7a - Basic Temperature Control (LAB)

LEARNING ACTIVITY PACKET 10
BASIC TEMPERATURE CONTROL
INTRODUCTION
Temperature controlled processes can use either a closed loop control system or an
on/off control system. The on/off control system is inexpensive but only controls the
temperature within a temperature range. A closed loop system is more expensive but
offers the ability to achieve a specific temperature. This LAP covers the operation of on/
off and closed loop temperature control systems.
In addition to controlling temperature processes, many controllers have discrete
inputs and outputs that are used to activate alarms and change controller operations from
a distant location. This LAP also covers controller discrete inputs and outputs.
ITEMS NEEDED
Amatrol Supplied
1 T5553-CF Thermal Process Control Learning System
School Supplied
1 Water Supply
1 Compressed Air Supply
1 Three-Phase Supply (208 VAC, 60 Hz or 400 VAC, 50 or 60 Hz)
1 PC with Inor ConSOFT Software
FIRST EDITION, LAP 10, REV. B

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 © 2020, 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,
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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 www.amatrol.com
B33301-CF10UEN BASIC TEMPERATURE CONTROL 2

Copyright © 2020 Amatrol, Inc.
SKILL 1 CONFIGURE AND OPERATE A HONEYWELL UDC 3500 CONTROLLER
BASED ON/OFF TEMPERATURE CONTROL SYSTEM
Procedure Overview
In this procedure, you will use the Honeywell controller on the T5553-CF
to control a temperature process using on/off control. This includes using the
thermistor as the temperature-sensing feedback element that sends its output
to the indicating transmitter, which linearizes the output and sends it to the
controller.
 1. Perform a lockout/tagout.
 2. Perform the following substeps to set up the T5553-CF, as shown in figure
10.
AMATROL
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
SS1 CC1 SS2 CC2 SS3 CC3 SS4 CC4 8.0
2.0
5.4
LOOP 1 LOOP 2 DISCRETE 1.6
FLOW FLOW ALARM INPUT INPUT INPUTS
PLC DISCRETE I/O 4.8
SET TO
SENSOR VALVE HORN TEMPERATURE TRANSMITTERS DI1 1.2
24 VDC
DI1 DI2 DI3 DI4 DI5 DI6 DI7 DI8 TT2 TT3
TC RTD TC RTD .8 3.2
24 INPUT INPUT
4-20mA 4-20mA VDC DI2
TC RTD/TM TC RTD/TM
.4 1.6
DO1 DO2 DO3 DO4 DO5 DO6 DO7 DO8
PC PC
CHAN 1 CHAN 2 CHAN 3
140 kPa
READ FLOAT AT
ALARM LARGEST DIA.
RELAYS TC RTD TC RTD TC RTD
VDC VDC
PLC ANALOG I/O DC POWER SUPPLY AL1
mV mV NC COM
4-20mA
AI1 AI2 AI3 AI4 24 VDC 24 VDC 24 VDC
(20 PSI)
OUTPUT OUTPUT OUTPUT OUTPUT AL2
AO1 AO2 AO3 AO4 4-20mA 4-20mA 4-20mA 4-20mA NC COM VDC VDC VDC
GND
AIR SUPPLY
VALVE FULLY VALVE VALVE FULLY CONNECTION
OPEN CLOSED OPEN
F44376
8.0
2.0
F44376 5.4
TIGHTEN
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
CAPS
.8 3.2
FULLY
READ FLOAT AT
LARGEST DIA.
.4 1.6
READ FLOAT AT
LARGEST DIA.
CLOSED
TIGHTEN
CAP
VALVE FULLY
CLOSED
Figure 10. T5553-CF Setup
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. Connect the pressure regulator to a pneumatic supply.
I. Set the pressure regulator to 140 kPa (20 psi).
J. If you are using a T5553-CFJ or T5553-CFN, plug the T5553’s electrical
power cord into a three-phase supply, and then 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
11. If you are using the single-loop controller, connect the circuit shown in
figure 12. For either controller, make sure the 250 ohm precision resistor
assembly is connected to the voltage (VDC) input jacks. The resistor converts
the 4-20 mA input to a 1-5 V input.
This circuit connects the temperature transmitter to the thermistor and a PC
for programming. It also sends the linearized output from the transmitter to
the Honeywell controller.

PC WITH
CONSOFT SOFTWARE
USB
CABLE ConSoft
TEMPERATURE TRANSMITTER OPERATOR INTERFACE TEMPERATURE SENSORS PID CONTROLLER

PUMP PUMP HEATER
PC-USB
ALM MAN C
0
TC1 TC2 RTD1 RTD2 TM1 TM2 DI
PV
OUT
-sp 0.0 SP
ANALOG INPUT ANALOG

TC RTD/TM OUTPUT
Func. Lower Man SP
Mv 4-20mA 24 VDC 24 VDC 24 VDC 24 VDC
Setup Run
Hold
SS1 CC1 SS2 CC2 SS3 CC3 SS4 CC4
LOOP 1 LOOP 2 DISCRETE

PLC DISCRETE I/O TEMPERATURE TRANSMITTERS DI1
SENSOR VALVE HORN
24 VDC
TC RTD TC RTD
4-20mA 4-20mA
24 INPUT INPUT
VDC DI2
TC RTD/TM TC RTD/TM
PC PC
ALARM
RELAYS
VDC VDC
PLC ANALOG I/O DC POWER SUPPLY AL1
mV mV NC COM
4-20mA

AO1 AO2 AO3 AO4 4-20mA 4-20mA 4-20mA 4-20mA NC COM
GND
Figure 11. On-Off Temperature Control Circuit Using Dual-Loop Controller

PC WITH
CONSOFT SOFTWARE
USB
CABLE ConSoft
TEMPERATURE TRANSMITTER OPERATOR INTERFACE TEMPERATURE SENSORS PID CONTROLLER

PUMP PUMP HEATER
PC-USB ALM MAN C
0
DI
OUT
-sp 0.0 SP
ANALOG INPUT ANALOG


Hold
FLOW FLOW ALARM ANALOG ANALOG

PLC DISCRETE I/O TEMPERATURE TRANSMITTERS
SENSOR VALVE HORN INPUT OUTPUT
24 VDC
TC RTD
4-20mA 4-20mA
24 INPUT INPUT
VDC
TC RTD/TM TC RTD/TM
4 - 20mA
PC PC
PLC ANALOG I/O DC POWER SUPPLY

mV mV
4-20mA VDC ALARM RELAY
NO COM NC
OUTPUT OUTPUT
AO1 AO2 AO3 AO4 4-20mA 4-20mA
GND
Figure 12. On-Off Temperature Control Circuit Using Single-Loop Controller

TEMPERATURE
TRANSMITTER
TT
600-A/B
FT
700

FV FE
700 700
OPTION
Figure 13. T5553-CF P&ID

FS
500
TI
600-B
TE TE
600-B 600-A
TI
800-A FI
700A
HV
500-C
LS
B33301-CF10UEN BASIC TEMPERATURE CONTROL

900
HEAT TI
EXCHANGER 800-C
TI TE JC
800-B 1100 1100
wiring are highlighted.
TE TI
T5552 600-C 600-A CONTROLLER
RETURN HT
FIC 1100
THERMISTOR
1000
FI I/P CONVERTER
500 HOT WATER TANK
FV AND HEATER
HV IYT PC
500-B 500
TI 1000 1000
600-C
PI PI
FI 1000-A
700B 1000-B
CHILLER PLANT
HV HV AIR
500-D 700
REACTOR HOT
TANK FEED WATER
DRAIN PUMP PUMP
DRAIN
T5552
FEED
PROPORTIONAL
VALVE FCV
700
HV
500-A
17
Figure 13 shows the P&ID for the T5553-CF. The active components and
 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. Adjust the thermostat setting for the hot water tank to 60 °C (140 °F).
 8. Turn ON the HOT WATER HEATER selector switch to turn on the heating
element and heat the water in the hot water tank.
 9. Program the Honeywell controller according to the settings shown in the
table in figure 14. All other parameters should be left at default settings.
GROUP FUNCTION VALUE OR GROUP FUNCTION VALUE OR

