Honeywell DC1000 SERIES User manual

Industrial Measurement & Control
DC1000 SERIES
DIGITAL CONTROLLE
R
PRODUCT MANUA
L

51-52-25-113
Issue1
March 2004
DC1010/1020/1030/1040 Product Manual

Copyright, Notices, and Trademarks
Printed in Taiwan - © Copyright 2004 Honeywell International Inc.
Issue 1 - March 2004
Warranty / Remedy
Honeywell warrants goods of its manufacture as being free to defective materials and faulty
workmanship. Contact your local sales office for warranty information. If warranted goods are
returned to Honeywell during the period of coverage, Honeywell will repair or replace without charge
those items it finds defective. The foregoing is Buyer’s sole remedy and is in lieu of all other
warranties, expressed or implied, including those of merchantability and fitness for a
particular purpose. Specifications may change without notice. The information we supply is believed
to be accurate and reliable as of this printing. However, we assume no responsibility for its use.
While we provide application assistance personally, through our literature and the Honeywell web site,
it is up to the customer to determine the suitability of the product in the application.
© Copyright 2004 Honeywell International Inc.
Sales and Service
Honeywell serves its customers through a worldwide network of sales offices and distributors. For
application assistance, current specifications, pricing, or name of the nearest Authorized Distributor,
contact your local sales office. See back page
Industrial Measurement and Control
Honeywell Korea
191 HanGangRo 2ga, YongSanGu
Seoul, Korea
DC1010/1020/1030/1040 Product Manual

Contacts
World Wide Web
The following lists Honeywell’s World Wide Web sites that will be of interest to our customers
Corporate http://content.honeywell.com/
Automation & Control Solutions http://www.acs.honeywell.com/ichome/Rooms/DisplayPages/LayoutInitial
Industrial Measurement & Control http://content.honeywell.com/imc/
Telephone
Contact us by telephone at the numbers listed below
United States and Canada 1-800-423-9883 Technical. Support
1-888-423-9883 Q&A Faxback (TACFACS)
1-800-525-7439 Service
Asia Pacific + (65) 6355 2828 Asia Pacific Headquarters
Europe + (32) 2 728 2111 Honeywell PACE, Brussels, Belgium
Latin America + [phone] Honeywell, Sunrise, Florida U.S.A
DC1010/1020/1030/1040 Product Manual

Symbol Definitions
The following advisory convention is used in this document to denote certain conditions.
Symbol Definition
CAUTION
This CAUTION symbol on the equipment refers the user to the Product Manual for
additional information. In this manual, this symbol appears next to required information.
Failure to comply with these instructions may result in product damage.
WARNING
PERSONAL INJURY: Risk of electrical shock. This symbol warns the user of the potential
shock hazard where HAZARDOUS LIVE voltages greater than 30 Vrms, 42.4 Vpeak, or 60
Vdc may be accessible.
Failure to comply with these instructions could result in death or serious injury.
DC1010/1020/1030/1040 Product Manual

Contents
1. Overview ............................................................................................................................ 1
1.1 Introduction.............................................................................................................................1
2. Installation......................................................................................................................... 2
2.1 Model Number Interpretation..................................................................................................2
2.2 Specification ...........................................................................................................................3
2.3 Mounting.................................................................................................................................4
2.4 External Dimension................................................................................................................4
2.4.1 DC1010...........................................................................................................................4
2.4.2 DC1020...........................................................................................................................5
2.4.3 DC1030...........................................................................................................................5
2.4.4 DC1040...........................................................................................................................5
2.5 Wiring Diagrams.....................................................................................................................6
2.5.1 DC1010...........................................................................................................................7
2.5.2 DC1020...........................................................................................................................8
2.5.3 DC1030...........................................................................................................................9
2.5.4 DC1040.........................................................................................................................10
3. Configuration ................................................................................................................... 11
3.1 Operator Interface................................................................................................................11
3.2 MODE Access ......................................................................................................................12
3.3 MODEs.................................................................................................................................13
3.3.1 Operation......................................................................................................................13
3.3.2 Configuration 1 .............................................................................................................14
3.3.3 Configuration 2 .............................................................................................................15
3.4 Alarms ..................................................................................................................................17
3.4.1 Deviation Alarm.............................................................................................................17
3.4.2 Absolute Value Alarm....................................................................................................18
3.4.3 Program Alarm..............................................................................................................19
3.4.4 System Alarm................................................................................................................19
3.5 Function Lock.......................................................................................................................20
4. Input Codes...................................................................................................................... 21
4.1 Thermocouples.....................................................................................................................21
4.2 RTDs ....................................................................................................................................22
4.3 Linear Inputs.........................................................................................................................22
5. Operation.......................................................................................................................... 23
5.1 Type of Control.....................................................................................................................23
5.1.1 Manual Operation.........................................................................................................23
5.1.2 ON/OFF Control............................................................................................................23
5.1.3 PID Control...................................................................................................................23
5.2 Set Point...............................................................................................................................23
5.3 Alarm Set Point ....................................................................................................................23
6. Error Message................................................................................................................... 24
DC1010/1020/1030/1040 Product Manual

