LEARNING ACTIVITY PACKET 5

BASIC TEMPERATURE CONTROL

ELEMENTS

INTRODUCTION
Process heating and cooling requires the use of a variety of temperature control
devices. This LAP covers the function and operation of some commonly used devices
including thermostats, heating elements, heat exchangers, and chillers.

ITEMS NEEDED
Amatrol Supplied
1 T5553-CF Thermal Process Control Learning System

School Supplied
1 Water Supply
1 Compressed Air Supply
1 Loop Calibrator or Digital Multimeter
1 Three-Phase Supply (208 VAC, 60 Hz or 400 VAC, 50 or 60 Hz)

FIRST EDITION, LAP 5, 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 © 2019 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]

B33301-CF05UEN BASIC TEMPERATURE CONTROL ELEMENTS 2

Copyright © 2019 Amatrol, Inc.
 SKILL 1 CONTROL WATER TEMPERATURE USING A SENSING BULB
THERMOSTAT

Procedure Overview
In this procedure, you will control the temperature of water in the hot
water loop at certain setpoints using the sensing bulb thermostat

 1. Perform a lockout/tagout.
 2. Perform the following substeps to set up the T5553-CF system, as shown in
figure 21.

AMATROL

VALVE FULLY
TEMPERATURE TRANSMITTER

PROCESS
PUMP
OPERATOR INTERFACE

HOT WATER
PUMP
HOT WATER
HEATER
CHILLER
TEMPERATURE SENSORS PID CONTROLLER DATA ACQUISITION
OPEN
ANALOG INPUT ANALOG
PC-USB

TC1 TC2 RTD1 RTD2 TM1 TM2

ALM

OUT
DI

-sp
MAN

0.0
0
C

PV

SP
WATER LEVEL
ABOVE
TC RTD/TM OUTPUT Func. Lower Man SP
Loop 1/2 Display Auto Select

Mv 4-20mA 24 VDC 24 VDC 24 VDC 24 VDC Setup Run

Hold F44376
8.0
2.0
SS1 CC1 SS2 CC2 SS3 CC3 SS4 CC4
5.4
1.6

DI1 DI2 DI3

PLC DISCRETE I/O
24 VDC
DI4 DI5 DI6 DI7 DI8
FLOW
SENSOR

4-20mA
FLOW
VALVE

4-20mA
ALARM
HORN

24
VDC
TEMPERATURE TRANSMITTERS
TT2
INPUT
TC RTD/TM
TT3
INPUT
TC RTD/TM
LOOP 1

TC
INPUT

RTD TC
LOOP 2
INPUT

RTD
DISCRETE
INPUTS
DI1

DI2
1.2

.8 3.2

.4 1.6
4.8

LEVEL SWITCH
DO1 DO2 DO3 DO4 DO5 DO6 DO7 DO8
READ FLOAT AT
PC PC LARGEST DIA.
ALARM CHAN 1 CHAN 2 CHAN 3
RELAYS TC RTD TC RTD TC RTD
VDC VDC
DC POWER SUPPLY AL1
PLC ANALOG I/O
mV mV NC COM
4-20mA

LEVEL
AI1 AI2 AI3 AI4 24 VDC 24 VDC 24 VDC

OUTPUT OUTPUT OUTPUT OUTPUT AL2

AO1 AO2 AO3 AO4 4-20mA 4-20mA 4-20mA 4-20mA NC COM VDC VDC VDC
GND

SWITCH

F44376
8.0
2.0
F44376 5.4
1.6

VALVE
8.0
2.0
4.8
1.2
5.4
1.6
.8 3.2
4.8
1.2
.4 1.6
.8 3.2

FULLY
READ FLOAT AT
LARGEST DIA.
.4 1.6

READ FLOAT AT
LARGEST DIA.

CLOSED

TIGHTEN
CAP

Figure 21. T5553 Setup

A. Tighten the hot water loop drain cap.

B. Fully close the hot water loop drain valve.
C. Fully open (counterclockwise) the hot water loop rotameter valve.
D. Fill the hot water tank with water until the level is above the level switch.
E. If you are using a T5553-CFJ or T5553-CFN, plug the electrical power
cord into a three-phase supply and skip to step 3.
F. Verify that the main circuit breaker on the stepdown transformer is off.
G. Plug the T5553’s electrical power cord into the stepdown transformer.
H. Plug the stepdown transformer into a three-phase supply.

