Honeywell DC1000 SERIES User manual

Industrial Measurement and Control
DC1000 Series
Digital Controller
Product Manual
51-52-25-113
August 2005
www.DataSheet4U.net

ii DC1010/1020/1030/1040 Product Manual 8/05
Copyright, Notices and Trademarks
Printed in Taiwan - © Copyright 2005 by Honeywell
Revison 1 - August 2005
WARRANTY/REMEDY
Honeywell warrants goods of its manufacture as being free of 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.
Industrial Measurement and Control
Honeywell Korea
191 HanGangRo 2ga, YongSanGu
Seoul, Korea

8/05 DC1010/1020/1030/1040 Product Manual iii
About This Document
Abstract
This document provides descriptions and procedures for the Installation, Configuration, and Operation of your DC1000
Controller.
Contacts
World Wide Web
The following lists Honeywell’s World Wide Web sites that will be of interest to our customers.
Honeywell Organization WWW Address (URL)
Corporate http://www.honeywell.com
Industrial Measurement and Control http://www.honeywell.com/imc
Telephone
Contact us by telephone at the numbers listed below.
Organization Phone Number
United States and Canada Honeywell 1-800-423-9883 Tech. Support
1-800-525-7439 Service
Asia Pacific Asia Pacific Headquarters (63-2) 633 2830
Europe Honeywell PACE, Brussels, Belgium Contact your Local Sales Office
Latin America Honeywell, Ft. Washington, PA U.S.A. 215-641-3610

Introduction
iv DC1010/1020/1030/1040 Product Manual 8/05
Symbol Definitions
The following table lists those symbols used in this document to denote certain conditions.
Symbol Definition
This CAUTION symbol on the equipment refers the user to the Product Manual for
additional information. This symbol appears next to required information in the manual.
WARNING
PERSONAL INJURY: Risk of electrical shock. This symbol warns the user of a
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.
ATTENTION, Electrostatic Discharge (ESD) hazards. Observe precautions for
handling electrostatic sensitive devices
Protective Earth (PE) terminal. Provided for connection of the protective earth (green
or green/yellow) supply system conductor.
Functional earth terminal. Used for non-safety purposes such as noise immunity
improvement. NOTE: This connection shall be bonded to protective earth at the source
of supply in accordance with national local electrical code requirements.
Earth Ground. Functional earth connection. NOTE: This connection shall be bonded to
Protective earth at the source of supply in accordance with national and local electrical
code requirements.
Chassis Ground. Identifies a connection to the chassis or frame of the equipment shall
be bonded to Protective Earth at the source of supply in accordance with national and
local electrical code requirements.
Equipment protected throughout by DOUBLE INSULATION or REINFORCED
INSULATION

Introduction
8/05 DC1010/1020/1030/1040 Product Manual v
Contents
1INTRODUCTION ...................................................................................................1
1.1 Overview.........................................................................................................................................1
2INSTALLATION.....................................................................................................3
2.1 Overview.........................................................................................................................................3
2.2 Condensed Specifications ...............................................................................................................4
2.3 Model Number Interpretation .........................................................................................................6
2.4 Mounting.........................................................................................................................................8
2.4.1 Physical Considerations .......................................................................................................8
2.4.2 Overall Dimensions..............................................................................................................8
2.4.3 Mounting Procedure...........................................................................................................10
2.5 Wiring ...........................................................................................................................................11
2.5.1 Electrical Considerations ...................................................................................................11
2.6 Wiring Diagrams...........................................................................................................................12
2.6.1 Identify Your Wiring Requirements ..................................................................................12
2.6.2 Making Terminal Connections...........................................................................................12
2.6.3 Wiring Diagrams................................................................................................................13
3OPERATION........................................................................................................ 17
3.1 Overview.......................................................................................................................................17
3.2 Operator Interface Overview ........................................................................................................17
3.2.1 Displays, LEDs, and Keys .................................................................................................18
3.3 Mode Access.................................................................................................................................19
3.3.1 How to move from one mode to another............................................................................19
3.4 Operation Mode ............................................................................................................................20
3.4.1 Key Functions ....................................................................................................................20
3.4.2 Operation Mode Prompts ...................................................................................................20
3.4.3 Control Types.....................................................................................................................21
3.4.4 Set Point .............................................................................................................................22
3.4.5 Alarm Functions and Associated Prompts .........................................................................23
4CONFIGURATION............................................................................................... 24
4.1 Introduction...................................................................................................................................24
4.2 Configuration 1 .............................................................................................................................24
4.2.1 Configuration 2 ..................................................................................................................26
4.3 ALARMS CONFIGURATION ....................................................................................................29
4.3.1 Alarm Function Selections.................................................................................................29
4.3.2 Deviation Alarm Overview ................................................................................................30
4.3.3 Absolute Value Alarm Overview.......................................................................................32
4.3.4 Program Alarm...................................................................................................................33

