-TN661.2.

0TN66Setting Transmitter FailureLevelsTechnical Note

Setting Failure Levels for Smart

Transmitters
in CCC Controllers

This technical note tells how to set transmitter failure levels within CCC
controllers for projects which use “smart” transmitters.
Smart transmitters use a diagnostic routine to monitor themselves during
normal operation. If a fault is detected, the transmitter can indicate the
condition by setting the output current to a configurable value beyond the
Technical Note
normal operating range. The controller can then detect the transmitter
fault and take appropriate control action.
Each smart transmitter can be configured to indicate a fault with either a
high or low output, and the controller must be configured for the proper
A/D failure limits and fallback action.
The operational range and fault levels for smart transmitters vary by man-
ufacturer. Alarm levels for various Standard and Namur transmitters are
shown in Figure 1 on page 2. Note the unique low and high fail detec-
tion thresholds for standard Yokogawa and Rosemount smart
transmitters.
A saturated output from a transmitter should not be considered as failure
as a saturated output can represent a real process condition.
AM CCC controllers test each transmitter input against a configured range,
as discussed in the following sections:
• “Series 3 Plus” on page 2
• “Series 3++” on page 3
• “Series 4” on page 3
• “Series 5 and 5M” on page 5
• “Prodigy” on page 6
The failure level threshold settings should be set in both primary and sec-
ondary controllers:
• Series 5: primary IOC and secondary IOC
• Prodigy: primary IOP and secondary IOP)

TN66 (1.2.0) August 2016

Setting Failure Levels for Smart Transmitters in CCC Controllers

Low Fail Low Saturation

Low Saturation Normal Range High Saturation High Fail

Rosemount Smart
3.80
Standard
< 3.75 > 3.90 4 - 20 < 20.90 > 21.75
NAMUR
< 3.60 > 3.80 4 - 20 < 20.50 > 22.50
Honeywell Smart
Standard
< 3.60 > 3.80 4 - 20 < 20.90 > 21.00
NAMUR
< 3.60 > 3.80 4 - 20 < 20.50 > 21.00

Yokogawa Smart 21.60

Standard 3.50
< 3.20 > 3.60 4 - 20 < 21.60 > 21.60
NAMUR
< 3.20 > 3.80 4 - 20 < 20.50 > 21.60

Foxboro HART
Standard
< 3.60 > 3.80 4 - 20 < 20.50 > 21.00

3.70 (figure not to scale) 21.00

(values in mA)
Low fail detection threshold High fail detection threshold
(for all but Yokogawa and Rosemount Standard) (for all but Yokogawa Standard)

Figure 1 Transmitter Alarm Levels in CCC Controllers

Series 3 Plus The maximum current that can be read within Series 3 Plus controllers is
20.48 mA. Since this value is typically within the saturation range of a
smart transmitter, the controller cannot tell the difference between a
transmitter that is saturated and a smart transmitter that is producing a
high-fault signal. Therefore, the smart transmitter must be configured to
produce a low signal upon failure, and the controller should be configured
as follows:
• The MODE:D ANIN # LOW parameter defines a minimum value
below which an input is considered to have failed. To detect a smart
transmitter fault and not a saturation level, it should be set to a value
between the highest low-fault signal and the lowest saturation level.
A setting of 18.5% (3.70 mA) is recommended for all projects, which
will also cover open wire or fuse failures.
Note:
Rosemount Standard = 19.0% (3.80 mA) recommended
Yokogawa Standard = 17.5% (3.50 mA) recommended

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 Setting Failure Levels for Smart Transmitters in CCC Controllers

• The MODE:D ANIN # HIGH parameter defines a maximum value

above which an input is considered to have failed. The controller will
accept a maximum setting of only 20.46 mA (102.3%, entered as
A2.3). Therefore, the transmitter should be configured to produce a
low signal upon failure, and MODE:D ANIN # HIGH should be set to
the desired level for the project, or disabled. (A setting of 20.48 mA
[102.4%, entered as A2.4] will disable it.)
For Series 3 Plus controllers, 0.0 mA corresponds to 0% and 20.0 mA to
100%. For more information on transmitter configuration and testing,
refer to Input/Output Features in Chapter 3 of IM301.

++ ++
Series 3 The maximum current that can be read within Series 3 controllers is
23.2 mA. Therefore, the controller can tell if a transmitter is saturated or a
smart transmitter is producing a high fault signal. The controller should be
configured as follows:
• A MODE:D ANIN # LOW parameter setting of 18.5% (3.70 mA) is
recommended for all projects, which will also cover open wire or
fuse failures.
Note:
Rosemount Standard = 19.0% (3.80 mA) recommended
Yokogawa Standard = 17.5% (3.50 mA) recommended
• The MODE:D ANIN # HIGH parameter should be set to 21.0 mA. A
setting of 102.3% (entered as A2.3) is specifically coded within a
++
Series 3 controller to correspond to a current of 21.0 mA.
Note:
Yokogawa Standard = 108.0% (21.6 mA) recommended
++
For Series 3 controllers, 0.0 mA corresponds to 0% and 20.0 mA to
100%. For more information on transmitter configuration and testing in
++
Series 3 controllers, refer to Input/Output Features in Chapter 3 of
UM3301.