B33301-CF05UEN BASIC TEMPERATURE CONTROL ELEMENTS 21

Copyright © 2019 Amatrol, Inc.
  3. Remove the lockout/tagout.
 4. If you are using a T5553-CFL, turn on the main circuit breaker on the
stepdown transformer.
 5. Turn on the T5553’s main circuit breaker.
 6. Perform the following substeps to control the temperature of the water in the
hot water loop using a sensing bulb thermostat.

NOTE
Make sure the water level in the hot water tank is above the level switch. If
not, fill the tank so that the level switch is completely submerged. Otherwise,
the hot water heater will not operate, even if the thermostat is turned on.

A. Rotate the temperature control adjustment dial on the sensing bulb

thermostat until the scale indicates 115 °F (46.1 °C), as shown in figure
22.
Rotating the dial in the clockwise direction increases the temperature.
Rotating it in the counterclockwise direction decreases the temperature.
The scale is read at the tip of the arrow.
100

INDICATING
ARROW
120

ADJUSTMENT
DIAL

Figure 22. Sensing Bulb Thermostat Set to 115 °F

B. Turn ON the HOT WATER HEATER selector switch to turn on the

heating element.

B33301-CF05UEN BASIC TEMPERATURE CONTROL ELEMENTS 22

Copyright © 2019 Amatrol, Inc.
 C. Record the temperature of the water in the hot water tank, as indicated
on the temperature gauge on the outside of the tank, every 2 minutes in a
table similar to the one shown in figure 23 until the temperature reaches
115 °F (46.1 °C).

HOT WATER TANK TEMPERATURE MEASUREMENT

TIME TEMP TIME TEMP TIME TEMP
(min) (°F/°C) (min) (°F/°C) (min) (°F/°C)
0 12 24
2 14 26
4 16 28
6 18 30
8 20 32
10 22 34

Figure 23. Hot Water Tank Temperature

D. Determine how long it takes for the temperature to reach 115 °F (46.1 °C).
Time to reach 115 °F (46.1 °C) ____________________________ (min)
You should find that the temperature reaches the setpoint after 20-25
minutes. This assumes starting from room temperature (approximately
72 °F/22.2 °C).
If the temperature starts above room temperature, it will take less time to
reach 115 °F (46.1 °C).
E. Wait three minutes and record the temperature of the water in the tank
again.
Temperature _________________________________________(°F/°C)
You should find that the temperature is maintained by the thermostat near
115 °F (46.1 °C).
F. Rotate the temperature control adjustment dial on the thermostat until the
scale indicates 130 °F (54.4 °C).
G. Record the time required for the water in the hot water tank to reach the
new temperature.
Time ________________________________________________ (min)
You should find that it takes approximately 10 minutes for the water in the
hot water tank to reach the new temperature.
H. Wait three minutes and record the temperature of the water in the tank
again.
Temperature _________________________________________(°F/°C)
You should find that the temperature is maintained by the thermostat near
130 °F (54.4 °C).
 7. Perform the following substeps to shut down the T5553-CF.
A. Turn off the HOT WATER HEATER selector switch.
B. Turn off the T5553’s main circuit breaker.
C. If you are using a T5553-CFL, turn off the main circuit breaker on the
stepdown transformer.

B33301-CF05UEN BASIC TEMPERATURE CONTROL ELEMENTS 23

Copyright © 2019 Amatrol, Inc.
 SKILL 2 OPERATE A BRAZED-PLATE HEAT EXCHANGER

Procedure Overview
In this procedure, you will test the ability of the heat exchanger to transfer
heat to the water in the process fluid loop from the water flowing in the hot
water loop.

