Peaktronics DHC-100 User manual

01-22-04 PRELIMINARY INFORMATION U.S. Patent 4,803,481 applies to this product; other patents pending
PEAKTRONICS
The Peaktronics DHC-100 is a high performance
digital positioner intended to control AC actuators, provid-
ing 450 points of resolution, and can be used with actuators
ranging from 2 sec to 90 sec and rated for 25% duty or
more. The DHC-100 has many automatic advanced fea-
tures that will enhance any actuator while making it easy to
install and set up.
The simple three button control is used to configure
all parameters the unit needs for a wide variety of applica-
tions, and allows the open and closed positions to be easily
set for direct or reversing acting without any rewiring. The
unit can be configured for various command types (4-
20mA, 1-5V, 0-5V, 0-10V, or a digital command), and its
default operation upon loss of command.
Various option modules are easily plugged in to
provide other features such as a position feedback signal
(current or voltage), auxiliary switches, fault relay contact,
or digital communications. A wide range of data is acces-
sible through a digital communications module, providing
additional control or information.
The unit is of single solid construction and is easily
mounted with two screws. The DHC-100 is interchange-
able with the AMC and LRC standard size controllers, and
can be used to upgrade performance for those applications.
DHC-100
Digital High-Resolution Controller
DHC-100 117VAC
DHC-100A 234VAC
DHC-100B 24VAC
FEATURES
•Positions to ±0.1°with quarter-turn actuators ranging from 2 sec to 90 sec (with or with-
out a brake).
•Adaptive Control feature continuously adjusts for load and actuator conditions and
eliminates calibration procedures and auto-cal operations.
•Three button control provides easy setup and eliminates the need for instrumentation.
•Polarity Detection feature allows direct or reverse acting operation without re-wiring.
•Electronic Brake feature can eliminate need for a mechanical brake in many applica-
tions, and extends mechanical brake life when used.
•Stall Detection feature protects actuator motor from a stall condition.
•Automatic Duty Cycle Control feature prevents shutdown of a process due to a ther-
mal overload of the actuator motor, and allows actuators rated for 25% duty or more to
be safely used.
•Operating temperature range of 0 to 60°C

DHC-100 01-22-04 PRELIMINARY INFORMATION
2 U.S. Patent 4,803,481 applies to this product; other patents pending PEAKTRONICS
OUTLINE
DHC-100
DHC-100A
DHC-100B
117VAC
234VAC
24VAC
AUTO
MANUAL / FB POT CAL
CLOSE
OPEN
AUX CLOSE OUTPUT
AUX OPEN OUTPUT
COMMAND TYPE
LOSS OF COMMAND
DIGITAL
4-20mA
1-5VDC
0-5VDC
0-10VDC
LAST
MODE
Digital High Resolution
AUX POSITION OUTFAULT
(FLASHING) CAL (STEADY ON)
(BOTH OFF)
PEAKTRONICS
FRONT PANEL

01-22-04 PRELIMINARY INFORMATION DHC-100
PEAKTRONICS U.S. Patent 4,803,481 applies to this product; other patents pending 3
BLOCK DIAGRAM
FEEDBACK
POT
ACTUATOR
J1
POWER / SIGNAL
J2
NOTE: See input signal
configurations for more
information.
WIPER
5
+2.5V
6
GND4
8
7
6
5
4
+15V OUTPUT
+5V OUTPUT
(+) 1-5, 0-5, 0-10 V INPUT
(+) 4-20mA INPUT
SIGNAL GND
3
2
1
L2 NEUTRAL
EARTH GND
L1 LINE
optional
brake
coil
LIMIT SWITCH
LIMIT SWITCH
THERMAL SWITCH
MOTOR 2
OUTPUT
3
MOTOR
NEUTRAL
2
MOTOR 1
OUTPUT1
DHC-100
DESCRIPTION
The DHC-100 is rated for motors with up to 5A
running currents and comes in three versions to accom-
modate different voltage applications. The DHC-100 is
rated for 117 VAC ±10%; the DHC-100A is rated for 234
VAC ±10%, and the DHC-100B is rated for 24 VAC
±10%. The unit is easily mounted with 2 screws and is
equipped with removable screw terminals that provide for
easy field wiring. The unit's size, mounting, and screw
terminals are compatible with the AMC-100, AMC-101 and
LRC-101 series controllers - the DHC-100 can be used as a
direct replacement for those units in nearly any application.