Introduction
vi DC1010/1020/1030/1040 Product Manual 8/05
4.3.5 System Alarm.....................................................................................................................33
4.4 Function Lock ...............................................................................................................................34
4.5 Parameter Display Set (Hide or Display)......................................................................................35
4.5.1 Overview............................................................................................................................35
4.5.2 Functions of SETs..............................................................................................................35
4.6 Input Codes ...................................................................................................................................37
4.6.1 Code Selection ...................................................................................................................37
5PROGRAMMER (OPTIONAL) ............................................................................ 41
5.1 Overview.......................................................................................................................................41
5.1.1 Introduction........................................................................................................................41
5.2 Programmer Terminologies ..........................................................................................................41
5.3 Operating Key Functions ..............................................................................................................41
5.4 Program Functions ........................................................................................................................41
5.4.1 Program Running Alarm ....................................................................................................41
5.4.2 Segment Completion Alarm...............................................................................................42
5.4.3 END Function ....................................................................................................................42
5.4.4 Linking Function................................................................................................................42
5.4.5 Wait Function.....................................................................................................................42
5.4.6 Other Functions..................................................................................................................43
5.5 Program Configuration Prompts ...................................................................................................44
5.5.1 Overview............................................................................................................................44
5.5.2 Configuration .....................................................................................................................44
5.5.3 Program Example...............................................................................................................47
6ERROR CODES ..................................................................................................48
6.1 Overview.......................................................................................................................................48
7INDEX..................................................................................................................49

Introduction
8/05 DC1010/1020/1030/1040 Product Manual vii
Tables
Table 2-1 Condensed Specifications _____________________________________________________ 4
Table 3-1 Displays, LEDs, and Keys ____________________________________________________ 18
Table 3-2 Mode Change Instructions ____________________________________________________ 19
Table 3-3 Operation Mode Prompts _____________________________________________________ 20
Table 4-1 Configuration 1 Mode________________________________________________________ 24
Table 4-2 Configuration 2 Mode________________________________________________________ 26
Table 4-3 Alarm Function Selections ____________________________________________________ 29
Table 4-4 Functions of Sets____________________________________________________________ 35
Table 4-5 Thermocouple Inputs ________________________________________________________ 37
Table 4-6 RTD Inputs ________________________________________________________________ 38
Table 4-7 Linear Inputs _______________________________________________________________ 39
Table 5-1 Key Functions ______________________________________________________________ 41
Table 5-2 Associated Program Functions _________________________________________________ 43
Table 5-3 Program Configuration Prompts ________________________________________________ 44
Table 6-1 Error Codes ________________________________________________________________ 48