 1. Perform a lockout/tagout.
 2. Perform the following substeps to set up the T5553-CF system, as shown in
figure 33.

WATER LEVEL
AMATROL ABOVE LEVEL
SWITCH

TEMPERATURE TRANSMITTER OPERATOR INTERFACE TEMPERATURE SENSORS PID CONTROLLER DATA ACQUISITION

PROCESS HOT WATER HOT WATER CHILLER

PUMP PUMP HEATER
PC-USB ALM MAN C

0
DI
TC1 TC2 RTD1 RTD2 TM1 TM2 PV
OUT

-sp 0.0 SP

ANALOG INPUT ANALOG

TC RTD/TM OUTPUT Func. Lower Man SP
Loop 1/2 Display Auto Select

Mv 4-20mA 24 VDC 24 VDC 24 VDC 24 VDC Setup Run

Hold F44376
8.0
2.0
SS1 CC1 SS2 CC2 SS3 CC3 SS4 CC4
5.4
1.6
LOOP 1 LOOP 2 DISCRETE 4.8
INPUT INPUT INPUTS 1.2
PLC DISCRETE I/O FLOW FLOW ALARM
SENSOR VALVE HORN TEMPERATURE TRANSMITTERS DI1
24 VDC .8 3.2
DI1 DI2 DI3 DI4 DI5 DI6 DI7 DI8 TT2 TT3
24 TC RTD TC RTD
INPUT INPUT
4-20mA 4-20mA VDC DI2 .4 1.6
TC RTD/TM TC RTD/TM
DO1 DO2 DO3 DO4 DO5 DO6 DO7 DO8
READ FLOAT AT
PC PC LARGEST DIA.
ALARM CHAN 1 CHAN 2 CHAN 3
RELAYS TC RTD TC RTD TC RTD
VDC VDC
DC POWER SUPPLY AL1
PLC ANALOG I/O
mV mV NC COM
4-20mA
AI1 AI2 AI3 AI4 24 VDC 24 VDC 24 VDC

OUTPUT OUTPUT OUTPUT OUTPUT AL2

AO1 AO2 AO3 AO4 4-20mA 4-20mA 4-20mA 4-20mA NC COM VDC VDC VDC
GND

VALVE VALVE VALVE FULLY

FULLY OPEN CLOSED OPEN

F44376
8.0

VALVE
2.0
F44376 5.4
1.6

TIGHTEN
8.0
2.0
4.8
1.2
5.4
1.6
.8 3.2

FULLY
4.8
1.2
.4 1.6

3/4
.8 3.2

CAPS .4 1.6

READ FLOAT AT
READ FLOAT AT
LARGEST DIA.

CLOSED
LARGEST DIA.

FULL

TIGHTEN
CAP

VALVE
FULLY
CLOSED

Figure 33. T5553-CF Setup

B33301-CF05UEN BASIC TEMPERATURE CONTROL ELEMENTS 32

Copyright © 2019 Amatrol, Inc.
 A. Tighten the process fluid loop and hot water loop drain caps.
B. Fully close (clockwise) the process fluid loop and hot water loop drain
valves.
C. Tighten the extension plugs on the ends of the process piping.
D. Fully close the pump-priming valve.
E. Fully open (counterclockwise) the process fluid loop and hot water loop
rotameter valves.
F. Fill the hot water tank with water until the level is above the level switch.
G. Fill the process tank approximately 3/4 of the maximum level.
H. If you are using a T5553-CFJ or T5553-CFN, plug the electrical power
cord into a three-phase supply and skip to step 3.
I. Verify that the main circuit breaker on the stepdown transformer is off.
J. Plug the T5553’s electrical power cord into the stepdown transformer.
K. Plug the stepdown transformer into a three-phase supply.
 3. Remove the lockout/tagout.
 4. If you are using a T5553-CFL, turn on the main circuit breaker on the
stepdown transformer.
 5. Turn on the T5553’s main circuit breaker.
 6. Perform the following substeps to operate the hot water loop.
A. Record the temperature of the water in the hot water tank, as indicated on
the temperature gauge on the front of the tank.
Temperature ________________________________________ (°F/°C)
You should find that the water in the tank is at room temperature
(approximately 70 °F (21 °C) unless it has been used recently.
B. Rotate the temperature control adjustment dial on the sensing bulb
thermostat until the scale indicates 130 °F (54.4 °C).
C. Turn ON the HOT WATER HEATER selector switch and allow the
temperature of the water in the tank to rise to 130 °F (54.4 °C).
This should take approximately 25 minutes from room temperature.
D. Turn ON the HOT WATER PUMP selector switch when the temperature
in the tank is 130 °F (54.4 °C).
You should notice that water begins flowing through the hot water loop.

B33301-CF05UEN BASIC TEMPERATURE CONTROL ELEMENTS 33

Copyright © 2019 Amatrol, Inc.
 E. Record the temperature of the water flowing through the hot water loop,
as indicated on the temperature gauges at the inlet and outlet of the heat
exchanger, as shown in figure 34.

F44376
8.0
2.0
5.4

PROCESS 1.6

1.2
4.8 HOT
.8 3.2

LOOP .4 1.6

READ FLOAT AT
WATER
LARGEST DIA.

SIDE

INLET

OUTLET
TEMPERATURE
GAUGE
HEAT
EXCHANGER

INLET
TEMPERATURE
GAUGE
OUTLET
(HOT WATER LOOP)

Figure 34. Hot Water Loop Temperature Gauges

Hot Water Loop Inlet Temperature _______________________ (°F/°C)

Hot Water Loop Outlet Temperature ______________________ (°F/°C)

You should notice that both temperature gauges read between 110 °F -
120 °F (43.3 °C - 48.9 °C). The temperature is a few degrees less than 130
°F (54.4 °C) because some heat is dissipated through the process piping.
F. Turn OFF the HOT WATER PUMP selector switch.

