Measurement Range and Span in Measurement: Aviation Glossary

Measurement Range

Measurement range is a foundational specification for any measurement instrument, denoting the complete interval between the minimum and maximum values that the device is engineered to measure with assured accuracy. In aviation, this is a critical criterion for selecting and calibrating sensors, transmitters, gauges, and avionics systems. The measurement range directly impacts safe and reliable operation, ensuring that flight-critical data—such as altitude, airspeed, fuel level, and system pressures—are monitored within known, validated limits.

The measurement range is defined by two boundaries: the Lower Range Value (LRV) and the Upper Range Value (URV). These are set by the manufacturer, based on sensor technology and physical constraints. For example, a pressure transducer for an aircraft hydraulic system might have a measurement range of 0 to 5,000 psi; within this range, the device’s accuracy and repeatability are guaranteed. Measurements outside this interval are unreliable and may lead to system malfunctions or even flight safety hazards.

Measurement range is specified in technical documentation and regulated by international standards (e.g., ICAO Annex 10 for Aeronautical Telecommunications), which require that all aviation instruments maintain performance within their stated range. For instance, an altimeter must maintain accuracy from ground level up to the aircraft’s maximum certified altitude.

Calibration and compliance checks are carried out within the measurement range, guided by ICAO Doc 8071 and manufacturer manuals. Calibration ensures that all readings within the specified range are accurate; deviations prompt maintenance actions. Modern digital avionics may allow software-based configuration of the measurement range within factory-set hardware limits, enhancing flexibility while ensuring safety.

Aircraft cockpit instruments, each with a defined measurement range critical for safe operation.

Example Measurement Ranges in Aviation

Span

Span is the numerical difference between an instrument’s upper and lower measurement limits. While the measurement range defines the operational window (LRV to URV), span quantifies its width:

Span = Upper Range Value (URV) – Lower Range Value (LRV)

In aviation, span is crucial for calibration and performance specification. For instance, a fuel sensor with a measurement range of 0–20,000 liters has a span of 20,000 liters. Instrument accuracy, linearity, and hysteresis are often specified as a percentage of span. For example, ±0.1% of span for a 20,000-liter sensor means a maximum error of ±20 liters.

During calibration, maintenance personnel adjust the span so the instrument’s output is linear and accurate across the span. ICAO and manufacturer guidelines (e.g., Doc 9640 for de-icing operations) reference span when specifying calibration for environmental sensors.

Some digital aviation sensors allow user configuration of the span, within manufacturer-set boundaries. This is useful in multi-role aircraft, where operational needs may change. However, regulatory authorities require that any configured span remains within certified limits and does not compromise accuracy or safety.

Example Spans in Aviation Systems

Measuring Range vs. Span

While the measuring range indicates the lowest and highest values an instrument can accurately measure, the span is simply the size of that interval. Both are vital in aviation calibration and compliance.

Example: An airspeed indicator with a measuring range of 40–400 knots has a span of 360 knots. Regulatory bodies such as ICAO specify instrument errors as a percentage of span, not the measuring range. This ensures consistent performance across the entire operational window.

Note: The measurement range is not always identical to the scale or indicator range of an instrument. A gauge may display 0–500 knots, but the certified measuring range (with guaranteed accuracy) could be 40–400 knots.

Pressure transmitter calibration curve: measuring range is the interval with guaranteed accuracy (LRV to URV), span is the width of that interval.

Measuring Range vs. Indicator (Scale) Range

The measuring range is the certified interval where accuracy and linearity are guaranteed; the indicator/scale range is simply the visible portion of the instrument scale, which may be wider. For example, an analog altimeter may indicate -2,000 to 60,000 feet, but its certified measuring range is -1,000 to 50,000 feet. Readings outside the measuring range are not valid for flight.

Technicians and pilots must ensure instruments are used only within their certified measuring range. Digital systems may restrict display or logging to the measuring range to avoid confusion and ensure compliance.

