Honeywell DC1000 Series Product Manual
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Honeywell DC1000 Series Product Manual

Honeywell DC1000 Series Product Manual

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DC1000 Series
Digital Controller
Product Manual
51-52-25-113
December 2018
Process Measurement and Control

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Summary of Contents for Honeywell DC1000 Series

  • Page 1 DC1000 Series Digital Controller Product Manual 51-52-25-113 December 2018 Process Measurement and Control...
  • Page 2 Revision 3 - December 2018 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.

  • Page 3: About This Document

     DC1000 series User’s manual : 51-52-25-113  DC1000 series Communication Manual : 30-10-41-18-EN 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...

  • Page 4: Symbol Definitions

    Introduction 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.

  • Page 5: Table Of Contents

    Introduction Contents INTRODUCTION ....................1 Overview ............................1 INSTALLATION ..................... 3 Overview ............................3 Condensed Specifications ....................... 4 Model Number Interpretation ......................7 Mounting ............................9 2.4.1 Physical Considerations ....................... 9 2.4.2 Overall Dimensions......................9 2.4.3 Mounting Procedure ......................11 Wiring ............................
  • Page 6 Introduction 4.3.4 Program Alarm ........................38 4.3.5 System Alarm ........................38 4.3.6 HBA (Heater Break Alarm) ....................39 Function Lock ..........................41 Parameter Display SET (Hide or Display) ................... 42 4.5.1 Overview ..........................42 Functions of ‘SET’ parameters ..................42 4.5.2 Input Codes ...........................
  • Page 7 Introduction Tables Table 2-1 Condensed Specifications _____________________________________________________ 4 Table 3-1 Displays, LEDs, and Keys ____________________________________________________ 20 Table 3-2 Mode Change Instructions ____________________________________________________ 21 Table 3-3 Operation Mode Prompts _____________________________________________________ 23 Table 4-1 Configuration 1 Mode ________________________________________________________ 28 Table 4-2 Configuration 2 Mode ________________________________________________________ 30 Table 4-3 Alarm Function Selections ____________________________________________________ 34 Table 4-4 Functions of Sets ____________________________________________________________ 42 Table 4-5 Thermocouple Inputs ________________________________________________________ 44...
  • Page 8 Introduction Figures Figure 2-1 Model DC1010 Dimensions ___________________________________________________ 9 Figure 2-2 Model DC1020 Dimensions ___________________________________________________ 9 Figure 2-3 Model DC1030 Dimensions __________________________________________________ 10 Figure 2-4 Model DC1040 Dimensions __________________________________________________ 10 Figure 2-5 DC1050 / DC1060 Dimensions _______________________________________________ 11 Figure 2-6 Mounting Procedure ________________________________________________________ 11 Figure 2-7 Model DC1010 Wiring ______________________________________________________ 14 Figure 2-8 Model DC1020 Wiring ______________________________________________________ 15 Figure 2-9 Model DC1030 Wiring ______________________________________________________ 16...

  • Page 9: Introduction

    Introduction 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, and 2 types of DIN rail mounting. With a typical accuracy of ...
  • Page 10 Introduction Various Control Algorithms The DC1000 series of controllers provides several different algorithms: • PID or ON/OFF Control • Heat/Cool Algorithms with 2 different PID sets • Motor Position Control without slidewire feedback • Single Phase Control with/without zero crossover control •...

  • Page 11: Installation

    Installation 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.

  • Page 12: Condensed Specifications

    Installation 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 TC (K, J, R, S, B, E, N, T, W, PL II, L) Type of Input RTD (Pt100)
  • Page 13 1500V AC 50/60Hz for 1min across output terminal and case(ground) Note1. For others, refer to ‘INPUT ACTUATIONS’. Note2. For ‘old’ in protocol, it’s compatible with old model and please refer to the Communication Manual for details. Note3. Please ask Honeywell. 7/05 DC1010/1020/1030/1040 Product Manual...
  • Page 14 -326~752F -50~2320C -58~4208F -50~1200C -58~2192F PLII -50~800C -58~1472F -199.9~850.0C -199.9~999.9F -199~850C -326~1562F Pt100 0~850C 32~1562F 0-20mA, 0-1V, 0-5V, 0-10V 0 - 50mV -1999~9999 4-20mA, 1-5V, 2-10V 10 - 50mV -1999~9999 * Regarding JPT100, please contact Honeywell. DC1010/1020/1030/1040 Product Manual 7/05...