B33301-CF05UEN BASIC TEMPERATURE CONTROL ELEMENTS 34

Copyright © 2019 Amatrol, Inc.
  7. Perform the following substeps to operate the process fluid loop.
A. Turn ON the PROCESS PUMP selector switch.
You should notice that water begins flowing through the process fluid
loop.
B. Record the temperature of the water in the process fluid loop, as indicated
on the temperature gauge on the front of the process tank as well as the
gauges at the inlet and outlet of the hot water heat exchanger, as shown in
figure 35.

PROCESS LOOP
PROCESS LOOP
TEMPERATURE GAUGE AT
TEMPERATURE GAUGE AT
HEAT EXCHANGER INLET
HEAT EXCHANGER
OUTLET

F44376
8.0
2.0
5.4
1.6

4.8
1.2

.8 3.2

.4 1.6

READ FLOAT AT
LARGEST DIA.

PROCESS TANK
TEMPERATURE GAUGE

Figure 35. Process Fluid Loop Temperature Gauges

Process Tank Temperature _____________________________ (°F/°C)

Process Inlet Temperature ______________________________ (°F/°C)

Process Outlet Temperature ____________________________ (°F/°C)

You should find that the water at each point in the process fluid loop is
approximately at room temperature.
C. Leave the process pump running for the next step.
 8. Perform the following substeps to transfer heat from the hot water loop to the
process fluid loop.
A. Turn ON the HOT WATER PUMP selector switch.
You should notice that water begins flowing through the hot water loop.
The hot water enters the heat exchanger at the top and exits at the bottom.
The process fluid enters the heat exchanger at the bottom and exits at the
top. This creates a counter flow pattern through the heat exchanger.

B33301-CF05UEN BASIC TEMPERATURE CONTROL ELEMENTS 35

Copyright © 2019 Amatrol, Inc.
 B. After allowing the fluid to flow through the hot water loop for approximately
10 seconds, record the temperature of the water in the hot water loop at the
inlet and outlet of the heat exchanger.
Hot Water Inlet Temperature ____________________________ (°F/°C)

Hot Water Outlet Temperature __________________________ (°F/°C)

You should find that the temperature of the hot water exiting the heat
exchanger (outlet temperature) is lower than the temperature of the water
entering the heat exchanger because heat is transferring to the process
loop.
C. Record the water temperature in the process tank as well as at the hot
water heat exchanger inlet and outlet on the process side.
Process Tank Temperature _____________________________ (°F/°C)

Process Side Inlet Temperature _________________________ (°F/°C)

Process Side Outlet Temperature ________________________ (°F/°C)
You should find that each of the temperatures are higher than the
temperatures you recorded in substep 6B. Heat is transferring from the
hot water flowing through the hot water loop to the cooler water flowing
through the process loop.
D. Rotate the temperature control adjustment dial on the thermostat to adjust
the temperature to 140 °F (60 °C).
E. After 5 minutes, record the temperature in the process loop.
Process Tank Temperature _____________________________ (°F/°C)

Process Side Inlet Temperature __________________________ (°F/°C)

Process Side Outlet Temperature ________________________ (°F/°C)

It is necessary to wait several minutes after making a thermostat adjustment
because it takes time for the heating element to increase the temperature of
the water in the hot water tank. You should find that the temperatures are
higher than those recorded in substep 7C, which indicates that more heat
is being transferred through the heat exchanger at the higher temperature
setting.
However, you should find that the temperature of the fluid in the process
tank rises slowly because it takes time to heat the entire volume of water
in the tank.
 9. Perform the following substeps to shut down the T5553-CF.
A. Turn OFF the HOT WATER HEATER selector switch.
B. Turn OFF the HOT WATER PUMP selector switch.
C. Turn OFF the PROCESS PUMP selector switch.
D. Turn off the T5553’s main circuit breaker.
E. If you are using a T5553-CFL, turn off the main circuit breaker on the
stepdown transformer.

B33301-CF05UEN BASIC TEMPERATURE CONTROL ELEMENTS 36

Copyright © 2019 Amatrol, Inc.
 SKILL 3 OPERATE AN AIR-COOLED CHILLER

Procedure Overview
In this procedure, you will cool the water in the process fluid loop using
the air-cooled chiller.