Factory Limits vs. User-Configurable Range

Aviation instruments are manufactured with factory limits—absolute minimum (Lower Range Limit, LRL) and maximum (Upper Range Limit, URL) values. Within these, some sensors allow a user-configurable range or span, provided settings do not exceed factory limits.

Changing user-configurable ranges may require recalibration and regulatory notification, especially in safety-critical systems. Factory limits protect instruments from overload or damage, and all configurations must be traceable and documented.

Example: A pressure sensor may have a factory range of 0–10,000 psi, but can be configured for 1,000–5,000 psi for a specific application. Exceeding factory limits risks system failure and regulatory non-compliance.

Aviation Examples and Use Cases

• Pressure Transmitter: Factory range 0–10,000 mmH₂O; user-calibrated range 500–3,000 mmH₂O; span 2,500 mmH₂O.
• Thermocouple: Input range -50°C to 1,200°C; span 1,250°C; used in turbine EGT measurement.
• Voltmeter: Measuring range -10 V to +10 V (span 20 V); monitors electrical bus voltages.
• Fuel System: Expected variation 1,000–18,000 liters; sensor range/ span should cover this for accurate fuel management.

Application and Importance in Instrument Selection

Correctly specifying measurement range and span is essential for aviation safety and regulatory compliance:

• Accuracy and Reliability: Instruments are accurate only within their certified measurement range and span. Exceeding these increases the risk of erroneous readings and flight hazards.
• Instrument Protection: A range that is too narrow risks overload and damage; too broad a range reduces resolution and sensitivity.
• Resolution Optimization: Matching span to operational needs improves resolution, enabling accurate detection of critical changes.
• Process Safety and Compliance: ICAO, FAA, and EASA require instruments to meet strict criteria within their range; non-compliance may restrict aircraft operations.

Best Practices:

• Select a measuring range covering all expected values plus a safety margin.
• Avoid operating near range limits.
• Configure span closely to expected variation for high accuracy.
• Adhere strictly to factory and regulatory limits.

Calibration, Limits of Error, and Performance

Calibration adjusts an instrument to ensure accuracy across its span, in accordance with regulatory (e.g., ICAO) and manufacturer procedures. The calibrated span is the window where performance is guaranteed.

Limits of Error are specified as the maximum deviation allowed (often as % of span). For example, ±0.5% of span for a 400-knot airspeed indicator means ±2 knots allowable error.

Key Characteristics:

• Linearity: Proportional output across the span; crucial for accuracy.
• Repeatability: Consistent readings for the same input.
• Response Time: Speed of instrument response to input changes.

Calibration records are part of airworthiness documentation; any out-of-tolerance findings require immediate correction.

Upper and Lower Range Limits (URL, LRL)

Upper Range Limit (URL): Highest value reliably measurable. Lower Range Limit (LRL): Lowest value reliably measurable.

Both are set by the manufacturer, and operation outside these limits is prohibited. Exceeding URL or LRL may trigger system faults or non-compliance findings.

Zero, Zero Suppression, and Zero Elevation

• Zero: Reference point where instrument output is defined as zero.
• Zero Suppression: LRV is set above physical zero (e.g., LRV = 100 psi).
• Zero Elevation: LRV is set below physical zero (less common).

Zero suppression/elevation ensures instrument display and output are meaningful and tailored to operational requirements.

Turndown Ratio (Rangeability)

Turndown ratio is the URL divided by the minimum calibrated span over which accuracy is maintained (e.g., 10,000 psi URL, 100 psi minimum span = 100:1 turndown). High turndown ratios offer flexibility but may reduce resolution.

Accuracy Specifications: % Full Scale vs. % Reading

• % Full Scale (of Span): Error is constant across the measuring range (e.g., ±1 unit for a 100-unit span).
  • At low readings, relative error increases.
• % Reading: Error is proportional to the measured value; more accurate at low readings, but less common in aviation.

Understanding measurement range and span is essential to aviation safety, regulatory compliance, and optimal instrument performance. Always consult manufacturer and regulatory documentation when configuring or calibrating flight instruments.