1. Overview
1.1 Introduction
Function The DC1000 family of microprocessor based controllers combine a
high degree of functionality and reliability in 4 different formats: 1/16
DIN, 1/8 DIN, 3/16 DIN, and 1/4 DIN.
With a typical accuracy of ±0.5% of span, the DC1000 is an ideal
controller for regulating temperature and other process variables in a
variety of applications including dryers, semiconductor packaging &
testing, plastic processing, packaging machinery, painting & coating,
and climatic chambers.
Easy to Configure Two different configuration levels provide easy access to parameters.
A 4-digit security code prevents unauthorized changes. Parameters
can also be hidden to the user to prevent improper configuration of
the unit.
Various Control Algorithms The DC1000 series of controllers provides several different
algorithms:
 PID or ON/OFF Control
 Hear/Cool Algorithms with 2 different PID sets
 Motor Position Control without slidewire feedback
 Single Phase Control with/without zero crossover control
 Three Phase Control with/without zero crossover control
Mount Anywhere The DC1000 family is industrial control equipments that must be
panel mounted. The wiring terminals must be enclosed within the
panel. The DC1000 is environmentally hardened and, when suitably
enclosed, can be mounted virtually anywhere in plant or factory; on
the wall, in a panel, or even on the process machine. It withstands
ambient temperature up to 50°C (122°F).
CE Conformity (Europe) This product is in conformity with the protection requirements of the
following European Council Directive: 73/23/EEC, the Low Voltage
Directive, and 89/336/EEC, the EMC Directive. Conformity of this
product with any other “CE Mark” Directive(s) is not guaranteed.
Enclosure Rating: Panel-mounted equipment rating IP00. This
controller must be panel mounted and all terminals must be enclosed
within the panel. Front panel IP65 (IEC 529) option is available.
DC1010/1020/1030/1040 Product Manual
1

2. Installation
WARNING
Local Regulations regarding electrical & safety must be observed.
Failure to comply with these instructions could result in death or serious injury.
2.1 Model Number Interpretation
Size
1 48*48
2 48*96
3 72*72
4 96*96
Program
C None
P Program
Input
R RTD
T TC
L Linear
Output 1
0 None
1 Relay
2 Volt Pulse
3 4~20mA
5 1ϕSSR
6 3ϕSSR
7 Motor V
8 1ϕSCR
9 3ϕSCR
A
0~5V
B 0~10V
C 1~5V
D 2~10V
Output 2
0 None
1 Relay
2 Volt Pulse
3 4~20mA
A
0~5V
B 0~10V
C 1~5V
D 2~10V
A
larm
0 None
1 1 alarm
2 2 alarms
3 3 alarms
Manual
E English
C Chinese
K Korean
Table III
A
ux.
0 None
1 4~20mA
2 0~20mA
A
0~5V
B 0~10V
C 1~5V
D 2~10V
Input 2
0 None
1 4~20mA
2 0~20mA
A
0~5V
B 0~10V
C 1~5V
D 2~10V
Table II
-
-
-
DC10 0
Table I
0 None
1 RS-232
2 RS-485
Comm.
DC1010/1020/1030/1040 Product Manual
2