 1. Perform a lockout/tagout.
 2. Perform the following substeps to set up the T5553-CF, as shown in figure
39.

AMATROL

TEMPERATURE TRANSMITTER OPERATOR INTERFACE TEMPERATURE SENSORS PID

PID CONTROLLER
CONTROLLER DATA ACQUISITION

PROCESS HOT WATER HOT WATER CHILLER

PUMP PUMP HEATER
PC-USB ALM MAN C

0
DI
TC1 TC2 RTD1 RTD2 TM1 TM2 PV
OUT

-sp 0.0 SP

ANALOG INPUT ANALOG

TC RTD/TM OUTPUT Func. Lower Man SP
Loop 1/2 Display Auto Select

Mv 4-20mA 24 VDC 24 VDC 24 VDC 24 VDC Run

Setup
Hold F44376
8.0
2.0
SS1 CC1 SS2 CC2 SS3 CC3 SS4 CC4
5.4
1.6
LOOP
LOOP 11 LOOP
LOOP 2 DISCRETE 4.8
1.2
FLOW FLOW ALARM INPUT
INPUT INPUT
INPUT INPUTS
PLC DISCRETE I/O TEMPERATURE TRANSMITTERS DI1
SENSOR VALVE HORN
24 VDC .8 3.2
DI1 DI2 DI3 DI4 DI5 DI6 DI7 DI8 TT2 TT3
24 TC
TC RTD
RTD TC
TC RTD
RTD
INPUT INPUT
4-20mA 4-20mA VDC DI2 .4 1.6
TC RTD/TM TC RTD/TM
DO1 DO2 DO3 DO4 DO5 DO6 DO7 DO8
READ FLOAT AT
PC PC LARGEST DIA.
ALARM CHAN 1 CHAN 2 CHAN 3
RELAYS TC RTD TC RTD TC RTD
VDC
VDC VDC
VDC
DC POWER SUPPLY AL1
PLC ANALOG I/O
mV mV NO
NC COM
4-20mA
AI1 AI2 AI3 AI4 24 VDC 24 VDC 24 VDC

OUTPUT OUTPUT OUTPUT

OUTPUT OUTPUT
OUTPUT AL2
AO1 AO2 AO3 AO4 4-20mA 4-20mA 4-20mA
4-20mA 4-20mA
4-20mA NC
NO COM VDC VDC VDC
GND

FULLY FULLY
CLOSED OPEN
OPEN
F44376
8.0
2.0
F44376 5.4
1.6

TIGHTEN
8.0
2.0
4.8
1.2
5.4
1.6
.8 3.2
4.8
1.2
.4 1.6
.8 3.2
READ FLOAT AT
LARGEST DIA.
.4 1.6

READ FLOAT AT
LARGEST DIA.

FULLY 3-WAY FLOW SWITCH

CLOSED HAND VALVE

Figure 39. T5553-CF Setup

B33301-CF05UEN BASIC TEMPERATURE CONTROL ELEMENTS 41

Copyright © 2019 Amatrol, Inc.
 A. Tighten the extension plugs and drain cap in the process fluid loop to
prevent leakage.
B. Fully close (clockwise) the process tank manual drain valve.
C. Fully open (counterclockwise) the hand valve on the drainpipe that allows
water to flow into the process tank.
D. Fully open the process fluid loop rotameter valve.
E. Fully close the pump-priming valve.
F. Fill the process tank 3/4 with water.
G. Rotate the 3-way hand valve on the front of the process tank clockwise
so that water flows out of the tank and to the right. The pointed end of the
hand valve and the large arrow should point to the right when the valve is
in this position, as shown in figure 40.

Figure 40. 3-Way Hand Valve Position

H. If you are using a T5553-CFJ or T5553-CFN, plug the electrical power

cord into a three-phase supply and skip to step 3.
I. Verify that the main circuit breaker on the stepdown transformer is off.
J. Plug the T5553’s electrical power cord into the stepdown transformer.
K. Plug the stepdown transformer into a three-phase supply.

B33301-CF05UEN BASIC TEMPERATURE CONTROL ELEMENTS 42

Copyright © 2019 Amatrol, Inc.
  3. Identify the compressor, condenser, expansion valve, and evaporator on the
T5553-CF, as shown in figure 41.

NOTE
The condenser on the trainer may look different than the one shown, but
the operation will be as described.