The simple three button control (MODE, ▲, and
▼) allows the user to perform a complete set-up from the
unit itself without the need for any instrumentation. The
adaptive control feature of the DHC-100 eliminates the
need for any calibration steps. In the simplest application,
only the closed and open positions need to be set and the
unit automatically and continuously sets all other parame-
ters when placed in the AUTO mode.
CAUTION ! These units are intended to be
mounted in an appropriate enclosure to avoid
electrical shocks. High voltages are present
on the outside of the unit when power is ap-
plied. AC power should be disconnected
prior to any wiring of these units. A heater
and thermostat should be used where conden-
sation may occur.

DHC-100 01-22-04 PRELIMINARY INFORMATION
4 U.S. Patent 4,803,481 applies to this product; other patents pending PEAKTRONICS
POWER / SIGNAL (J2)
Power is connected to pins 1, 2, and 3 as shown in
the block diagram. The fuse installed on the unit is rated
for maximum output current that can be safely delivered
by the AC outputs. Replacement fuses must not exceed
the maximum rating to prevent damage to the unit.
Smaller fuse sizes can be used with smaller motors - con-
sult the actuator manufacturer for appropriate fuse size
and type.
An appropriate command signal, either 0-5V, 0-
10V, 1-5V, or 4-20mA, should be connected to pin 5 or 6
(as shown in the Block Diagram) while using pin 4 as the
return signal ground. The DHC-100 must be configured
for the type of command signal that is to be used (see
COMMAND TYPE).
Pin 7 of J2 provides an auxiliary +5V output
which can be used to connect a command potentiometer.
By connecting one end of a potentiometer to pin 7, the
other end to pin 4, and the wiper to pin 6, a local control
knob can be implemented. Pin 8 provides an auxiliary
+15VDC output which can be used to power an input or
output 4-20mA transmitter.
ACTUATOR (J1)
The actuator motor and feedback potentiometer
are connected to J1 as shown in the Block Diagram. The
Motor Neutral wire must be connected to pin 2 while one
motor winding is connected to pin 1 and the other winding
to pin 3. The feedback potentiometer wiper must be con-
nected to pin 5 while one end is connected to pin 4 and the
other end to pin 6. The Polarity Detection feature of the
DHC-100 automatically determines which motor winding
to control based on where the open and closed positions
are set; this feature also eliminates the need to rewire the
unit for direct or reverse acting applications.
When the ▲and ▼buttons are used to control the
actuator, the ▲button will turn on the motor winding con-
nected to pin 1, while the ▼button will turn on the motor
winding connected to pin 3. See MANUAL/FB POT
CAL for more details.
MODE
The MODE button is used to select the desired
function of operation. When the MODE button is pressed,
the unit will switch to the next function and the appropri-
ate LED indicator will turn on to let the user know which
function is selected. Except for the MANUAL/FB POT
CAL mode, the associated mode indicator will be steady
on; for some of the modes other indicators will flash to
indicate specific settings associated with the mode. Each
of the modes are described in more detail in the following
sections.
If a 0-5V or 0-10V command signal is used, the
LOSS OF COMMAND function cannot be used. The
MODE button will skip over the LOSS OF COMMAND
mode when the unit is configured for a 0-5V or 0-10V
command signal (see COMMAND TYPE).
ADJUST UP (▲) and ADJUST DOWN (▼
▼▼
▼)
The adjust up (▲) and adjust down (▼) buttons
are used to adjust the setting of any given function. When
a function is selected by the MODE button, the adjust but-
tons will affect that function only. Note, that the AUTO
mode does not have any adjustable settings, and therefore,
the adjust up (▲) and adjust down (▼) buttons have no
effect.
AUTO
The AUTO function is the normal mode of opera-
tion for the DHC-100; all the other functions are used to
set up the unit. While in AUTO, the unit can be controlled
by various external signals, some of which can be selected
by the COMMAND INPUT function. When the unit is
not in the AUTO mode, all external controls described
below will be disabled.