2.2 Specification
TECHNICAL DAT
A
Type of Input TC (K, J, R, S, B, E, N, T, W, PL II, U, L), RTD (Pt100Ω, JPt100Ω, JPt50Ω)
Linear (-10~10mV, 0~10mV, 0~20mV, 0~50mV, 10~50mV)
Input Sampling Time 500 ms
PV Input
Input Resolution 14 bit (each)
PV/SP Indication 4-digit, 7 segment display
Constant Value Storage System Non-volatile memory (EEPROM)
Indication Indication Accuracy ±0.5%FS
Proportional Band (P) 0~200% (On/Off action at P=0)
Integral Time (I) 0~3600 sec (PD action at I=0)
Derivative Time (D) 0~900 sec (PI action at D=0)
Control Mode
Cycle Time 0~150 sec (4~20mA0, SSR1, relay10)
Relay Output Contact, SPST(DC1010)/SPDT(1020,1030,1040), 3A/240VAC
Voltage Output Voltage Pulse, 20VDC/20mA
Linear Output 4~20mA, 0~5V, 0~10V, 1~5V, 2~10V
Motor Control Output Three Position Step Control (Time proportional motor control)
Output
Others 1ϕSSR, 3ϕSSR, 1ϕSCR, 3ϕSCR
Alarm Channel 3 channels (optional)
Mode 17 alarm mode available
Timer Flicker alarm, continued alarm, on delay timer alarm
Output Signal SP, PV
Aux. Output Type of Output 4~20mA, 0~20mA, 0~5V, 0~10V, 1~5V, 2~10V
Type of Input 4~20mA, 0~20mA, 0~5V, 0~10V, 1~5V, 2~10V2nd Input
(RSP) Sampling Time 500 ms
Pattern/Segment 2 pattern/ 8 segment (each)
Program Availability Pattern link & repeat, program/segment end alarm
Communication Type of Communication RS-232, RS-485
Rated Power Supply
Voltage & Frequency AC 90-240V, 50/60Hz or DC15-50V, 4VA
Power Consumption Max. 8VA
Storage Temperature -25°C~65°C
Ambient Temperature 0°C~50°C
General
Specifications
Ambient Humidity 50~85% RH (no condensation)
INPUT ACTUATIONS K 0.0~200.0, 400.0, 600.0, 800.0, 1000, 1200 °C
J 0.0~200.0, 400.0, 600.0, 800.0, 1000, 1200 °C
R 0.0~1600, 1769 °C
S 0.0~1600, 1769 °C
B 0.0~1820 °C
E 0.0~800, 1000 °C
N 0.0~1200,1300 °C
T 0.0~400.0, 200.0 °C, 0.0~350.0 °C
W 0.0~2000, 2320 °C
PL II 0.0~1300, 1390 °C
U -199.9~600.0, 200.0 °C, 0.0~400.0 °C
TC
L 0.0~400.0, 800.0 °C
Pt100 -199.9~600.0, 400.0, 200.0 °C, 0.0~200.0, 400.0, 600.0 °C
JPt100 -199.9~600.0, 400.0, 200.0 °C, 0.0~200.0, 400.0, 600.0 °C
RTD JPt50 -199.9~600.0, 400.0, 200.0 °C, 0.0~200.0, 400.0, 600.0 °C
AN1 -10~10mV
AN2 0~10mV
AN3 0~20mV
AN4 0~50mV 0~20mA, 0~1V, 0~5V, 0~10V
Linear
AN5 10~50mV 4~20mA, 1~5V, 2~10V
DC1010/1020/1030/1040 Product Manual
3

2.3 Mounting
CAUTION
Installation Precautions
The controller can be mounted on either a vertical or tilted panel using the mounting
bracket supplied. Adequate access space must be available at the back of the panel fo
r
installation and servicing activities.
Failure to comply with these instructions may result in product damage.