 The T5553-CF uses an air-cooled chiller that circulates R134 refrigerant

through one side of a heat exchanger (the evaporator) to cool process fluid
flowing through the other side. The chiller cooling rate is 2500 Btu/hr. This
rate is not manually adjustable.
EVAPORATOR
EXPANSION
(HEAT EXCHANGER)
VALVE

COMPRESSOR

CONDENSER

Figure 41. T5553 Chiller

B33301-CF05UEN BASIC TEMPERATURE CONTROL ELEMENTS 43

Copyright © 2019 Amatrol, Inc.
  The CHILLER selector switch, shown in figure 42, on the operator panel
controls power to the chiller. However, the selector switch is also wired to the
flow switch in the process loop, which prevents power from being supplied to
the chiller if the flow rate through the process loop is less than 1.5 lpm or 0.4
gpm.

CHILLER

ON

24 VDC

SS1 CC1

Figure 42. Process Pump Selector Switch

 4. Remove the lockout/tagout.
 5. If you are using a T5553-CFL, turn on the main circuit breaker on the
stepdown transformer.
 6. Turn on the T5553’s main circuit breaker.

B33301-CF05UEN BASIC TEMPERATURE CONTROL ELEMENTS 44

Copyright © 2019 Amatrol, Inc.
  7. Perform the following substeps to cool the water in the process fluid loop.
A. Turn ON the PROCESS PUMP selector switch.
You should notice that water begins flowing through the process fluid
loop.
B. Record the temperature of the water in the process fluid loop, as indicated
on the temperature gauges on the front of the process tank and at the
chiller and hot water heat exchangers outlets, as shown in figure 43.

PROCESS
TEMPERATURE GAUGE
AT HEAT
EXCHANGER OUTLET

PROCESS
F44376
2.0
8.0 TEMPERATURE GAUGE
5.4
1.6

1.2

.8
4.8

3.2
AT
.4 1.6

READ FLOAT AT
LARGEST DIA.
CHILLER OUTLET

Figure 43. Temperature Gauges

Process Tank Temperature _____________________________ (°F/°C)

Process Temperature At Chiller Outlet ____________________(°F/°C)

Process Temperature At Hot Water Heat Exchanger Outlet

___________________________________________________ (°F/°C)
You should find that all of the gauges indicate approximately the same
temperature (near room temperature) because neither the chiller nor the
hot water loop is operating.
C. Turn ON the CHILLER selector switch.
You should notice a noise similar to an operating household refrigerator,
indicating that the compressor is circulating refrigerant.

B33301-CF05UEN BASIC TEMPERATURE CONTROL ELEMENTS 45

Copyright © 2019 Amatrol, Inc.
 D. Record the temperature of the water flowing through the process fluid
loop every 5 minutes in a table similar to the one shown in figure 44.

PROCESS TEMPERATURE MEASUREMENTS

TIME TANK AFTER THE AFTER THE
(min) TEMPERATURE CHILLER EXCHANGER
(°F/°C) (°F/°C) (°F/°C)
0
5
10
15
20
25
30

Figure 44. Temperature Table

You should find that the temperature gauges indicate a continued drop in
temperature (temperature may vary depending on the starting temperature).
You should also notice that the temperature decreases 3-4 °F (1.7-2.2 °C)
every 5 minutes. This is the pre-set cooling rate for the air-cooled chiller.
It is not adjustable.
 8. Perform the following substeps to shut down the T5553-CF system.
A. Turn OFF the CHILLER selector switch.
B. Turn OFF the PROCESS PUMP selector switch.
C. Turn off the T5553’s main circuit breaker.
D. If you are using a T5553-CFL, turn off the main circuit breaker on the
stepdown transformer.

B33301-CF05UEN BASIC TEMPERATURE CONTROL ELEMENTS 46

Copyright © 2019 Amatrol, Inc.
 SKILL 4 MANUALLY CONTROL THE TEMPERATURE OF A PROCESS

Procedure Overview
In this procedure, you will manually adjust the controller output to control
the temperature of the process fluid.