PROMPT PROMPT SELECTION PROMPT PROMPT SELECTION
SP RAMP SP RAMP DISABL ALGROTHM CONT ALG ON OFF
SP RATE DISABL TIMER DISABLE
CONTROL PV SOURC INPUT 1 OUT ALG OUT ALG CURRENT
PID SETS 1 ONLY
INPUT 1 IN1 TYPE 1-5 V
LSP’S 1 ONLY
XMITTER1 LINEAR
RSP SCR NONE
IN1 HIGH 77 (if °C) or 170 (if °F)
SP TRACK NONE
IN1 LOW 10 (if °C) or 50 (if °F)
PWR MODE MANUAL
BIAS IN1 0
SP HiLIM 77 (if °C) or 170 (if °F)
SP LoLIM 10 (if °C) or 50 (if °F) COM ComSTATE DISABLE
ACTION DIRECT
ALARMS A1S1TYPE NONE
OUT RATE DISABLE
A1S2TYPE NONE
OUTHiLIM 100
A2S1TYPE NONE
OUTLoLIM 0
A2S2TYPE NONE
I Hi LIM 100
BLOCK DISABL
I Lo LIM 0
DROP OFF 0 DISPLAY DECIMAL ONE
OUT HYST 10.0 TEMPUNIT DEG F or DEG C
FAILSAFE 0 PWR FREQ 50 HZ or 60 HZ
FAILMODE NO LATCH LANGUAGE ENGLISH
MAN OUT 0
AUTO OUT 0
PBorGAIN GAIN
MINorRPM MIN
Figure 14. Honeywell Controller Settings
NOTE
If you have the dual-loop controller, there are some additional parameter
groups and parameters. You will need to check and set the parameters shown
in figure 15 for the dual-loop controller.
GROUP FUNCTION VALUE OR

PROMPT PROMPT SELECTION
INPUT 2 IN2 TYPE DISABLE
8SEG CH1 DISABLE
8SEG CH2 DISABLE
MATH
TOTALIZE DISABLE
POLYNOM DISABLE
LOGIC LOG GATE DISABLE
Figure 15. Parameters for Dual-Loop Controller

 10. Perform the following substeps to set up the temperature transmitter’s USB
communication to the PC.
A. Remove the hex-head bolts, shown in figure 16, from the trainer panel so
that the cabinet door can be opened.
HEX-HEAD
BOLT HEX-HEAD
BOLT
Figure 16. Trainer Cabinet Door Hex-Head Bolts

B. Open the T5553’s cabinet door, raise the door vertically, and attach the
safety cable to the side-oriented bolt, as shown in figure 17.
SIDE-ORIENTED
BOLT
SAFETY
CABLE
Figure 17. Trainer Door Held Open with Safety Cable

C. Verify that the USB cable is connected between the ICON-X USB
Interface and the temperature transmitter, as shown in figure 18.
ICON-X
USB INTERFACE
TEMPERATURE
TRANSMITTER
USB CABLE
Figure 18. USB Cable between ICON-X USB Interface and Temperature
Transmitter
D. While holding the T5553’s cabinet door, remove the safety cable from the
side-oriented bolt, and carefully lower the door into its original position.
E. Replace the hex-head bolts to securely close the cabinet door.
F. Locate the USB A-B cable, shown in figure 19.
USB CABLE
TYPE B TYPE A
CONNECTION CONNECTION
(TO TEMPERATURE (TO PC)
TRANSMITTER PANEL)
Figure 19. USB A-B Cable

G. Connect the Type A end of the USB cable to your PC, similar to shown in
figure 20.
USB CABLE
(TYPE A
CONNECTION)
Figure 20. USB Cable Connected to PC
H. Connect the Type B end of the USB cable to the temperature transmitter’s
USB adapter on the Temperature Transmitter panel, as shown in figure 21.
USB CABLE
(TYPE B
CONNECTION)
Figure 21. USB Cable Connected to Temperature Transmitter’s USB Adapter

 11. Turn on the power to the PC.
 12. Ask your instructor if you need to install the temperature transmitter’s
ConSoft software and/or the USB drivers on your PC. If so, perform the steps
in the Appendix and then return to step 13 in this skill.
 13. If you saved ConSoft’s thermistor file in LAP 9 Skill 3, perform the following
substeps to alter that file for use in this skill. Otherwise, skip to step 14.
A. Open the ConSoft software by double clicking the ConSoft icon on your
desktop or by selecting ConSoft from the Start menu.
Figure 22. ConSoft Icon
The ConSoft initialization screen should appear, similar to shown in figure

23.
OPEN
PROJECT
ICON
Figure 23. ConSoft Initialization Screen

B. Click the Open Project icon.
C. Click the TM_xxx project (where xxx is your initials) to open it.
D. On the Sensor tab, verify the settings are as shown in the table in figure
24. If not, make the selections match these.
Option Setting
Configure input > Change sensor Resistance
Configure input > Connection 3 wire
Configure input > Custom linearization enabled (checked)
Figure 24. Thermistor Sensor Tab Settings
E. On the Function tab, verify the settings are as shown in the table in figure
25. If not, make the selections match these.
Option Setting
Measuring Range > Lower range value -77 (if using °C) or -170 (if using °F)
Measuring Range > Upper range value -10 (if using °C) or -50 (if using °F)
Filter 1.4
Figure 25. Thermistor Function Tab Settings
F. On the Function tab, Enable (check) the Inverse Output checkbox.

G. On the Conversion Table tab, verify that the Temperature unit option is
set to °C (if using °C) or °F (if using °F). If not, use the drop-down menu
for that field to change it.
H. On the Conversion Table tab, verify that the Engineering unit option is
disabled (unchecked). If not, disable it.

I. On the Conversion Table tab, verify that the entries are as shown in the
table in figure 26. If not, make these entries.
Resistance (ohm) °C (if using °C) °F (if using °F)
170 -80 -176
187 -77 -170
203 -74 -165
220 -71 -160
239 -68 -155
261 -66 -150
284 -63 -145
310 -61 -140
338 -57 -135
370 -54 -130
405 -52 -125
438 -49 -120
489 -46 -115
537 -43 -110
592 -41 -105
653 -38 -100
721 -35 -95
794 -32 -90
884 -29 -85
977 -27 -80
1088 -24 -75
1213 -21 -70
1364 -18 -65
1527 -16 -60
1704 -13 -55
1899 -10 -50
2100 -7 -45
Figure 26. Thermistor Temperature Conversion Table
J. On the Error monitoring tab, verify that the Upscale ( 21 mA) radio is
selected. If not, select it.
K. Skip to step 15.

 14. Perform the following substeps to use the Inor ConSoft software to program
the transmitter for temperature measurement using the thermistor.
A. Open the ConSoft software by double clicking the ConSoft icon on your

28.
NEW
PROJECT
ICON

B. Click the New Project icon.
The ConSoft Select transmitter screen will appear, similar to shown in
figure 29.
C/R330 ICON
Figure 29. ConSoft Select Transmitter Screen

C. Click the C/R330 icon.
The ConSoft Select generation 1 or generation 2 dialog will appear,
similar to shown in figure 30.
GENERATION 2
BUTTON
Figure 30. ConSoft Select Generation 1 or Generation 2 Dialog

D. Click the Generation 2 button.
The ConSoft programming screen will open, similar to shown in figure
31.
The ConSoft programming screen defaults to an RTD sensor selected.
SENSOR
TAB
Figure 31. ConSoft Initial Programming Screen

E. On the Sensor tab, use the Change sensor drop-down menu to change the
sensor to Resistance, as shown in figure 32.
The Resistance selection is used for a thermistor.
SENSOR TAB
3-WIRE
CONNECTION
TYPE
RESISTANCE
SELECTION
Figure 32. ConSoft Programming Screen - Resistance Sensor Selected
F. On the Sensor tab, verify that the Connection field is set to 3 wire, as
shown in figure 32. If not, use the Connection drop-down menu to select
3 wire.