Once the open and closed positions have been set,
the AUTO mode will control the position of the actuator
according to the command input signal. For an input sig-
nal of 0V (for 0-5V or 0-10V input), 1V (for 1-5V input),
4.0 mA (for 4-20mA input), or 0% (for a digital input), the
DHC-100 will position the actuator to the closed position
as set by the user. Conversely, an input of 10V, 5V,
20mA, or 100% will position the actuator to the defined
open position.
When the DHC-100 is configured to use a 0-5V,
0-10V, 1-5V, or 4-20mA command, the command signal
should be connected to the appropriate pin on J2 - note
that the unused input pin must be left unconnected. When
the DHC-100 is configured for a Digital command type,
an appropriate communications option module must be
installed. A communications module may be installed
when using one of the analog command types and can be
used to override the analog command. The AUTO indica-
tor will flash whenever the unit is being controlled by the
communications module.

01-22-04 PRELIMINARY INFORMATION DHC-100
PEAKTRONICS U.S. Patent 4,803,481 applies to this product; other patents pending 5
MANUAL/FB POT CAL
The MANUAL/FB POT CAL function allows
manual operation of the actuator by using the adjust but-
tons (▲and ▼) without affecting any other settings within
the DHC-100. When the ▲button is pressed, the motor
winding connected to J1-1 is turned on while the ▼button
turns on the J1-3 winding. Whether the actuator moves
toward the open or closed position depends on which mo-
tor winding is connected to J1-1 and J1-3.
The POT CAL feature provides an indication of
the feedback potentiometer's setting. When the MANU-
AL/POT CAL function is selected, the Manual/Pot Cal
indicator will turn on - it may flash or be on steady, de-
pending on the actuator position. The indicator will be on
steady whenever the DHC-100 detects that the feedback
potentiometer is at midrange of its rotation. As the actua-
tor moves, causing the feedback potentiometer to move
away from midrange, the indicator will begin to flash, and
the indicator will flash at a decreasingly slower rate as the
actuator moves further away from midrange.
By using the adjust buttons to position the actua-
tor to midstroke (half way point between the desired open
and closed positions), the feedback potentiometer can then
be adjusted until a steady light occurs. This insures that
the feedback potentiometer has maximum range to reach
the open and closed positions.
CLOSE
The CLOSE function is used to set the desired
closed position; however, prior to doing this, the feedback
potentiometer should be checked for optimum position
(see MANUAL/POT CAL). In the CLOSE function, the
adjust buttons are used to set the actuator to any desired
position, and upon pressing the MODE button (to select
the next function, OPEN), the DHC-100 will retain the
setting as the defined closed position.
Upon selecting the CLOSE function, the DHC-
100 will begin moving the actuator to the previously set
closed position; it is not necessary to make an adjustment
if the unit has been previously set to the desired position.
A command signal input of 0V, 1V, 4mA, or 0% auto-
matically corresponds to the defined closed position.
OPEN
The OPEN function works the same way as the
CLOSE function with the exception that the adjust buttons
are used to set the desired open position. As with the
CLOSE function, upon selecting the OPEN function, the
actuator will move to the previously set open position.
Once the desired position is set, the DHC-100 will auto-
matically correspond a command signal input of 10V, 5V,
20mA, or 100% to the open position.
AUX CLOSE OUTPUT
The AUX CLOSE OUTPUT function is used to
set an optional output setting that is associated with the
closed position - an appropriate relay option module is
required to use this output. The adjust buttons are used to
set the actuator to a desired position. Whenever the actua-
tor position falls between the defined closed position and
the Aux Close position, the Aux Close Output indicator
will flash. Additionally, the DHC-100 will turn on a relay
output on the optional relay module - the output can be
used to drive an alarm or merely act as an auxiliary limit
switch.
Upon selecting the AUX CLOSE OUTPUT func-
tion, the DHC-100 will begin moving the actuator to the
previously set position. It is not necessary to make an ad-
justment if the unit has been previously set to the desired
position.
AUX OPEN OUTPUT
The AUX OPEN OUTPUT function is used to set
an optional output setting that is associated with the open
position - an appropriate relay option module is required
to use this output. The adjust buttons are used to set the
actuator to a desired position. Whenever the actuator po-
sition falls between the defined open position and the Aux
Open position, the Aux Open Output indicator will flash.
Additionally, the DHC-100 will turn on a relay output on
the optional relay module - the output can be used to drive
an alarm or merely act as an auxiliary limit switch.