Introduction
viii DC1010/1020/1030/1040 Product Manual 8/05
Figures
Figure 2-1 Model DC1010 Dimensions ___________________________________________________ 8
Figure 2-2 Model DC1020 Dimensions ___________________________________________________ 8
Figure 2-3 Model DC1030 Dimensions ___________________________________________________ 9
Figure 2-4 Model DC1040 Dimensions ___________________________________________________ 9
Figure 2-5 Mounting Procedure ________________________________________________________ 10
Figure 2-6 Model DC1010 Wiring______________________________________________________ 13
Figure 2-7 Model DC1020, DC1025 Wiring ______________________________________________ 14
Figure 2-8 Model DC1030 Wiring______________________________________________________ 15
Figure 2-9 Model DC1040 Wiring______________________________________________________ 16
Figure 3-1 Operator Interface __________________________________________________________ 17
Figure 3-2 Mode Access Diagram_______________________________________________________ 19
Figure 4-1 Deviation Alarms___________________________________________________________ 30
Figure 4-2 Upper Limit Deviation Alarm (Alarm Code 01, Alarm release in the first alarming situation) ___ 30
Figure 4-3 Upper Limit Deviation Alarm (Alarm Code 11, No alarm release in the first alarming situation) _30
Figure 4-4 Lower Limit Deviation Alarm (Alarm Code 02, Alarm release in the first alarming situation) ___ 31
Figure 4-5 Lower Limit Deviation Alarm (Alarm Code 12, No alarm release in the first alarming situation)_31
Figure 4-6 Dev. Band Breakaway Alarm (Alarm Code 03, Alarm release in the first alarming situation) ____ 31
Figure 4-7 Dev. Band Breakaway Alarm (Alarm Code 13, No alarm release in the first alarming situation) __ 31
Figure 4-8 Deviation Band Alarm (Alarm Code 04, Alarm release in the first alarming situation) _________ 31
Figure 4-9 Deviation Band Alarm (Alarm Code 14, No alarm release in the first alarming situation)_______ 31
Figure 4-10 Absolute Value Alarm ______________________________________________________ 32
Figure 4-11 Absolute Upper Limit Alarm (Alarm Code 05, Alarm release in the first alarming situation) ___ 32
Figure 4-12 Absolute Upper Limit Alarm (Alarm Code 15, No alarm release in the first alarming situation)_32
Figure 4-13 Absolute Lower Limit Alarm (Alarm Code 06, Alarm release in the first alarming situation)___ 32
Figure 4-14 Absolute Lower Limit Alarm (Alarm Code 16, No alarm release in the first alarming situation) 32
Figure 4-15 Program RUN Alarm – Code 17 ______________________________________________ 33
Figure 4-16 System Error Alarm – Code 08 _______________________________________________ 33
Figure 4-17 System Error Alarm – Code 18 _______________________________________________ 33
Figure 4-18 Display Status ____________________________________________________________ 35
Figure 5-1 Program Example __________________________________________________________ 47

Introduction
8/05 DC1010/1020/1030/1040 Product Manual 1
1 Introduction
1.1 Overview
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
unauthorized 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 controller family is industrial control equipment 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 a plant or factory; on a wall, in a panel, or even on the process machine. It
withstands ambient temperature of up to 50°C (122°F).

Introduction
2 DC1010/1020/1030/1040 Product Manual 8/05
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)
shall not be assumed.
Enclosure Rating: Panel-mounted equipment, IP00. This controller must be panel
mounted. Terminals must be enclosed within panel. Front panel IP65 (IEC 529)
optionally.

Installation
8/05 DC1010/1020/1030/1040 Product Manual 3
2 Installation
2.1 Overview
Introduction
Installation of the DC1000 consists of mounting and wiring the controller according to
the instructions given in this section. Read the pre-installation information, check the
model number interpretation (Subsection 2.3), and become familiar with your model
selections, then proceed with installation.
CAUTION
Installation should be performed only by personnel who are technically competent to do
so. Local Regulations regarding electrical & safety must be observed.
Pre-installation Information
If the controller has not been removed from its shipping carton, inspect the carton for
damage then remove the controller.
• Inspect the unit for any obvious shipping damage and report any damage due to
transit to the carrier.
• Make sure a bag containing mounting hardware is included in the carton with the
controller.
• Check that the model number shown on the inside of the case agrees with what you
have ordered.