Side View

1 - Put the mounting bracket in the rail on
the top & bottom of the case.
2 - Bend the grip of the bracket & slide
the bracket along the rail until the case
is secured against the panel.
3 - Put the grip of the bracket on the
groove to fasten the case to the panel.
2.4 External Dimension
2.4.1 DC1010
DC1010/1020/1030/1040 Product Manual
4

2.4.2 DC1020
2.4.3 DC1030
2.4.4 DC1040
DC1010/1020/1030/1040 Product Manual
5

2.5 Wiring Diagrams
WARNING
Electrical Consideration / Precautions
The controller is considered “rack and panel mounted equipment” per EN61010-1, Safety
Requirements for Electrical Equipment for Measurement, Control and Laboratory Use, Part 1:
General Requirements. Conformity with 72/23/EEC Low Voltage Directive, requires the user to
provide adequate protection against a shock hazard. The user shall install this controller in an
enclosure that prevents OPERATOR access to the rear terminals.
Failure to comply with these instructions could result in death or serious injury.
CAUTION
Applying 85-264Vac to a controller rated for 15-50Vdc will severely damage the controlle
r
and is a fire and smoke hazard.
Failure to comply with these instructions may result in product damage.
CAUTION
Wiring Requirements
Shielded twisted pair cable is required for all Analog I/O, Process Variable, RTD, Thermocouple, dc
millivolt, low level signal, mA, Digital Output, and computer interface circuits.
Failure to comply with these instructions may result in product damage.
CAUTION
Line Voltage Wiring
This controller is suitable for connection to 90-240 Vac, 50/60 Hz or 15-50 Vdc, power suppl
y
mains. It is the user responsibility to provide the following
 90-240 Vac - a switch, fuse (1/2A, 250V) or a circuit breaker.
 15-50 Vdc – a switch, fuse (1A, 125A) or a circuit breaker
Fuse types – NorthAmerica non-time delay, Europe – Type F, quick acting fuse(s).
The above items should be installed together with DC1000 for the products electrical protection.
The switch or circuit-breaker should be located close to the controller, within easy reach of the
operator. The switch or circuit-breaker should be marked as the disconnecting device for the
controller.
When applying power to multiple instruments, make sure that sufficient current is supplied.
Otherwise, the instruments may not start up normally due to the voltage drop caused by the in-
rush current.
Failure to comply with these instructions may result in product damage.
DC1010/1020/1030/1040 Product Manual
6

2.5.1 DC1010
Noise
Filter
POWER
AC 90 ~ 240V
(
50 / 60Hz
)
PV
Rela
y
OUT2
DC 15 ~ 50V
(option)
Volt Linear
2
3
OUT1
4
5
2
3
OUT1
=
7
COM
CLOSE
OPEN
11
12
G1
K1
13
14
A
,B,C,D
231
OUT1
=
5
OUTPUT
7
8
9
10
7
8
9
10
7
8
9
10
A
B
B
Linear
R
TD
T
C
ALARM
2
3
AL2
AL1
11
12
13
RD
SD
SG
11
12
13
D-
D+
COMM
RS232
COMM
RS485
1
11
6
2
12
7
3
13
8
4
14
9
510
A
UX. OUT
11
12
TRS
COMM.
4
5
A
,B,C,D
231
11
12
AL1
13
14
G2
K2
Rela
y
Volt Linear
L
N
DC1010/1020/1030/1040 Product Manual
7

2.5.2 DC1020
OUT 2
9
10
8
6
7
OUT 1
9
10
6
7
8
OUT1
=
7
COM
CLOSE
OPEN
A
,B,C,D
231
A
,B,C,D
231
17
18
19
20
17
18
19
20
17
18
19
20
A
B
B
Linear
R
TD
T
C
4
5
3
12
13
11
7
6
NO
NC
COM NC
NO
COM
NC
NO
COM
A
L1
A
L2
A
L
3
15
16
14
15
16
14
RD
SD
SG
15
16
14
D-
D+
COMM
RS232
COMM
RS485
111
212
313
414
515
616
717
818
919
10 20
12
13
TR
S
11
Noise
Filter
POWER
AC 90 ~ 240V
(
50 / 60Hz
)
DC 15 ~ 50V
(option)
PV
OUTPUT
A
LARM AUX. OUT
COMM.
Rela
y
Volt Linear
Rela
y
Volt Linear
INPUT2
N
L
DC1010/1020/1030/1040 Product Manual
8