Upon selecting the AUX OPEN OUTPUT func-
tion, the DHC-100 will begin moving the actuator to the
previously set position. It is not necessary to make an ad-
justment if the unit has been previously set to the desired
position.
COMMAND TYPE
The COMMAND TYPE function is used to
configure the command signal input for either 4-20mA, 1-
5V, 0-5V, 0-10V, or digital so as to match the type of
command signal being used. Upon selecting the
COMMAND TYPE function, the Command Input
indicator will turn on steady, while the indicator for the
selected type will flash Use the adjust buttons (▲or ▼)
to select the desired input type. The selection will be
saved when the MODE button is pressed, which will also

DHC-100 01-22-04 PRELIMINARY INFORMATION
6 U.S. Patent 4,803,481 applies to this product; other patents pending PEAKTRONICS
MODE button is pressed, which will also advance the unit
to the LOSS OF COMMAND function.
LOSS OF COMMAND
When using 1-5V, 4-20mA, or a Digital input type
for the command signal, the DHC-100 will detect when
the command signal is lost or out of range. A loss of com-
mand condition is detected whenever the input is discon-
nected, the input becomes less than 0.75V or 3mA, or the
input becomes greater than 5.5V or 22mA. If the DHC-
100 detects a loss of the command signal, the Fault indica-
tor will flash and the actuator will be moved to one of
three preset positions: the open position, the closed posi-
tion, or the position last attained prior to losing the com-
mand signal. The LOSS OF COMMAND function is used
to set the desired default position.
When the LOSS OF COMMAND function is se-
lected, the adjust buttons are used to set the default posi-
tion. The DHC-100 indicates the selected default setting
by flashing the Open function indicator for the open de-
fault position, or it will flash the Close function indicator
for the closed default position. When neither indicator is
on, then the "last position" default is selected.
When a 0-5V or 0-10V command signal is used, a
loss of command signal cannot be detected. Therefore, if
the unit is configured for a 0-5V or 0-10V command sig-
nal (see COMMAND INPUT), the MODE button will not
select the LOSS OF COMMAND function.
AUX POSITION OUT CAL
Note that the AUX POSITION OUT CAL indica-
tor also serves as a Fault indicator. When the indicator is
on steady, the AUX POSITION OUT CAL function is
selected. When the indicator flashes, a Fault condition has
been detected (see FAULT INDICATOR for details). The
AUX POSITION OUT CAL function is used to calibrate
an optional feedback transmitter output. An appropriate
transmitter option module is required to use this feature.
When the AUX POSITION OUT CAL function is
first selected (by pressing the MODE button while in the
LOSS OF COMMAND function), the CLOSE indicator
will flash, and the voltage or current associated with the
closed position will appear at the option module output. If
desired, the output can be adjusted (using the adjust but-
tons) to any value from 0 to 10V (for a voltage output) or
0 to 20mA (for a current output). The new setting is then
associated with the closed position.
Pressing the MODE button again will leave the
unit in the AUX POSITION OUT CAL function except
that the OPEN indicator will flash, and the output voltage
or current associated with the open position will appear at
the option module output. Like the closed setting, the out-
put can be adjusted to any voltage (from 0 to 10V) or
current (from 0 to 20mA), and the new setting is then as-
sociated with the open position.
FAULT INDICATOR
The DHC-100 detects various fault conditions that
prohibit the unit from controlling the actuator. When any
of these conditions are detected, the Fault indicator will
flash, and the motor outputs are turned off until all fault
conditions have been corrected. If an appropriate relay
option module is installed, the Fault relay output on the
option module will also turn on. A communications op-
tion module can read the specific condition(s) causing the
fault. Note that a fault condition DOES NOT disable the
motor outputs when manually controlling the actuator
with the the adjust buttons; while useful for troubleshoot-
ing, care should be excercised when operating the motor
under a fault condition. The various fault conditions are
described below:
LOSS OF COMMAND - If the command signal is dis-
connected or out of range, the fault indicator will remain
on until the signal is reconnected or back in range.
FEEDBACK POT FAULT - A fault condition is detected
whenever the feedback signal is out of range (that is, less
than 5% of the potentiometer value or more than 95% of
the potentiometer value), or when any of the potentiome-
ter connections are broken. Normal operation resumes
when the potentiometer is reconnected or back in range.