 1. Perform a lockout/tagout.
 2. Perform the following substeps to set up the T5553-CF, as shown in figure
48.

AMATROL

TEMPERATURE TRANSMITTER OPERATOR INTERFACE TEMPERATURE SENSORS PID

PID CONTROLLER
CONTROLLER DATA ACQUISITION

PROCESS HOT WATER HOT WATER CHILLER

PUMP PUMP HEATER
PC-USB ALM MAN C

0
DI
TC1 TC2 RTD1 RTD2 TM1 TM2 PV
OUT

-sp 0.0 SP

ANALOG INPUT ANALOG

TC RTD/TM OUTPUT Func. Lower Man SP
Loop 1/2 Display Auto Select

Mv 4-20mA 24 VDC 24 VDC 24 VDC 24 VDC Setup Run

Hold F44376
8.0
2.0
SS1 CC1 SS2 CC2 SS3 CC3 SS4 CC4
5.4
1.6
LOOP
LOOP 11 LOOP
LOOP 22 DISCRETE 4.8
1.2
FLOW FLOW ALARM INPUT
INPUT INPUT
INPUT INPUTS
PLC DISCRETE I/O TEMPERATURE TRANSMITTERS DI1
DI1
SENSOR VALVE HORN
24 VDC .8 3.2
DI1 DI2 DI3 DI4 DI5 DI6 DI7 DI8 TT2 TT3
24 TC
TC RTD
RTD TC
TC RTD
RTD
INPUT INPUT .4 1.6
4-20mA 4-20mA VDC DI2
DI2
TC RTD/TM TC RTD/TM
DO1 DO2 DO3 DO4 DO5 DO6 DO7 DO8
READ FLOAT AT
PC PC LARGEST DIA.
ALARM CHAN 1 CHAN 2 CHAN 3
RELAYS TC RTD TC RTD TC RTD
VDC
VDC VDC
VDC
DC POWER SUPPLY AL1
AL1
PLC ANALOG I/O
mV mV NO
NC COM
COM
4-20mA
AI1 AI2 AI3 AI4 24 VDC 24 VDC 24 VDC

OUTPUT OUTPUT OUTPUT

OUTPUT OUTPUT
OUTPUT AL2
AL2
AO1 AO2 AO3 AO4 4-20mA 4-20mA 4-20mA
4-20mA 4-20mA
4-20mA NC
NO COM
COM VDC VDC VDC
GND

SET TO
20 psi
(140 kPa)

F44376
8.0
2.0

AIR SUPPLY
F44376 5.4
1.6

TIGHTEN
8.0
2.0
4.8
1.2
5.4
1.6
.8 3.2
4.8
1.2

CONNECTION
.4 1.6
.8 3.2

CAPS .4 1.6

READ FLOAT AT
LARGEST DIA.
READ FLOAT AT
LARGEST DIA.

VALVE
FULLY
CLOSED

TIGHTEN
CAP

VALVE FULLY
CLOSED

Figure 48. T5553-CF Setup

B33301-CF05UEN BASIC TEMPERATURE CONTROL ELEMENTS 51

Copyright © 2019 Amatrol, Inc.
 A. Tighten the process fluid loop and hot water loop drain caps.
B. Fully close (clockwise) the process fluid loop and hot water loop drain
valves.
C. Tighten the extension plugs on the ends of the process piping.
D. Fully close the pump-priming valve.
E. Fully open (counterclockwise) the process fluid loop and hot water loop
rotameter valves.
F. Fill the hot water tank with water until the level is above the level switch.
G. Connect the air supply line to the T5553-CF.
H. Set the pressure regulator to 20 psi (140 kPa).
I. Fill the process tank approximately 3/4 of the maximum level.
J. If you are using a T5553-CFJ or T5553-CFN, plug the electrical power
cord into a three-phase supply and skip to step 3.
K. Verify that the main circuit breaker on the stepdown transformer is off.
L. Plug the T5553’s electrical power cord into the stepdown transformer.
M. Plug the stepdown transformer into a three-phase supply.
 3. If you are using the dual-loop controller, connect the circuit shown in figure
49. If you are using the single-loop controller, connect the circuit shown in
figure 50.
 This circuit connects the controller to the 3-way proportional valve through
the I/P converter, allowing manual control of the valve.