G. On the Sensor tab, enable (check) the Custom linearization option, as
shown in figure 33.
Notice that after the Custom linearization option is selected, a Configuration
is invalid indication appears in the lower left corner of the display. This
indication will continue to be displayed until the thermistor’s temperature
and resistance characteristics have been correctly set.
CUSTOM
LINEARIZATION
SELECTED
CONFIGURATION
IS INVALID
INDICATION
Figure 33. Resistance Custom Linearization Selected

H. Select the Function tab on the ConSoft programming screen.
TEMPERATURE UNIT FIELD
FUNCTION
TAB
TEMPERATURE
UPPER RANGE
VALUE FIELD
TEMPERATURE
LOWER RANGE
VALUE FIELD
INVERSE
OUTPUT
SELECTED
Figure 34. Function Tab on ConSoft Programming Screen
I. In the Temperature unit field, use the drop-down menu to select °C (if
using °Celsius) or °F (if using °Fahrenheit).
The Function tab initially shows the Upper range value highlighted in red,
similar to shown in figure 36, because that value needs to be entered for
the specific thermistor being used.
J. Click the Upper range value field, and enter -10 (if using °C) or -50 (if
using °F).
This sets the maximum temperature for the thermistor to -10 °C or -50 °F.
The thermistor being used has a negative temperature coefficient (NTC),
so its resistance decreases as temperature increases. ConSoft requires the
temperature and resistance to both increase as the values are entered in
the linearization table later. One way to force this relationship is to enter
the temperatures as negative numbers. In other words, the temperatures
shown are not really negative. They are just being entered that way to
accommodate the ConSoft software.
After the Upper range value is entered, the Lower range value will be
highlighted in red, because that value needs to be entered for the specific
thermistor being used.
K. Click the Lower range value field, and enter -77 (if using °C) or -170 (if
using °F).
This sets the minimum temperature for the thermistor to -77 °C or -170 °F.
As noted in substep J, these temperatures are not really negative. The
temperature range specified is really 10 to 77 °C (50 to 177 °F).
L. Verify that the Filter parameter set to its default value of 1.4. If not, use
the drop-down menu to change it to 1.4.
M. Enable (check) the Inverse Output checkbox.
When the Inverse Output option is not selected, the temperature transmitter
outputs 4 mA at the “minimum” temperature (-77 (if using °C) or -170 (if
using °F)) and 20 mA for the “maximum” temperature (-10 (if using °C)
or -50 (if using °F)). Since the temperatures are not really negative here,
this would cause a problem when the output is connected to the controller.
When the Inverse Output option is selected, the temperature transmitter
outputs 4 mA when the temperature is at its actual minimum (10 (if using
°C) or 50 (if using °F)), and it outputs 20 mA when the temperature is at
its actual maximum (77 (if using °C) or 170 (if using °F)).
N. Select the Conversion Table tab.
The Conversion Table tab will appear, similar to shown in figure 35.
TEMPERATURE
ENGINEERING
(°C OR °F)
UNIT
COLUMN
OPTION
CONVERSION
TABLE
TAB
RESISTANCE
(OHM)
COLUMN
Figure 35. Conversion Table Tab on ConSoft Programming Screen
O. Verify that the Engineering unit option is disabled (unchecked). If not,

disable (uncheck) it.
The conversion table should show Resistance (ohm) and °C (or °F) at the
top of the two columns.
P. Use the drop-down menu for Temperature unit field to °C (if using °C) or
°F (if using °F), if it is not already set as desired.
Q. Click the blank field under Resistance (ohm) and enter 170.

R. Tab to the blank field under °C (or °F) and enter -80 (if using °C) or -176
(if using °F).
The ConSoft software expects entries that begin and end slightly outside
of the temperature range specified above, so you entered values more
negative than -77 °C or -170 °F.
S. Continue filling in the conversion table with the values shown in the table
in figure 36.
Be careful to use the values for °C or °F, depending on which temperature
you are using. Also be careful that all of your temperatures are entered as
negative numbers.
Resistance (ohm) °C (if using °C) °F (if using °F)
187 -77 -170
203 -74 -165
220 -71 -160
239 -68 -155
261 -66 -150
284 -63 -145
310 -61 -140
338 -57 -135
370 -54 -130
405 -52 -125
438 -49 -120
489 -46 -115
537 -43 -110
592 -41 -105
653 -38 -100
721 -35 -95
794 -32 -90
884 -29 -85
977 -27 -80
1088 -24 -75
1213 -21 -70
1364 -18 -65
1527 -16 -60
1704 -13 -55
1899 -10 -50
2100 -7 -45
Figure 36. Temperature Conversion Table for Thermistor

T. When all of the conversion table entries have been made and verified,
click the Save Table button.
After the Save Table option is selected, the status in the lower left corner
of the display should change to Ready, as shown in figure 37. If it does not
change to Ready, double check your entries in the Conversion table and
your entries on the other tabs. If you do not find an error in your settings,
consult your instructor.
SAVE TABLE
BUTTON
READY
STATUS
Figure 37. ConSoft Indicates Configuration Ready Status

U. Select the Error monitoring tab on the ConSoft programming screen.
V. Select the Upscale ( 21 mA) radio if it is not already selected, as shown
in figure 38.
ERROR
MONITORING
TAB
UPSCALE
(≥ 21 mA)
RADIO
Figure 38. Error Monitoring Tab on ConSoft Programming Screen

 15. Perform the following substeps to write the thermistor configuration to
the temperature transmitter and begin reading the thermistor’s temperature
readings from the temperature transmitter.
WRITE
ICON
READ
ICON
Figure 39. ConSoft Read and Write Icons
A. Click the Write icon in the upper left corner of the ConSoft programming
screen.
B. A Transfer to transmitter dialog will appear, similar to figure 40. This
notifies the user that this write operation will change the settings in the
transmitter.
Figure 40. ConSoft Transfer to Transmitter Dialog
C. Click the Yes button.

While ConSoft is writing the new configuration to the temperature transmitter,
the status in the lower left corner of the ConSoft screen will indicate that the
write is in progress, similar to shown in figure 41.
WRITE IN
PROGRESS
INDICATION
Figure 41. ConSoft Configuration Write to Transmitter in Progress

D. After the write completes, click the Read icon in the upper left corner of
the ConSoft programming screen.
An Exit dialog will appear, similar to shown in figure 42.
Figure 42. ConSoft Exit Dialog
E. If you want to save the configuration file for later use, click the Yes button
and follow the prompts to name and save the file. Otherwise, click the No
button.
After the Read operation completes, a Log and Simulation tab is added on
the ConSoft programming screen. That tab will be used in later to view the
thermistor’s temperature indications.
 16. Set the controller setpoint (SP) to 26 (if using °C) or 78 (if using °F).
With a setpoint of 26 °C, the controller should maintain the process tank
temperature between 22.65 °C and 29.35 °C because 10% (output hysteresis)
of the span (77 - 10 = 67) is 6.7, which represents the deadband. Half the
deadband is established above the SP and the other half is below it (±3.35 °C
about 26 °C). The span is taken from the SP HiLim and SP LoLim parameter
settings in the controller.
With a setpoint of 78 °F, the controller should maintain the process tank
temperature between 72 °F and 84 °F because 10% (output hysteresis) of
the span (170 - 50 = 120) is 12, which represents the deadband. Half of the
deadband is established above the SP and the other half is below it (±6 °F
about 78 °F). The span is taken from the SP HiLim and SP LoLim parameter
settings in the controller.
 17. Place the controller in automatic mode and press the Lower Display key
until the controller output (OUT) is displayed.

 18. Perform the following steps to monitor the temperature indicated by the
thermistor’s resistance.
A. Select the Log and Simulation tab on the ConSoft programming screen.
The Log and Simulation tab’s screen will appear, similar to shown in
figure 43.
LOG AND
SIMULATION
TAB
INPUT FIELD
(TEMPERATURE)
CURRENT LOOP
MONITOR
FIELD
AREA
START
BUTTON
Figure 43. Log and Simulation Tab on ConSoft Programming Screen
B. In the Monitor area in the center of the screen, select the Start button.
In the Input: field in the Monitor area, the ConSoft software displays
the water temperature being reported by the thermistor. In the Current
loop: field, the ConSoft software displays the current output from the
temperature transmitter.
The reported temperature should be approximately room temperature,
which is typically about 20 °C (68 °F) but will vary based on your room’s
temperature. The current should be about 8 mA, depending on the exact
temperature being measured.