Installation
4 DC1010/1020/1030/1040 Product Manual 8/05
2.2 Condensed Specifications
Honeywell recommends that you review and adhere to the operating limits listed in Table
2-1 when you install your controller.
Table 2-1 Condensed Specifications
TECHNICAL DATA
Type of Input
TC (K, J, R, S, B, E, N, T, W, PL II, U, L)
RTD (Pt100Ω, JPt100Ω, JPt50Ω)
Linear (4 – 20mA)
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 (4~20mAÆ0, SSRÆ1, relayÆ10)
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
Channel 3 channels (optional)
Mode 17 alarm mode available
Alarm
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 100-240V, 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)

Installation
8/05 DC1010/1020/1030/1040 Product Manual 5
INPUT ACTUATIONS
K 0.0~200.0, 400.0, 600, 800, 1000, 1200 °C
J 0.0~200.0, 400.0, 600, 800, 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
Linear AN4
AN5
0~50mV
10~50mV
0~20mA, 0~1V, 0~5V, 0~10V
4~20mA, 1~5V, 2~10V

Installation
6 DC1010/1020/1030/1040 Product Manual 8/05
2.3 Model Number Interpretation
Introduction
Write your controller’s model number in the spaces provided below and circle the corresponding
items in each table. This information will also be useful when you wire your controller.
Instructions
Select the desired Key Number. The arrow to the right marks the selections available.
Make one selection each from Tables I through III using the column below the proper arrow.
A dot ( ) denotes unrestricted availability. A letter denotes restricted availability.
Key Numbers
DC10_ _ _ _ - _ _ _ - _ _ _ - _
KEY NUMBER
Description Selection
Size 48 x 48 mm (DIN) 1/16) DC1010_ _
48 x 96 mm (DIN 1/8) DC1020_ _
72 x 72 mm DC1030_ _
96 x 96 (DIN 1/4) DC1040_ _
Power 90-240 Vac Power DC10_0_ _
15-50 Vdc Power DC10_1_ _ bbbb
90-240 Vac Power / IP 65 DC10_2_ _
15-50 Vac Power / IP65 DC10_3_ _ bbbb
90-240 Vac Power / UL Agency Approval DC10_4_ _
15-50 Vdc Power / UL Agency Approval DC10_5_ _ bbbb
Program None DC10_ _C_
Program (2 patterns, 8 segments per 1 pattern) DC10_ _P_
Input RTD DC10_ _ _R
TC DC10_ _ _T
Linear DC10_ _ _L
TABLE I
Control Output 1 None 0 _ _
Relay, Contact, SPDT, 3A / 240 VAC 1 _ _
Volt, Voltage Pulse, 20VDC / 20 mA 2 _ _
mA Current, 4-20mA 3 _ _
Open loop circuit servo motor control 7 _ _ cdc
0-5 V A _ _
0-10 V B _ _
1-5 V C _ _
2-10 V D _ _
Control Output 2 None _ 0 _
(Heat/Cool) Relay, Contact, SPDT, 3A / 240VAC _ 1 _
Volt, Voltage Pulse, 20VDC / 20mA _ 2 _
mA Current, 4-20mA _ 3 _
0-5V _ A _
0-10V _ B _
1-5V _ C _
2-10V _ D _
Alarm Event 1 Alarm Relay _ _ 1 ei
2 Alarm Relays _ _ 2 fgj
3 Alarm Relays _ _ 3 hk
Availability
III II
I