2.5.3 DC1030
OUT2
6
7
5
3
4
OUT1
6
7
3
4
5
OUT1
=
7
COM
CLOSE
OPEN
15
17
G1
G2
19
20
PROT
A
,B,C,D
231
A
,B,C,D
231
OUT1
=
5
18
20
15
16
17
21
G1
K1
PROT
G2
K2
OUT1
=
8
11
12
13
14
11
12
14
13
11
12
14
13
A
B
B
Linear
R
TD
T
C
9
10
8
4
3
NO
NC
COM
NC
NO
COM
A
L2
A
L1
10
9
Rem ote SP
16
17
15
RD
SD
SG
16
17
15
D-
D+
COMM
RS232
COMM
RS485
1
15 8
216
9
317 10
418 11
5
19 12
620
13
721 14
19
18
TRS
Noise
Filter
POWER
AC 90 ~ 240V
(
50 / 60Hz
)
DC 15 ~ 50V
(option)
INPUT2
PV
OUTPUT
A
LARM
A
UX. OUT
COMM.
Rela
y
Volt Linear
Rela
y
Volt Linear
N
L
DC1010/1020/1030/1040 Product Manual
9

DC1010/1020/1030/1040 Product Manual
10
2.5.4 DC1040
OUT 2
9
10
8
6
7
OUT 1
9
10
6
7
8
OUT 1
=
7
COM
CLOSE
OPEN
31
33
G1
G2
39
40
PROT
37
39
31
33
35
40
RG
RG
PROT
TG1
TG2
A,
B
,
C
,
D
231
OUT 1
=
6
A,
B
,
C
,
D
231
OUT 1
=
5
34
35
31
32
33
36
G1
K1
PROT
G2
K2
OUT 1
=
8
34
39
31
32
33
40
G1
K1
PROT
G2
K2
OUT 1
=
9
35
36
G3
K3
17
18
19
20
17
18
19
20
17
18
19
20
A
B
B
L
inear
R
TD
T
C
4
5
3
12
13
11
7
6
NO
NC
COM
NC
NO
COM
NC
NO
COM
AL1
AL2
AL3
15
16
14
R
e
m
ote
S
P
15
16
14
RD
SD
SG
15
16
14
D-
D+
COMM
RS232
COMM
RS485
32
33
31
RD
SD
SG
32
33
31
D-
D+
COMM
RS232
COMM
RS485
1
31
11
2
32
12
3
33
13
4
34
14
5
35
15
6
36
16
7
37
17
8
38
18
9
39
19
10
40
20
40
39
TR
S
Noise
Filter
POWER
AC 90 ~ 240V
(
50 / 60Hz
)
DC 15 ~ 50V
(option)
Rela
y
Volt Linear
Rela
y
Volt Linear
INPUT2
PV
OUTPUT
A
LARM
A
UX. OUT
COMM.
COMM.
N
L
* Once INPUT2 and COMM. options are selected together,
the wiring terminal for COMM will be changed as above.

3. Configuration
3.1 Operator Interface
Upper Display 4 digits dedicated to display the PV. In configuration mode, this display indicates
the name of parameter.
Lower Display 4 digits dedicated to display the SP. In configuration mode, this display indicates
the value of parameter or the status of parameter selected.
Bar Graph A bargraph of 10 green LEDs’ indicates the value of the output in percentage.
LEDs
OUT1 Status of ‘Output 1’.
OUT2 Status of ‘Output 2’.
AT When the LED is ON, it indicates the controller is in automatic tuning process .
AL1 Status of ‘Alarm 1’.
AL2 Status of ‘Alarm 2’.
AL3 Status of ‘Alarm 3’.
MAN When the LED is ON, it indicates the controller is in manual mode.
PRO When a program is running, the LED flickers.
When a program is suspended, the LED is ON.
When no program is running, the LED is OFF.
Keys
SET SET key allows moving from one parameter to another or saving a new value of
parameter or a status of parameter changed.
A/M A/M key allows switching from automatic mode to manual mode or from manual
mode to automatic mode.
SHIFT SHIFT key allows shifting the digits to modify parameters.
UP UP key allows increasing the value of a digit selected or changing the status of
parameter.
DOWN DOWN key allows decreasing the value of a digit selected or changing the status
of parameter.
20
0%
40
60
80
100%
Bar Graph
LEDs
Down key
Up key
SHIFT key
A
/M key
SET key
Lower Display
Upper Display
DC1010/1020/1030/1040 Product Manual
11