 19. Record the temperature shown on ConSoft’s Monitor tab, the temperature on
the process tank’s temperature gauge, and the controller output.
Temperature shown in ConSoft_____________________________ (°F, °C)
Process Tank Temperature ________________________________ (°F, °C)
Output ___________________________________________________(%)
You should find that the controller output is 0% because the temperature in the
process tank, which the thermistor senses, is below the upper limit (29.35 °C
or 84 °F). The temperature of the water in the tank should be approximately
21 °C (70 °F) or room temperature.
 20. Turn ON the PROCESS PUMP selector switch to start flow through the
process fluid loop.
 21. Turn ON the HOT WATER PUMP selector switch to start flow through the
hot water loop.
 22. Record the temperature indicated on the process tank temperature gauge after
5 minutes.
Tank Temperature _______________________________________ (°F, °C)
You should find that the temperature is higher than the one you recorded in
step 19. Heat is being transferred to the process loop side through the hot
water heat exchanger.
 23. Record the temperature indicated on the controller display when the controller
output (OUT) increases to 100%.
Temperature ___________________________________________ (°F, °C)
You should find that the controller output increases to 100% when the
temperature rises above 29.35 °C or 84 °F. Above this temperature, the
controller closes the three-way valve port leading to the heat exchanger and
diverts all of the hot water back to the tank. You should also notice that the
controller output switches immediately from 0% to 100% instead of gradually
increasing. This indicates that the controller is using on/off control.

 24. Turn ON the CHILLER selector switch.
The chiller refrigerant should begin to flow through the right side of the
chiller heat exchanger, cooling the process fluid flowing through the left side.
This allows the process fluid to cool faster than it would if only allowed to
transfer heat to the surroundings.
 25. Record the temperature indicated on the controller when the controller output
(OUT) decreases to 0%.
Temperature ___________________________________________ (°F, °C)
You should find that the controller output decreases to 0% when the
temperature drops below 22.65 °C or 72 °F. Below this temperature, the
controller opens the three-way valve port leading to the heat exchanger and
diverts all of the hot water through the hot water heat exchanger. You should
also notice that the controller output switches immediately from 100% to 0%
instead of gradually decreasing. This also indicates that the controller is using
on/off control.
 26. Turn OFF the CHILLER selector switch.
This allows the process tank temperature to increase faster. You should find
that when the temperature rises above 29.35 °C or 84 °F, the controller output
again increases to 100% to close the valve port leading to the hot water heat
exchanger.
 27. After the system completes another cycle (from 0% to 100% to 0%), turn
OFF the PROCESS PUMP selector switch to stop flow through the process
loop.
 28. Enter the controller setup menu and program the parameters listed in the
table in figure 44.
CONTROLLER SETTINGS
Function Group Parameter Settings for °C Setting for °F
IN1 HIGH 77 170
INPUT 1
IN1 LOW 10 50
CONTROL OUT HYST 5 5
Figure 44. Controller Settings

 29. Change the setpoint (SP) to 24 (if using °C) or 75 (if using °F).
 30. Press the Lower Display key until the controller output (OUT) is displayed.

 31. Repeat steps 19-27 using the new controller settings to observe on/off control
at a new setpoint.
You should find that the controller uses on/off control to maintain the PV
between 22.325 °C and 25.675 °C or between 72 °F and 78 °F. The dead
band is smaller because the hysteresis value is lower. Also, the dead band has
shifted due to the new SP.
 32. Perform the following substeps to shut down the T5553-CF learning system.
A. Make sure the CHILLER selector switch is OFF.
B. Turn OFF the PROCESS PUMP selector switch to stop flow through the
process fluid loop.
C. Turn OFF the HOT WATER PUMP selector switch to stop flow through
the hot water loop.
D. Turn OFF the HOT WATER HEATER selector switch to turn of the
heating element.
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 transfer.
G. Disconnect the circuit.
H. Click the Stop button in the Monitor area on the ConSoft screen and then
close the ConSoft software.
I. Shut down the PC.

SKILL 2 CONFIGURE AND OPERATE A HONEYWELL UDC 3500 CONTROLLER
BASED CLOSED LOOP TEMPERATURE CONTROL SYSTEM
Procedure Overview
In this procedure, you will set up and operate a basic closed loop control
system to control the temperature of water flowing through the process fluid
loop. You will first configure the controller then operate the closed loop system.
56.
AMATROL

PUMP PUMP HEATER
PC-USB ALM MAN C
0
DI
OUT
-sp 0.0 SP
ANALOG INPUT ANALOG


Hold
F44376
2.0
5.4
PLC DISCRETE I/O TEMPERATURE TRANSMITTERS DI1 1.2
4.8
24 VDC
SENSOR VALVE HORN
SET TO
24 INPUT INPUT
TC RTD/TM TC RTD/TM
C .4 1.6
PC PC
ALARM CHAN 1 CHAN 2 CHAN 3 READ FLOAT AT
LARGEST DIA.
RELAYS
140 kPa
TC RTD TC RTD TC RTD
VDC VDC
DC POWER SUPPLY AL1
PLC ANALOG I/O
mV mV NC COM
4-20mA
(20 PSI)
AO1 AO2 AO3 AO4 4-20mA 4-20mA 4-20mA 4-20mA NC COM VDC VDC VDC
GND
AIR SUPPLY
VALVE VALVE FULLY CONNECTION
VALVE FULLY
OPEN CLOSED OPEN
F44376
8.0
2.0
F44376 5.4
1.6
TIGHTEN 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
CAPS .4 1.6
READ FLOAT AT
LARGEST DIA.
READ FLOAT AT
LARGEST DIA.
FULLY
CLOSED
TIGHTEN
CAP
VALVE FULLY
CLOSED

valves.
rotameter valves.

57. If you are using the single-loop controller, connect the circuit shown in
figure 58.
This circuit allows you to operate a closed loop temperature control system.
OPERATOR INTERFACE TEMPERATURE SENSORS PID CONTROLLER

PUMP PUMP HEATER
TC1 TC2 RTD1 RTD2 TM1 TM2
Func. Lower Man SP

24 VDC 24 VDC 24 VDC 24 VDC Setup Run

Hold

SENSOR VALVE HORN TEMPERATURE TRANSMITTERS DI1
TT2 TT3
TC RTD TC RTD
4-20mA 4-20mA
24 INPUT INPUT
VDC DI2
TC RTD/TM TC RTD/TM
PC PC
ALARM
RELAYS
VDC VDC
DC POWER SUPPLY AL1
mV mV NC COM
24 VDC 24 VDC 24 VDC

4-20mA 4-20mA 4-20mA 4-20mA NC COM
GND
Figure 57. Connections for Closed Loop Temperature Control Using Dual-Loop Controller

PUMP PUMP HEATER
Func. Lower Man SP


Hold

SENSOR VALVE HORN TEMPERATURE TRANSMITTERS INPUT OUTPUT
TT2 TT3
TC RTD
4-20mA 4-20mA
24 INPUT INPUT
VDC
TC RTD/TM TC RTD/TM
4 - 20mA
PC PC
DC POWER SUPPLY
mV mV
VDC ALARM RELAY
NO COM NC
OUTPUT OUTPUT
4-20mA 4-20mA
GND
Figure 58. Connections for Single-Loop PID Controller