MOTOR 1 STALL - A fault condition is detected when no
actuator motion is detected while the Motor 1 output is
turn on. The fault condition will only disable the Motor 1
output, and the fault is cleared when the DHC-100 detects
a motion greater than 1.5°in either direction. The fault
can be cleared if 1) the command signal commands a Mo-
tor 2 operation, 2) manaul operation with the adjust but-
tons results in a motion greater than 1.5°, or 3) a mechani-
cal manual override forces the 1.5°motion, provided the
mechanical motion is monitored by the feedback pot.
MOTOR 2 STALL - A fault is detected when no actuator
motion is detected while the Motor 2 output is turn on.
The fault can be cleared in the same manner as a Motor 1
Stall (see above).
DOUBLE STALL - If the DHC-100 detects no actuator
motion in either direction, both motor outputs will be dis-
abled. The command signal cannot clear this condition;

01-22-04 PRELIMINARY INFORMATION DHC-100
PEAKTRONICS U.S. Patent 4,803,481 applies to this product; other patents pending 7
only manual operation or a mechanical override can clear
the fault. Alternatively, the DHC-100 can be powered off
and then on to temporarily clear the fault; however, this
practice should be avoided without permanently correcting
the cause of such a fault.
STALL DETECTION FEATURE
The Stall Detection feature of the DHC-100 (see
FAULT INDICATOR) essentially performs a similar
function as commonly used torque switches; however, the
differences should be considered before eliminating the
torque switches. The DHC-100 feature does not measure
torque, but rather motion; if the load is sensitive to exces-
sive torque, the torque switches may be desirable. Since
common torque switches are mechanical devices, they can
provide a fail safe feature in the event of electrical failures
(such as shorted wires or damage to the DHC-100).
The Stall Detection feature is useful for detecting
when any of the motor wires become disconnected. How-
ever, limit switches employed in actuators essentially dis-
connect one of the motor windings. The DHC-100 will
detect this as a motor stall. To avoid this condition, the
limit switches must be set outside of the operating range
set by the CLOSE and OPEN functions.
ELECTRONIC BRAKE FEATURE
The Electronic Brake feature of the DHC-100
provides highly reliable and accurate braking of the motor,
and it is a key element in achieving high resolution. A
mechanical brake can still be implemented without inter-
fering with the DHC-100 operation. Mechanical brakes
can be useful for providing a holding brake in the event
power to the actuator is lost.
Since the Electronic Brake feature provides the
primary braking of the motor, the life of a mechanical
brake is dramatically extended. Additonally, the Adap-
tive Control feature of the DHC-100 automatically com-
pensates for changes in a mechanical brake's performance
due to temperature or age.
Note that the actuator's limit switches should be
set outside of the operating range set by the CLOSE and
OPEN functions. The Electronic Brake feature degrades
in performance if a limit switch is engaged. Limit
switches exhibit wide variations, and the DHC-100 can
position the actuator more precisely at closed and open
than the limit switches. A limit switch serves better as a
fail safe device to protect against electrical failures in the
actuator.
DUTY CYCLE CONTROL FEATURE
The Duty Cycle Control feature of the DHC-100
allows actuators rated at 25% duty or more to be safely
used in automated valve applications. The DHC-100 acu-
rately monitors the relative heating of the motor and
automatically duty cycles the unit at a safe level when a
process becomes unstable, or if a control loop is not prop-
erly set. While the thermal switch in the motor protects
the motor from overheating, thermal switches can shut-
down the actuator for ten minutes or more. Further, typi-
cal thermal switches do not activate until temperatures
inside the actuator become too high for other components
in the actuator.
The Duty Cycle Control feature allows continu-
ous operation of the motor until it detects an excess heat
build up in the motor (usually well below the limit of the
thermal switch). At that time, duty cycle operation is
automatically enabled and continues until the motor cools
enough to resume continuous operation. The duty cycle
period is approximately 2 seconds with an on time that
automatically various depending on the heating of the mo-
tor. While this operation slows down the actuator's opera-
tion, it does not impact the resolution performance of the
DHC-100, and it prevents disruption of a process due to a
thermal switch shutdown.

DHC-100 01-22-04 PRELIMINARY INFORMATION
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