OPERATOR INTERFACE PID CONTROLLER

PROCESS HOT WATER HOT WATER CHILLER

PUMP PUMP HEATER
ALM MAN C

0
DI
PV
OUT

-sp 0.0 SP

Func. Lower Man SP

Loop 1/2 Display Auto Select

24 VDC 24 VDC 24 VDC 24 VDC Setup Run

Hold

SS1 CC1 SS2 CC2 SS3 CC3 SS4 CC4

LOOP 1 LOOP 2 DISCRETE

FLOW FLOW ALARM INPUT INPUT INPUTS
DI1
SENSOR VALVE HORN

TC RTD TC RTD

4-20mA 4-20mA 24 DI2

VDC

ALARM
RELAYS
VDC VDC
AL1
DC POWER SUPPLY
NC COM

24 VDC 24 VDC 24 VDC

OUTPUT OUTPUT AL2

4-20mA 4-20mA NC COM

GND

Figure 49. Flow Control Circuit Using Dual-Loop Controller

B33301-CF05UEN BASIC TEMPERATURE CONTROL ELEMENTS 52

Copyright © 2019 Amatrol, Inc.
 OPERATOR INTERFACE PID CONTROLLER

PROCESS HOT WATER HOT WATER CHILLER

PUMP PUMP HEATER

ALM MAN C

0
DI
PV
OUT

-sp 0.0 SP

Func. Lower Man SP

Loop 1/2 Display Auto Select
24 VDC 24 VDC 24 VDC 24 VDC
Setup Run
Hold

SS1 CC1 SS2 CC2 SS3 CC3 SS4 CC4

FLOW FLOW ALARM ANALOG ANALOG

SENSOR VALVE HORN INPUT OUTPUT
TC RTD
4-20mA 4-20mA 24

VDC 4 - 20mA

DC POWER SUPPLY
VDC ALARM RELAY
24 VDC 24 VDC 24 VDC
NO COM NC

GND

Figure 50. Flow Control Circuit with Single-Loop Controller

 4. Remove the lockout/tagout.
 5. If you are using a T5553-CFL, turn on the main circuit breaker on the
stepdown transformer.
 6. Turn on the T5553’s main circuit breaker.
 7. Perform the following substeps to operate the hot water loop.
A. Rotate the temperature control adjustment dial on the thermostat to 140 °F
(60 °C).
B. Turn ON the HOT WATER HEATER selector switch.
C. When the temperature gauge on the front of the hot water tank indicates
140 °F (60 °C), turn ON the HOT WATER PUMP selector switch.
You should find that water begins flowing through the hot water loop.
 8. Perform the following substeps to operate the process loop.
A. Turn ON the PROCESS PUMP selector switch.
B. Fully open (counterclockwise) the process fluid loop rotameter valve.
You should find that the flow rate is approximately 2.0 gpm (7.6 lpm).
C. Observe the temperature gauge at the hot water heat exchanger and the
one on the front of the process tank.
You should notice that the temperature begins to rise as the heat is
transferred from the hot water to the process liquid.
 9. Perform the following substeps to manually control the temperature of the
water in the process tank at 82 °F (27.8 °C).
A. Press the Man/Auto key on the Honeywell controller, if necessary, to
place the controller in manual mode.
B. Press the Lower Display key to display the controller output (OUT) in the
lower display area.

B33301-CF05UEN BASIC TEMPERATURE CONTROL ELEMENTS 53

Copyright © 2019 Amatrol, Inc.
 C. Record the temperature of the water in the process tank.
Process Tank Temperature _____________________________ (°F/°C)
You should find that the temperature is approximately 70 °F/21.1 °C.
This temperature may vary depending on the temperature of the room the
T5553-CF is in before starting the skill or the initial temperature of the
water used to fill the tank.
D. Press the down ▼ key to lower the controller output (OUT) to 0%.
This causes the valve to be fully open, which allows maximum hot water
flow to the heat exchanger to raise the temperature of the process liquid
faster.
E. When the process tank temperature gauge indicates a temperature of 76 °F
(24.4 °C), turn on the CHILLER selector switch to start the refrigerant
flow through the chiller heat exchanger.
F. Press the up ▲ key or the Honeywell controller to increase the controller
output to 50%.
This partially blocks the valve port leading to the heat exchanger and
slows the temperature increase. If the process tank temperature begins to
decrease or stabilize go to substep G, if it continues to increase, skip to
substep H.
G. If the process tank temperature begins to decrease before reaching 82 °F
(27.8 °C), decrease the controller output to allow more hot water flow to
the heat exchanger until the temperature begins to increase.
H. If the process tank temperature continues to increase, increase the controller
output as necessary to allow less hot water flow to the heat exchanger and
to allow the chiller to have a larger effect on the flow through the process
fluid loop.
I. Continue to make adjustments to the controller output as necessary until
the process tank temperature stabilizes at 82 °F (27.8 °C).
Consider the system stable if the process tank remains within ±2 °F of
82 °F (within ±1 to 2 °C of 27.8 °C) for five minutes.
 10. Perform the following substeps to shut down the T5553-CF.
A. Turn OFF the CHILLER selector switch to stop the chiller.
B. Turn OFF the PROCESS PUMP selector switch to stop flow through the
process loop.
C. Turn OFF the HOT WATER HEATER selector switch to turn off the hot
water pump.
D. Turn OFF the HOT WATER PUMP to stop flow through the hot water
loop.
E. Turn off the T5553’s main circuit breaker.
F. If you are using a T5553-CFL, turn off the main circuit breaker on the
stepdown transformer.
G. Disconnect the circuit.

B33301-CF05UEN BASIC TEMPERATURE CONTROL ELEMENTS 54

Copyright © 2019 Amatrol, Inc.