FT
700
FE

FV
700 700
FS OPTION

500
TI
600-B
TE TE
600-B 600-A
RTD FI
TI 700A
HV 800-A
500-C
LS

900
HEAT TI
EXCHANGER 800-C
TE JC
TI 1100 1100
TE 800-B
TI
T5552 600-C 600-A
RETURN HT
FIC CONTROLLER 1100
1000
FI HOT WATER TANK
500 I/P CONVERTER AND HEATER
HV FV
500 IYT PC
TI 500-B 1000 1000
600-C
PI PI
FI 1000-A
700B 1000-B
CHILLER PLANT
HV HV AIR
500-D 700
REACTOR HOT
TANK FEED WATER
DRAIN PUMP PUMP
DRAIN
T5552
FEED
FCV
700
HV
500-A
60
 7. Rotate the temperature control adjustment dial on the hot water sensing bulb
thermostat to 60 °C (140 °F).
 8. Turn on the HOT WATER HEATER selector switch to turn on the heating
element and provide time for the water to heat while you perform other steps.
 9. Perform the following substeps to set up the Honeywell process controller for
closed loop control.
A. Make sure the setpoint (SP) value is displayed in the lower portion of the
controller display.
If the setpoint value is not displayed, repeatedly press the Lower Display
key on the controller’s keypad until the setpoint value is displayed.
The setpoint value is identified by the letters SP before the value.
B. If necessary, use the  and  keys on the keypad to change the setpoint
(SP) value to 29 (if using °C) or 85 (if using °F).
NOTE
The longer you press and hold the up/down (/) keys, the faster the
value changes.
C. Press the Setup key repeatedly to scroll through the different selections
until INPUT 1 appears on the display.
D. Press the Func Loop 1/2 key. The parameter IN 1 TYPE should appear
on the screen.
E. Use the  and  keys to set the parameter to 100 LO.
This indicates to the controller that the input signal is from a 100-ohm
platinum RTD.
100 LO and 100 PT are both 100-ohm platinum RTDs. The LO indicates
that the range is smaller (i.e. -184 °C to 149 °C instead of -184 °C to
649 °C, or -300 °F to 300 °F instead of -300 °F to 1200 °F). All other
characteristics are the same.
F. Press the Func Loop 1/2 key to move to the next parameter, IN1 HIGH.
G. Make sure this parameter is set to 149 (if using °C) or 300 (if using °F). If
not, use the  and  keys to set this parameter to 149 or 300.
This is the maximum temperature value for the RTD.
H. Press the Func Loop 1/2 key to move to the next parameter, IN1 LOW.
I. Make sure this parameter is set to -184 (if using °C) or -300 (if using °F)
If not, use the  and  keys to set this parameter to -184 or -300.
This is the minimum value for the RTD.

J. Press the Func Loop 1/2 key repeatedly until the BIAS IN1 parameter
appears.
K. Use the  and  keys to set the parameter to 0.
L. Press the Setup key repeatedly until ALGORITHM appears on the
display.
M. Press the Func Loop 1/2 key until CONT ALG appears on the display.
This parameter sets the control algorithm (program) for the controller.
N. Use the  and  keys to set the parameter to PID A.
Selecting PID A allows the controller to use a combination of automatic
control methods to control the process.
O. Set the following parameters in the TUNING group of the setup menu.
GAIN: 60
RSET MIN: 0.25
RATE MIN: 0.03
The gain, rset min, and rate min parameters set the proportional, integral,
and derivative control values, respectively. These control methods work
together to maintain the PV at the SP.
P. Press the Lower Display key repeatedly to exit the setup menu and display
the setpoint value.
NOTE
All other parameters should remain the same as set in the previous skill
(pages 22 and 24).
 10. Perform the following substeps to use the controller to automatically control
the process.
A. Place the controller in the automatic mode by pressing the Man/Auto
key.
“A” should appear in the upper left portion of the display if the controller
is in the automatic mode.
B. Record the temperature indicated on the controller display and the
temperature gauge at the outlet of the hot water heat exchanger on the
process fluid loop side.
Controller Display Temperature _________________________ (°F, °C)
Gauge Temperature ___________________________________ (°F, °C)

You should find that the temperature is approximately room temperature
(e.g. 21 °C (70 °F)). You should also find that the controller and gauge
temperatures are approximately the same.
C. Press the Lower Display key repeatedly until the controller output (OUT)
appears on the display.

D. Record the controller output (OUT).
Output _________________________________________________(%)
You should find that the controller output is 0%. This results in minimum
air pressure on the valve diaphragm, which allows the valve port leading
to the hot water heat exchanger to fully open in an effort to decrease the
error (i.e. the difference between the PV and the SP). However, you should
notice that the PV value is not changing because there is no flow through
the system.
E. When the temperature in the hot water tank reaches 60 °C (140 °F), turn
ON the HOT WATER PUMP selector switch to start flow through the
hot water loop.
F. Turn ON the PROCESS PUMP selector switch to start flow through the
process fluid loop.
G. Use the Lower Display key to display the SP value.
H. Observe the controller display as water flows through the hot water and
process fluid loops.
You should notice that the PV value is displayed above the SP value, as
figure 60 shows. The PV value should increase because the controller is
sending an output signal that keeps the valve open, allowing the hot water
to heat the process fluid through the heat exchanger.
ALM 1234 C
DI 1234
PV
OUT 1234
-SP SP
Figure 60. PV Value and SP Value Displayed
I. Turn ON the CHILLER selector switch to start refrigerant flow through

the chiller.

J. Record the temperature indicated on the controller and the temperature
gauge at the outlet of the hot water heat exchanger on the process fluid
loop side when the PV reaches steady state.
Steady state is indicated by a relatively constant value (i.e. oscillation less
than ±1 °C (±2 °F)) for at least 2 minutes.
Controller Display PV Temperature ______________________ (°F, °C)
Gauge Temperature ___________________________________ (°F, °C)

You should find that the controller display PV and gauge temperatures are
approximately equal and that the controller maintains the temperature at
approximately 29 °C (±1 °C) or 85 °F (±2 °F). You may notice error in the
controlled temperature because the controller is not properly tuned (i.e.
programmed). Tuning methods are covered in another LAP.
K. Observe the controller output (OUT) on the controller display.
You should notice that the controller decreases its output to open the valve
and allow more hot water to flow through the hot water heat exchanger.
This allows more heat transfer to the process fluid so that the temperature
increases and returns to the setpoint.
 11. Turn OFF the HOT WATER PUMP selector switch to stop flow through the
hot water loop.
 12. Turn OFF the CHILLER selector switch to stop refrigerant flow through the
chiller heat exchanger.
 13. Turn OFF the PROCESS PUMP selector switch to stop flow through the
process fluid loop.
 14. Change the SP to 33 (if using °C) or 92 (if using °F) and repeat step 9.
However, do not turn on the chiller.
You should find that when the SP is increased to 33 °C or 92 °F, the controller
decreases its output to the I/P converter to open the valve and allow more hot
water to flow to the hot water heat exchanger. The controller should begin to
increase its output signal as the PV approaches the SP and should maintain
the temperature near the setpoint. This may take several minutes.
 15. Perform the following substeps to shut down the T5553-CF.
A. Turn OFF the HOT WATER PUMP selector switch to stop flow through
the hot water loop.
B. Turn OFF the HOT WATER HEATER selector switch to turn off the
heating element.
C. Turn OFF the PROCESS PUMP selector switch to stop flow through the
process fluid loop.
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
F. Disconnect the circuit.

SKILL 3 CONNECT AND OPERATE ALARM OUTPUTS ON
A HONEYWELL UDC 3500 CONTROLLER
Procedure Overview
In this procedure, you will operate a temperature control circuit that uses
the alarm relays on the Honeywell controller to indicate when the process
variable goes above and below preset high and low limits, respectively.
65.
AMATROL

PUMP PUMP HEATER
PC-USB
ALM MAN C
0
PV
OUT
-sp 0.0 SP
ANALOG INPUT ANALOG

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

Setup
Hold
F44376
2.0
5.4
SET TO
4.8
24 VDC
SENSOR VALVE HORN
24 INPUT INPUT
TC RTD/TM TC RTD/TM
.4 1.6
140 kPa
PC PC
LARGEST DIA.
RELAYS TC RTD TC RTD TC RTD
VDC VDC
DC POWER SUPPLY AL1
PLC ANALOG I/O
mV mV NC COM
4-20mA
AO1 AO2 AO3 AO4

GND
OUTPUT
4-20mA
OUTPUT
4-20mA
OUTPUT
4-20mA
OUTPUT
4-20mA NC
AL2
COM VDC VDC VDC
(20 PSI)
AIR SUPPLY
OPEN CLOSED OPEN
F44376
8.0
2.0
F44376 5.4
TIGHTEN
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
CAPS
.8 3.2
FULLY
READ FLOAT AT
LARGEST DIA.
.4 1.6
READ FLOAT AT
LARGEST DIA.
CLOSED
TIGHTEN
CAP
VALVE FULLY
CLOSED

valves.
rotameter valves.