Installation
8/05 DC1010/1020/1030/1040 Product Manual 7
Availability
DC10_ _ _ _ 10 20 30 40
Table II
Transmitter None 0 _ _
4-20 mA 1 _ _
0-20 mA 2 _ _
0-5 V A _ _
0-10 V B _ _
1-5 V C _ _
2-10 V D _ _
Remote SP None _ 0 _
4-20 mA _ 1 _ lll
0-20 mA _ 2 _ lll
0-5 V _ A _ lll
0-10 V _ B _ lll
1-5 V _ C _ lll
2-10 V _ D _ lll
Communication None _ _ 0
RS-232 _ _ 1 mn
RS-485 _ _ 2 mn
TABLE III
Manual English E
Chinese C
French F
Korean K
RESTRICTIONS / NOTES
Restriction Available Only With Not Available With
Letter Table Selection Table Selection
bX _ _
c _ 0 1, _ 0 2
d DC10 _ _ _ _ - _ 0 1 - _ 0 _ - _
eDC10_ _ _ _ - _ X _ - 0 _ 2 - _
fDC10_ _ _ _ - _ X _ - X _ 0 - _
gDC10_ _ _ _ - _ X _ - X _ _ - _
X _ X
h DC10_ _ _ _ - _ 0 _ - 0 _ 0 - _
iDC10_ _ _ _ - _ X _ - _ X _ - _
j DC10_ _ _ _ - _ 0 _ - _ 0 _ - _
k DC10_ _ _ _ - _ 0 _ - _ _ 0 - _
lDC10_ _ _ P
mX _ _
n_ X _
* X : Option Selected
0 : Option Not Selected
I & II
I & II
I & II
II
Selection
I
I & II
II
I & II
I & II
II
II
I & II
I & II

Installation
8 DC1010/1020/1030/1040 Product Manual 8/05
2.4 Mounting
2.4.1 Physical Considerations
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 for
installation and servicing activities.
• Overall dimensions and panel cutout requirements for mounting the controller are
shown in Figure 2-1 through.Figure 2-4
2.4.2 Overall Dimensions
Figure 2-1 Model DC1010 Dimensions
Figure 2-2 Model DC1020 Dimensions

Installation
8/05 DC1010/1020/1030/1040 Product Manual 9
Figure 2-3 Model DC1030 Dimensions
Figure 2-4 Model DC1040 Dimensions

Installation
10 DC1010/1020/1030/1040 Product Manual 8/05
2.4.3 Mounting Procedure
Before mounting the controller, refer to the nameplate on the outside of the case and
make a note of the model number. It will help later when selecting the proper wiring
configuration.
Side View
c
de1. 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.
Figure 2-5 Mounting Procedure

Installation
8/05 DC1010/1020/1030/1040 Product Manual 11
2.5 Wiring
2.5.1 Electrical Considerations
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, the 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 the OPERATOR access to the rear
terminals.
Mains Power Supply
This controller is suitable for connection to 100-240 Vac, 50/60 Hz or 15-50 Vdc, power
supply mains. It is the user’s responsibility to provide a switch and non-time delay (North
America), quick-acting, high breaking capacity, Type F(Europe), 1/2A, 250V fuse(s) or
circuit breaker for 100-240Vac operation as part of the installation. 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.
Applying 100-240Vac to a controller rated for 15-50Vdc will severely damage
the controller and is a fire and smoke hazard

Installation
12 DC1010/1020/1030/1040 Product Manual 8/05
2.6 Wiring Diagrams
2.6.1 Identify Your Wiring Requirements
To determine the appropriate diagrams for wiring your controller, refer to the model
number interpretation in this section. The model number of the controller is on the
outside of the case.
Shielded twisted pair cable are required for all Analog I/O, Process Variable, RTD,
Thermocouple, dc millivolt, low level signal, mA, Digital Output, and computer interface
circuits.
2.6.2 Making Terminal Connections
(1) Connection of power supply input terminal
• Type: Round
• Cable square: 1.25 mm(0.049 in)
• Diameter: 3.0 ~ 3.7 mm(0.118~ 0.145 in)
1.25
5
R1.5
Terminal with tube(R, 1.25 * M3)
• Tighten the terminal screws using a torque between 0.8 N_ m or less.