the wiring and the power supply both check out, it is time to check the transmitter or other similar instrument in the control loop. With a loop calibrator, process calibrator or multi-function clamp-on meter, use its mA simulate mode to substitute for the transmitter. If the loop performs as requested, the problem lies with the transmitter; if not, it is elsewhere.

If a final control element (valve positioner, etc.) is suspected, use the mA source/simulate mode on the clamp meter to feed a signal into it while watching the local indicator for a response.

Loop Malfunctions

If the problem is not a dead loop but an inaccurate one, likely possibilities include a bad I/O card on the PLC or a bad final control element (I/P on a valve positioner, etc.). It is usually best to start by doing a field check of the transmitter, local or remote indicator or final control element.

For a final control element, use a clamp-on meter to measure loop current and compare the value to the local position indicator on the valve or other final control element. Relay that information to the operator or compare to the control system console to verify findings.

In the case of a measurement loop, use the clamp meter to measure loop current, then check with the operator to see how well the value indicated on the control panel agrees with the actual loop current. This will give a quick check on the PLC I/O card that handles that particular loop. It is also possible to use the meter's mA source/simulate mode to send a known signal to the control system; as before, compare the value as read by the operator or displayed on the console to the actual current in the loop.

Some loops show random fluctuations or intermittent faults that tend not to happen while an electrician is watching. The solution here is to use a clamp meter with a scaled mA output. In this mode the meter measures the current in the loop without breaking the circuit, and produces an identical and isolated mA output. Feed that output to a DMM with a logging function; by allowing the DMM to record over time, any disturbance will be recorded.

Commissioning and Retro-Commissioning

The most common process is to check each wire at the controller and verify amperage. Start by using a clamp-on loop current meter to check each loop for current in a matter of seconds, without disconnecting anything.

If a loop is not working, a multifunction clamp meter can also make quick work of diagnostics. If current is not present on some loops, proceed with classic troubleshooting: check the wiring, the power supply and the control system's I/O cards (by using the meter to inject a signal into the I/O, then contacting the operator or referring to the console to verify the indication).

If the indication agrees with what is sent, then there may be something amiss with the transmitter-either the transmitter itself or, if this is a new installation, perhaps miswiring the sensor's input to the transmitter.

Checking Loop Isolators

Loop isolators are often used to prevent damage to sophisticated control systems from overvoltage conditions caused by lightning strikes or other voltage transients. To check a loop isolator, apply a mA input signal to the device and measure its 4 to 20 mA output using the clamp-on current measuring function. This two channel simultaneous source/measure method can also be used for valves that report their position using 4-20 mA.

Checking VFDs

Variable frequency drives (VFDs) are used to power motors, blowers and fans in process applications as well as conveyor systems and machine tools. Control inputs are generally voltage (1-5 V or 0-10V) or current (4-20 mA). A mA process clamp meter can feed in a signal to simulate a normal input while the technician observes the result. If the drive does not interpret the signal correctly on the display or the motor being controlled does not change in speed accordingly, the drive or motor would be suspect.

Summary

Today's mA process clamp meters can save electricians and automation specialists a great deal of troubleshooting time. In some cases, the new tools replace a number of separate instruments. In other cases, electricians may never have had access to this type of measurement before, because of the higher cost of most calibration tools.

Above all, the electrician can make the measurements he needs to get to the root of the problem, without spending 15 minutes going back to the shop or truck to get a specialized instrument. One user mentioned that "Instead of having two tools in your pouch, you now have one tool in your pouch for doing all 4-20 mA loop calibrations and troubleshooting."

Pumps & Systems