3.2 MODE Access
O
p
eration Confi
g
uration 1
Confi
g
uration 2Pro
g
ram
Set U
p
(3)
(2)
(2)
(3)
(1)
How to move from one MODE to another
(1) Press ‘SET’ key for 5 seconds; it grants access to ‘Configuration 1’ mode or return to
‘Operation’ mode from ‘Configuration 1’ mode.
(2) Press ‘SHIFT’ key for 5 seconds while pressing ‘SET’ key first; it grants access to
‘Configuration 2’ mode or return to ‘Operation’ mode.
(3)
A
ll parameters related to program configuration will be displayed next to parameters in
‘Operation’ mode. (* These parameters will be shown in program model only)
NOTICE
DO NOT access ‘Set Up’ mode without instruction from technical assistant.
DC1010/1020/1030/1040 Product Manual
12

3.3 MODEs
3.3.1 Operation
Parameter Description
PV Display
SET
SET
SET
SET
SET
SP Display
Output Limit To limit the Maximum of Control Ou
p
ut
Percentage (%)
A
uto Tuning
* Default ‘No’
Status
Enter deviation value or absolute value
A
larm 1
Depending on alarm mode selected
Value of alarm setpoint
A
larm 2
T
he same with Alarm1
A
larm 3
T
he same with Alarm 1
* The ‘OUTL’ is not shown in default mode.
* ‘AL2’ & ‘AL3’ are shown only in the model the relevant options are taken.
DC1010/1020/1030/1040 Product Manual
13

3.3.2 Configuration 1
‘Configuration 1’ will be shown by pressing ‘SET’ key for 5 seconds in ‘Operation’ mode.
Main Control (OUT1)
P value (Proportional Band)
Main Control (OUT1)
I value (Integral Time)
Main Control (OUT1)
D v
a
l
ue
(
D
e
riv
at
iv
e
Tim
e)
Main Control
Dead
-
Band Time
Main Control (OUT1)
‘
Auto tuning’ offset
Main Control (OUT1)
Cycle of Control Output
Main Control (OUT1)
Actuat
i
o
n
o
f H
yste
r
s
i
s
Sub Control (OUT2)
P value (Proportional band)
Sub Control (OUT2)
I value (Integral Time)
Sub Control (OUT2)
D value (Derivative Time)
Sub Control (OUT2)
C
y
cle of Control Out
p
ut
Sub Control (OUT2)
Hysteresis
Main Control (OUT 1)
Gap
Sub Control (OUT2)
Gap
Function Lock
Range: 0~200%
P1=0, ON/OFF Control
Range: 0~3600 seconds
I=0, Integral off
Range: 0~900 seconds
D=
0,
D
e
riv
at
iv
e
o
ff
* DO NOT CHANGE THE VALUE
Range: 0~ Upper limit value (USPL)
Prevent from ‘Overshoot’ during auto tuning
Output type (SSR 1, 4~20mA0, relay10)
Range: 0~150 seconds
Just in case of ON/OFF control (P1
=
0) (Range: 0
~
1000)
The same with the method of P1 configuration
The same with the method of I1 configuration
The same with the method of D1 configuration
The same with the method of CYT1 configuration
The same with the method of HYS1 configuration
Control ouput is turned off before getting to SP
Control Output to be turned on before getting to SP
* R
e
f
e
r
to
‘
2.
3
F
u
n
ct
i
o
n L
oc
k
’
in P.1
0
ON : PV<=(SP-HYS1)
OFF
: PV > (SP+HYS1)
Turning Point = SP-GAP1; OFF (OUT1=Heat)
Turning Point = SP+GAP2; ON (OUT2=Cool)
SET
SET
SET
SET
SET
SET
SET
SET
SET
SET
SET
SET
SET
SET
SET
* The parameters are only for ‘Output’ 2 function, so it will appear only in the model which has the “OUT2” option.
Descri
p
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DC1010/1020/1030/1040 Product Manual
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