66.
If you are using the single-loop controller, connect the circuit shown in figure
67.
This circuit also indicates high and low temperature alarm conditions.

PUMP PUMP HEATER
ALM MAN C
0
PV
OUT
-sp 0.0 SP
Func. Lower Man SP

24 VDC 24 VDC 24 VDC 24 VDC Run

Setup
Hold

TT2 TT3 TC RTD TC RTD

4-20mA 4-20mA
24 INPUT INPUT
VDC DI2
TC RTD/TM TC RTD/TM
PC PC
ALARM
RELAYS
VDC VDC
DC POWER SUPPLY AL1
mV mV NC COM

4-20mA 4-20mA 4-20mA 4-20mA NC COM
GND
Figure 66. Connections for Closed Loop Temperature Control Using Dual-Loop Controller

PUMP PUMP HEATER
ALM MAN C
0
DI
PV
OUT
-sp 0.0 SP
Func. Lower Man SP

24 VDC 24 VDC 24 VDC 24 VDC
Setup Run
Hold

SENSOR VALVE HORN TEMPERATURE TRANSMITTERS INPUT OUTPUT
TT2 TT3
TC RTD
4-20mA 4-20mA
24 INPUT INPUT
VDC
TC RTD/TM TC RTD/TM
4 - 20mA
PC PC
DC POWER SUPPLY
mV mV
VDC ALARM RELAY
NO COM NC
OUTPUT OUTPUT
4-20mA 4-20mA
GND
Figure 67. Connections for Single-Loop PID Controller

FT
700
FE

FV
700 700
FS OPTION

500
TI
600-B
TE TE
600-B 600-A
RTD FI
TI 700A
HV 800-A
500-C
LS
900

HEAT TI
EXCHANGER 800-C
TE JC
TI 1100 1100
TE 800-B
TI
T5552 600-C 600-A
RETURN HT
FIC CONTROLLER 1100
1000
FI
500 HOT WATER TANK
I/P CONVERTER AND HEATER
HV FV
500 IYT PC
TI 500-B 1000 1000
600-C
FI PI PI
700B 1000-B 1000-A
CHILLER PLANT
HV HV AIR
500-D 700
REACTOR HOT
TANK FEED WATER
DRAIN PUMP PUMP
DRAIN
T5552
FEED
FCV
700
HV
500-A
73
 7. Rotate the temperature control adjustment dial on the sensing bulb thermostat
to 60 °C (140 °F).
 9. Perform the following substeps to set up the controller.
A. Place the controller in manual mode.
B. Press the Setup key to go to the setup menu.
C. Set the following parameters in the INPUT 1 setup group:
NOTE
Recall that to scroll through the setup menu groups, press the Setup key.
To scroll through the parameters in a group, press the Func Loop 1/2 key, and
to change the parameter settings, press the  and  keys.
PARAMETER SETTING FOR °C SETTING FOR °F

IN1 TYPE 100 LO 100 LO
IN1 HIGH 149 300
IN1 LOW -184 -300
NOTE
When the IN1 TYPE parameter is set to 100 LO, this indicates a 100-ohm
platinum RTD with a low temperature range of -184 °C to 149 °C (-300 °F to
300 °F). The IN1 HIGH and IN1 LOW parameters are automatically set when
an RTD or thermocouple is selected for IN1 TYPE. If 100 PT is selected, the
temperature range is -184 °C to 649 °C (-300 °F to 1200 °F).

D. Set the following parameters in the ALARMS setup group:
PARAMETER SETTING
A1S1 TYPE PV
A1S1 VAL 29 (if using °C) or 85 (if using °F)
A1S1 H L LOW
A1S2TYPE PV
A1S2 VAL 35 (if using °C) or 95 (if using °F)
A1S2 H L HIGH
ALM 1HYST 0.0
The A1S1 VAL parameter indicates the alarm 1 setpoint 1 value, which
for this application is 29 °C or 85 °F. The A1S2 VAL parameter indicates
the alarm 1 setpoint 2 value, which is 35 °C or 95 °F for this application.
A1S1TYPE and A1S2TYPE parameters determine the type of value that
triggers the alarm. In this case, A1S1TYPE and A1S2TYPE are based on
the process variable (PV).
The parameters A1S1 H L and A1S2 H L indicate whether the alarm is
high (H) or low (L). Therefore, A1S1 is a low alarm and A1S2 is a high
alarm.
E. Press the Lower Display key to return to the control display mode.
F. Change the setpoint (SP) for the controller to 37 (if using °C) or 98 (if
using °F).
G. Determine if the alarm buzzer is on. Also, determine if the alarm indicator
is present on the display of the controller.
Is the Alarm On? ____________________________________ (Yes/No)
Is the alarm indicator present on the display? ______________ (Yes/No)

H. If the alarm sounds, determine which level condition triggered the alarm.
Level Condition ________________________ (High Temp/Low Temp)
You should find that the alarm is on because the temperature is below 29
°C (85 °F). Therefore, a low temperature alarm condition exists.
I. Place the controller in the automatic mode.
 10. Turn ON the HOT WATER PUMP selector switch to start flow through the
hot water loop.
 11. Turn ON the PROCESS PUMP selector switch to start flow through the
process fluid loop.
You should notice that the temperature indicated on the controller display
begins to increase as heat is transferred to the process fluid loop through the
hot water heat exchanger.

 12. Determine if the alarm buzzer stays on when the temperature indicated on the
controller display exceeds 29 °C (85 °F).
Does the Alarm Buzzer Stay On? _________________________ (Yes/No)
You should find that the alarm does not stay on after the temperature rises
above 29 °C (85 °F) because it is in the operating range (29 °C to 35 °C or
85 °F to 95 °F).
 13. Determine the status of the alarm buzzer when the temperature rises above
35 °C (95 °F).
Is the Alarm Buzzer On? ________________________________ (Yes/No)
You should find that the alarm is on because the temperature is above the high
temperature alarm setpoint (35 °C or 95 °F).
 14. Turn OFF the HOT WATER PUMP selector switch to stop flow through the
hot water loop and place the controller in the manual mode.
 15. Turn ON the CHILLER selector switch to start refrigerant flow through the
chiller heat exchanger and cool the process fluid.
 16. When the temperature indicated on the controller display reaches 21 °C (70
°F), turn OFF the CHILLER selector switch.
 17. Repeat steps 8E –16 to operate the system using different alarm setpoints.
Set the following parameters:

A1S1 VAL 24 75
A1S2 VAL 27 80
SP 29 85
You should find that the alarm sounds when the temperature is below 24 °C
(75 °F) or above 27 °C (80 °F).
A. Turn OFF the HOT WATER HEATER selector switch to turn off the
heating element.
B. Turn OFF the PROCESS PUMP selector switch to stop flow through the
process fluid loop.
C. Disable the alarms by setting parameters A1S1 TYPE and A1S2 TYPE to
NONE.

SKILL 4 CONFIGURE AND OPERATE DISCRETE INPUTS ON
A HONEYWELL UDC 3500 CONTROLLER
Procedure Overview
This procedure requires the T5553-C2 dual-loop controller. If your
T5553-CF has the T5553-C1 single-loop controller, you will not be able to
perform this procedure.
In this procedure, you will connect a temperature control circuit that uses
the discrete inputs on the Honeywell controller to switch from one setpoint to
a different setpoint.
72.
AMATROL

PUMP PUMP HEATER
PC-USB ALM MAN C
0
PV
OUT
-sp 0.0 SP
ANALOG INPUT ANALOG

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

Setup Run
Hold
F44376
2.0
5.4
4.8
24 VDC
SENSOR VALVE HORN
SET TO
24 INPUT INPUT
TC RTD/TM TC RTD/TM
.4 1.6
PC PC
LARGEST DIA.
140 kPa
RELAYS
TC RTD TC RTD TC RTD
VDC VDC
DC POWER SUPPLY AL1
PLC ANALOG I/O
mV mV NC COM
4-20mA
(20 PSI)
AO1 AO2 AO3 AO4 4-20mA 4-20mA 4-20mA 4-20mA NC COM
VDC VDC VDC
GND
AIR SUPPLY
OPEN CLOSED OPEN
F44376
8.0
2.0
F44376 5.4
TIGHTEN
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
CAPS
.8 3.2
FULLY
READ FLOAT AT
LARGEST DIA.
.4 1.6
READ FLOAT AT
LARGEST DIA.
CLOSED
TIGHTEN
CAP
VALVE FULLY
CLOSED

valves.
rotameter valves.
J. If you are using a T5553-CFJ or T5553-CFN, plug the electrical power
cord into a three-phase supply, and then skip to step 3.
 3. Using the dual-loop controller, connect the circuit shown in figure 73.
This circuit also allows you to switch between different setpoints using the
controller’s discrete inputs.