Series 4 The maximum transmitter current that can be read within Series 4 con-
trollers can vary depending on hardware configuration. Therefore, a “low-
fault” smart transmitter configuration may be required in some projects,
while a “low-fault” or “high-fault” configuration may be possible in others.
The _sys_ani_failure_low, _sys_ani_failure_high system parameters set
the low and high alarms for each transmitter input. A failure will be trig-
gered if a transmitter input exceeds an alarm level for longer than the
number of scans configured with the _sys_ani_fail_limit parameter.
• _sys_ani_failure_low has a range of -4095 to 4095 counts. Setting it
to -4095 counts will mask low alarms
• _sys_ani_failure_high has a range of 0 to 4095 counts. Setting it to
4095 will mask high alarms

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Setting Failure Levels for Smart Transmitters in CCC Controllers

Table 1 gives the recommended low and high transmitter alarm settings
for each type of Series 4 daughter card for all types of smart transmitters
except Rosemount Standard (see Table 2) and Yokogawa Standard (see
Table 3 on page 5). The recommended settings correspond to a low
alarm level of 3.70 mA and a high alarm level of 21.0 mA.

Table 1 Recommended Series 4 Transmitter Input Alarm Settings

_sys_ani_failure_low _sys_ani_failure_high
Daughter Card
(counts) (counts)
DC5100 546 4335
DC5200 548 4357
DC5201 545 4319
DC5412 539 4287

Table 2 gives the recommended alarm settings for a Rosemount Stan-

dard transmitter for each type of Series 4 daughter card. The
recommended settings correspond to a low alarm level of 3.80 mA and a
high alarm level of 21.0 mA.

Table 2 Recommended Series 4 Alarm Settings for Rosemount Std

_sys_ani_failure_low _sys_ani_failure_high
Daughter Card
(counts) (counts)
DC5100 568 4335
DC5200 570 4357
DC5201 567 4319
DC5412 560 4287

Table 3 on page 5 gives the recommended alarm settings for a Yok-

ogawa Standard transmitter for each type of Series 4 daughter card. The
recommended settings correspond to a low alarm level of 3.50 mA and a
high alarm level of 21.6 mA.

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 Setting Failure Levels for Smart Transmitters in CCC Controllers

Table 3 Recommended Series 4 Alarm Settings for Yokogawa Std

_sys_ani_failure_low _sys_ani_failure_high
Daughter Card
(counts) (counts)
DC5100 502 4467
DC5200 504 4489
DC5201 501 4450
DC5412 495 4417

Series 5 and The maximum transmitter current that can be read within Series 5 and
5M 5M controllers can vary depending on hardware configuration. Therefore,
a “low-fault” smart transmitter configuration may be required in some
projects, while a “low-fault” or “high-fault” configuration may be possible
in others.
The failure level threshold settings should be set in both primary and sec-
ondary controllers (primary IOC and secondary IOC).
The _LIO.IOC#_Config.ANI.ani_##.ani_alarm_Low and ani_alarm_High
parameters set the transmitter input low and high values for each analog
input, beyond which an LL or HH out-of-range error and alarm are
indicated:
• ani_alarm_Low can be set between a range of -50% (-4 mA) and
25% (8 mA), and has a default setting of -10% (2.4 mA). A setting of
-1.875% (3.70 mA) is recommended for all projects.
Note:
Rosemount Standard = -1.250% (3.80 mA) recommended
Yokogawa Standard = -3.125% (3.50 mA) recommended
• ani_alarm_High can be set between a range of 25% (8 mA) and
150% (28 mA), and has a default setting of 110% (21.6 mA). A set-
ting of 106.25% (21.0 mA) is recommended for all projects.
Note:
Yokogawa Standard = 110.0% (21.6 mA) recommended
An analog input signal greater than 100% (20 mA) but below 110% (21.6
mA) will result in a constant 100% signal within the control application.
Similarly, a signal between 0% (4 mA) and -10% (2.4 mA) will result in a
constant 0% signal in the application. An analog input signal above 110%
or below -10% will produce an input signal failure within the control
application.
For Series 5 controllers, 4.0 mA corresponds to 0% and 20.0 mA to
100%.

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 Setting Failure Levels for Smart Transmitters in CCC Controllers

Prodigy The maximum transmitter current that can be read within Prodigy control-
lers can vary depending on hardware configuration. Therefore, a “low-
fault” smart transmitter configuration may be required in some projects,
while a “low-fault” or “high-fault” configuration may be possible in others.
The failure level threshold settings should be set in both primary and sec-
ondary controllers (primary IOP and secondary IOP).
The _LIO.IOP_#_config.ANI.ani[#].lowLimit and highLimit parameters set
the transmitter input low and high values for each analog input, beyond
which an LL or HH out-of-range error and alarm are indicated:
• lowLimit can be set between a range of -50% (-4 mA) and 25% (8
mA), and has a default setting of -10% (2.4 mA). A setting of -1.875%
(3.70 mA) is recommended for all projects.
Note:
Rosemount Standard = -1.250% (3.80 mA) recommended
Yokogawa Standard = -3.125% (3.50 mA) recommended
• highLimit can be set between a range of 25% (8 mA) and 150% (28
mA), and has a default setting of 110% (21.6 mA). A setting of
106.25% (21.0 mA) is recommended for all projects.
Note:
Yokogawa Standard = 110.0% (21.6 mA) recommended
An analog input signal greater than 100% (20 mA) but below 110% (21.6
mA) will result in a constant 100% signal within the control application.
Similarly, a signal between 0% (4 mA) and -10% (2.4 mA) will result in a
constant 0% signal in the application. An analog input signal above 110%
or below -10% will produce an input signal failure within the control
application.
For Prodigy controllers, 4.0 mA corresponds to 0% and 20.0 mA to 100%.

Non-Smart For other analog input signals, such as from non-smart analog transmit-
ters, DCS (RLC, remote set point), motor current, valve position feedback
signals etc., a setting not to exceed 3 mA is recommended since those
signals often drift significantly.

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++
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trademarks of Compressor Controls Corp. © 2016

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TN66 (1.2.0) 4725 121st Street, Des Moines, Iowa 50323-2316, U.S.A.
August 2016
Phone: (515) 270-0857 • Fax: (515) 270-1331 • Web: www.cccglobal.com