PUMP PUMP HEATER
ALM MAN C
0
DI
OUT
-sp 0.0 SP
Func. Lower Man SP


Hold

TT2 TT3
TC RTD TC RTD
4-20mA 4-20mA
24 INPUT INPUT
VDC DI2
TC RTD/TM TC RTD/TM
PC PC
ALARM
RELAYS
VDC VDC
DC POWER SUPPLY AL1
mV mV NC COM

4-20mA 4-20mA 4-20mA 4-20mA NC COM
GND
Figure 73. Connections for Closed Loop Temperature Control Dual-Loop Controller

FT
700
FE

FV
700 700
FS OPTION

500
TI
600-B
TE TE
600-B 600-A
RTD FI
TI 700A
HV 800-A
500-C
LS
900

HEAT TI
EXCHANGER 800-C
TE JC
TI 1100 1100
TE 800-B
TI
T5552 600-C 600-A
RETURN HT
FIC CONTROLLER 1100
1000
FI HOT WATER TANK
500 I/P CONVERTER AND HEATER
HV FV
500 IYT PC
TI 500-B 1000 1000
600-C
PI PI
FI 1000-A
700B 1000-B
CHILLER PLANT
HV HV AIR
500-D 700
REACTOR HOT
TANK FEED WATER
DRAIN PUMP DRAIN PUMP
T5552
FEED
FCV
700
HV
500-A
84
 7. Rotate the temperature control adjustment dial on the hot water sensing bulb
thermostat to 60 °C (140 °F).
 9. Perform the following substeps to set up the controller
A. Place the controller in manual mode.
B. Press the Setup key to go to the setup menu.
NOTE
Recall that to scroll through the setup groups, press the Setup key. To scroll
through the parameters in a group, press the Func Loop 1/2 key, and to change
the parameter settings, press the  and  keys.
C. Set the following parameters in the INPUT 1 group:

IN1 TYPE 100 LO 100 LO
IN1 HIGH 149 300
IN1 LOW -184 -300
D. Press the Setup key repeatedly until you reach the CONTROL group.
E. Press the Func Loop 1/2 key repeatedly until you reach the LSPs
parameter.
This is the local setpoints parameter.
F. Use the  and  keys to set this parameter to TWO.
This allows you to program 2 local setpoints into the controller.
G. In the OPTIONS group, set parameter DIG INP1 to TO 2SP.
This tells the controller to change from local setpoint 1 to local setpoint
2 when the contact closes. The controller switches back to (SP) when the
contact opens.
H. Press the Lower Display key to return to the control mode.
I. Press the SP Select key until the SP value appears on the display.
J. Use the  and  keys to set the SP value to 26 (if using °C) or 78 (if
using °F).
K. Press the Lower Display key repeatedly until the 2SP value appears on
the display.
L. Use the  and  keys to set the 2SP value to 29 (if using °C) or 85 (if
using °F).
M. Press the Man/Auto key to place the controller in automatic mode.

 10. Perform the following substeps to operate the controller’s discrete input.
A. Turn ON the HOT WATER PUMP selector switch to start flow through
the hot water loop.
B. Turn ON the PROCESS PUMP selector switch to start flow through the
process fluid loop.
You should notice that the temperature indicated on the controller display
begins to increase as heat is transferred to the process fluid loop through
the hot water heat exchanger.
C. Turn ON the CHILLER selector switch to start the chiller.
D. Determine the temperature of the process fluid indicated on the controller
display when the system reaches a steady state.
A relatively constant temperature for at least 2 minutes indicates a steady
state. You can also determine this by observing a relatively constant
controller output over time.
Controller Display Temperature _________________________ (°F, °C)
You should find that the system reaches steady state at approximately 26
°C (78 °F), the first local setpoint for the controller. The temperature may
be a degree or two above or below the setpoint because the controller is
not fully tuned.
E. After the temperature stabilizes, connect a jumper (using either the red or
black banana plugs) across the discrete input (DI1) terminals. The jumper
serves the same purpose as the closed contacts on a switch.
Figure 75 shows this connection for the dual-loop controller.
CAUTION
The discrete inputs on the Honeywell controller are contact closure.
Therefore, you should never send a voltage to these inputs. Doing so will
damage the controller.
DUAL-LOOP CONTROLLER
PID CONTROLLER
ALM MAN C
0
DI
PV
OUT
-sp 0.0 SP
Func. Lower Man SP

Setup Run
Hold

INPUT INPUT INPUTS
DI1
TC RTD TC RTD
DI2
ALARM
RELAYS
VDC VDC
AL1
NO COM
OUTPUT OUTPUT AL2

4-20mA 4-20mA NO COM
JUMPER
CONNECTION
Figure 75. Jumper Connection for Controller Discrete Input

You should find that when the jumper is connected, the temperature begins
to increase to the second setpoint (29 °C or 85 °F). You should also notice
a 1 next to the DI label on the display panel, indicating that digital input 1
is active, as shown in figure 76.
DIGITAL INPUT 1
ALM 1234 A C
ACTIVE
DI 1
1234
PV
OUT 1234
-SP SP
Func. Lower Man SP

Setup Run
Hold
Figure 76. Discrete Input Active Indicator on a Honeywell Controller
F. After the temperature settles at SP2, disconnect the jumper across the
discrete input terminals.
You should find that the temperature begins to decrease to SP1 (26 °C or
78 °F). You should also notice that the 1 no longer appears on the controller
display, indicating that the digital input is no longer active. The value of
the discrete input may not be obvious because the controller is located
on the system. However, recall that in industry, the controller may be in
a remote location and the digital input activation may be accomplished
using a pushbutton or selector switch in the process area.
A. Turn OFF the HOT WATER PUMP selector switch to stop flow through
the hot water loop.
B. Turn OFF the HOT WATER HEATER selector switch to turn off the
heating element.
C. Turn OFF the PROCESS PUMP selector switch to stop flow through the
process fluid loop.

APPENDIX
INSTALLING THE TEMPERATURE TRANSMITTER’S
CONSOFT SOFTWARE AND USB DRIVERS
 1. Start the internet browser on the PC on which the ConSoft software is to be

installed.
 2. Navigate to the Inor website, www.inor.com.
 3. Select Download from the Inor home page.
 4. Locate and select Software from the Download page.
 5. Expand the ConSoft 3.4.27 (or higher) area, similar to shown in figure 77.
Leave this area expanded on your PC. You will also need it for step 9.
CONSOFT
3.4.27
AREA
CONSOFT SETUP
USB INTERFACE
Figure 77. ConSoft Software Downloads

 6. If you only need to install the USB drivers, skip to step 9. Otherwise, if you
need to install the ConSoft software and the USB drivers, proceed to step 7.
 7. Click ConSoftSetup.
 8. Follow the prompts to download and save the ConSoft software to your PC.
After the installation process is complete, the ConSoft icon, as shown in figure
78, will appear on the desktop. Later you can start the ConSoft software by
double clicking that icon or by selecting ConSoft from the Start menu.

 9. From the expanded ConSoft 3.4.27 (or higher) area, similar to shown in
figure 77, click USB-Interface.
 10. Follow the prompts to download and save the USB Interface hex file to your
PC.
A USB-Interface_1.2.07.zip file of approximately 10 KB will be saved in
your Downloads folder, similar to shown in figure 79.
USB_INTERFACE_
1.2.07.ZIP FILE
Figure 79. USB-Interface_1.2.07.zip File Saved

 11. Double click the USB-Interface_1.2.07.zip file and follow the prompts to
unzip it.
A USB-Interface_1.2.07.hex file of approximately 92 KB will be saved in
your Downloads > USB-Inetrface_1.2.07 folder, similar to shown in figure
80.
USB_INTERFACE_
1.2.07.HEX FILE
Figure 80. USB-Interface_1.2.07.hex File Saved

 12. If you are using the T5553-CFL, verify that the main circuit breaker on the
stepdown transformer is in the OFF (down) position.
 13. Verify that the T5553’s main circuit breaker is in the OFF (down) position.
 14. Remove the hex-head bolts, shown in figure 81, from the trainer panel so that
the T5553’s cabinet door can be opened.
HEX-HEAD
BOLT HEX-HEAD
BOLT
Figure 81. Trainer Cabinet Door Hex-Head Bolts

 15. Open the T5553’s cabinet door, raise the door vertically, and attach the safety
cable to the side-oriented bolt, as shown in figure 82.
SIDE-ORIENTED
BOLT
SAFETY
CABLE
Figure 82. Trainer Door Held Open with Safety Cable

 16. Locate the USB cable connected between the ICON-X USB Interface and the
temperature transmitter, as shown in figure 83.
ICON-X
USB INTERFACE
TEMPERATURE
TRANSMITTER
USB CABLE
Figure 83. USB Cable Between ICON-X USB Interface and Temperature
Transmitter
 17. Disconnect the USB cable from the temperature transmitter, as shown in
figure 84.
TEMPERATURE
TRANSMITTER
USB CABLE
DISCONNECTED
Figure 84. ICON-X USB Interface to Temperature Transmitter Disconnected
NOTE
The temperature transmitter should not be connected to the USB interface
while the USB drivers are being installed.

 18. While holding the T5553’s cabinet door, remove the safety cable from the
side-oriented bolt, and carefully lower the door to its original position.
 19. Replace the hex-head bolts to securely close the cabinet door.
 20. Locate the USB A-B cable, shown in figure 85.
USB CABLE
TYPE B TYPE A
CONNECTION CONNECTION
(TO TEMPERATURE (TO PC)
TRANSMITTER PANEL)
Figure 85. USB A-B Cable

 21. Connect the Type A end of the USB cable to your PC, similar to shown in
figure 86.
USB CABLE
(TYPE A
CONNECTION)
Figure 86. USB Cable Connected to PC

 22. Connect the Type B end of the USB cable to the temperature transmitter’s
USB adapter on the T5553, as shown in figure 87.
USB CABLE
(TYPE B
CONNECTION)
Figure 87. USB Cable Connected to Temperature Transmitter’s USB

Adapter

 23. Open the ConSoft software by double clicking the ConSoft icon on your
88.
SELECT AN OPTION
DIALOG

 24. Click the red X in the upper right corner of the Select an option part of the
screen.

 25. Click the Update USB interface icon, shown in figure 89.
UPDATE USB
INTERFACE
ICON
Figure 89. Update USB Interface Icon
An Update USB Interface dialog will appear, as shown in figure 90.
LOAD FILE
BUTTON
Figure 90. Update USB Interface Dialog

 26. Click the Load file button.
A file directory, similar to shown in figure 91, will open.
USB INTERFACE
HEX FILE
Figure 91. Load File Directory

 27. Select the hex file that was downloaded earlier and click the Open button.
The Update USB Interface dialog will change, similar to shown in figure 92.
Figure 92. Update USB Interface Dialog

 28. Click the Start update button.
The Update USB Interface dialog will indicate when the update has completed,
similar to shown in figure 93.
The USB interface has been updated and is ready for use.
Figure 93. USB Interface Update Complete

 29. Click the red X in the upper right corner of the Update USB Interface dialog.
 30. Open the T5553’s cabinet door, raise the door vertically, and attach the safety
cable to the side-oriented bolt.
 31. Re-connect the temperature transmitter’s USB cable to the temperature
transmitter, as shown in figure 94.
ICON-X
USB INTERFACE
TEMPERATURE
TRANSMITTER
USB CABLE
CONNECTED
Figure 94. ICON-X USB Interface to Temperature Transmitter

 32. While holding the T5553’s cabinet door, remove the safety cable from the
side-oriented bolt, and carefully lower the door to its original position.
 33. Replace the hex-head bolts to securely close the cabinet door.
 34. Click the red X in the upper right corner of the ConSoft software screen to
close ConSoft.
 35. Leave the PC powered up, if desired. Otherwise, shut down the PC.


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LEARNING ACTIVITY PACKET 10

BASIC TEMPERATURE CONTROL

FIRST EDITION, LAP 10, REV. B

B33301-CF10UEN BASIC TEMPERATURE CONTROL 2

PROCESS HOT WATER HOT WATER CHILLER

ANALOG INPUT ANALOG

Figure 10. T5553-CF Setup

B33301-CF10UEN BASIC TEMPERATURE CONTROL 13

B33301-CF10UEN BASIC TEMPERATURE CONTROL 14

TEMPERATURE TRANSMITTER OPERATOR INTERFACE TEMPERATURE SENSORS PID CONTROLLER

PROCESS HOT WATER HOT WATER CHILLER

ANALOG INPUT ANALOG

SS1 CC1 SS2 CC2 SS3 CC3 SS4 CC4

LOOP 1 LOOP 2 DISCRETE

OUTPUT OUTPUT OUTPUT OUTPUT AL2

Figure 11. On-Off Temperature Control Circuit Using Dual-Loop Controller

B33301-CF10UEN BASIC TEMPERATURE CONTROL 15

TEMPERATURE TRANSMITTER OPERATOR INTERFACE TEMPERATURE SENSORS PID CONTROLLER

PROCESS HOT WATER HOT WATER CHILLER

ANALOG INPUT ANALOG

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

SS1 CC1 SS2 CC2 SS3 CC3 SS4 CC4

FLOW FLOW ALARM ANALOG ANALOG

PLC ANALOG I/O DC POWER SUPPLY

Figure 12. On-Off Temperature Control Circuit Using Single-Loop Controller

B33301-CF10UEN BASIC TEMPERATURE CONTROL 16

Copyright © 2020 Amatrol, Inc.

Figure 13. T5553-CF P&ID

B33301-CF10UEN BASIC TEMPERATURE CONTROL

GROUP FUNCTION VALUE OR GROUP FUNCTION VALUE OR

GROUP FUNCTION VALUE OR

B33301-CF10UEN BASIC TEMPERATURE CONTROL 18

Figure 16. Trainer Cabinet Door Hex-Head Bolts

B33301-CF10UEN BASIC TEMPERATURE CONTROL 19

Figure 17. Trainer Door Held Open with Safety Cable

B33301-CF10UEN BASIC TEMPERATURE CONTROL 20

Figure 19. USB A-B Cable

B33301-CF10UEN BASIC TEMPERATURE CONTROL 21

Figure 20. USB Cable Connected to PC

Figure 21. USB Cable Connected to Temperature Transmitter’s USB Adapter

B33301-CF10UEN BASIC TEMPERATURE CONTROL 22

Figure 22. ConSoft Icon

The ConSoft initialization screen should appear, similar to shown in figure

Figure 23. ConSoft Initialization Screen

B33301-CF10UEN BASIC TEMPERATURE CONTROL 23

Figure 24. Thermistor Sensor Tab Settings

Figure 25. Thermistor Function Tab Settings

F. On the Function tab, Enable (check) the Inverse Output checkbox.

B33301-CF10UEN BASIC TEMPERATURE CONTROL 24

Figure 26. Thermistor Temperature Conversion Table

B33301-CF10UEN BASIC TEMPERATURE CONTROL 25

Figure 27. ConSoft Icon

The ConSoft initialization screen should appear, similar to shown in figure

Figure 28. ConSoft Initialization Screen

B33301-CF10UEN BASIC TEMPERATURE CONTROL 26

Figure 29. ConSoft Select Transmitter Screen

B33301-CF10UEN BASIC TEMPERATURE CONTROL 27

Figure 30. ConSoft Select Generation 1 or Generation 2 Dialog

B33301-CF10UEN BASIC TEMPERATURE CONTROL 28