  • Page 15: Model Number Interpretation

    Installation 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. 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.
  • Page 16 _ _ A RS-485 (Modbus RTU) _ _ B TABLE III Manual English Chinese Korean French TABLE IV Extended warraty None Extended Warranty - 1 year Extended Warranty - 2 years Regarding model availability, please contact Honeywell. DC1010/1020/1030/1040 Product Manual 7/05...

  • Page 17: Mounting

    Installation 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. •...

  • Page 18: Figure 2-3 Model Dc1030 Dimensions

    Installation Figure 2-3 Model DC1030 Dimensions Figure 2-4 Model DC1040 Dimensions DC1010/1020/1030/1040 Product Manual 7/05...

  • Page 19: Mounting Procedure

    Installation (2) DIN-Rail Mounting Figure 2-5 DC1050 / DC1060 Dimensions 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.

  • Page 20: Wiring

    Installation 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.

  • Page 21: Wiring Diagrams

    Installation 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.

  • Page 22: Wiring Diagrams

    Installation 2.6.3 Wiring Diagrams Noise POWER Filter AC 100 ~ 240V (50 / 60Hz) DC 24V (option) OUTPUT OUT2 OUT1=5 inear Volt Linear Relay A,B,C,D OUT1 Linear Relay Volt ALARM A,B,C,D OUT1=7 COMM. AUX. OUT CLOSE RS232 RS485 OPEN CT INPUT Figure 2-7 Model DC1010 Wiring Note) the wiring depends on model selection.

  • Page 23: Figure 2-8 Model Dc1020 Wiring

    Installation Noise POWER Filter AC 100 ~ 240V DC 24V (option) OUTPUT OUT2 inear Relay Volt Linear A,B,C,D OUT1 Relay Volt Linear ALARM AUX. OUT A,B,C,D OUT1=7 CLOSE CT INPUT INPUT2 COMM. OPEN RS232 RS485 Figure 2-8 Model DC1020 Wiring Note) the wiring depends on model selection.

  • Page 24: Figure 2-9 Model Dc1030 Wiring

    Installation Noise AUX. OUT POWER Filter AC 100 ~ 240V DC 24V (option) CT INPUT OUTPUT inear OUT2 OUT1=5 Relay Volt Linear A,B,C,D OUT1 Relay Volt Linear ALARM A,B,C,D OUT1=8 OUT1=7 CLOSE COMM. INPUT2 OPEN RS232 RS485 Remote SP Figure 2-9 Model DC1030 Wiring Note) the wiring depends on model selection.

  • Page 25: Figure 2-10 Model Dc1040 Wiring

    Installation COMM. Noise POWER Filter COMM COMM AC 100 ~ 240V DC 15 ~ 50V AUX. OUT CT INPUT OUTPUT OUT2 OUT1=5 OUT1=8 Relay Volt Linear inear A,B,C,D OUT1 Relay Volt Linear ALARM OUT1=6 OUT1=9 A,B,C,D OUT1=7 COMM. INPUT2 CLOSE Remote SP RS232 RS485...

  • Page 26: Figure 2-11 Model Dc1050 Wiring

    Installation Input COMM Power Alarm 1 OUT2 OUT1 Alarm 2 TC / mV Power Input mA / V Alarm 1 Alarm 2 mA / V Relay mA / V OUT2 Relay mA / V RS-485 T/R (B) T/R (A) COMM OUT1 Figure 2-11 Model DC1050 Wiring Lower side...

  • Page 27: Operation

    Operation 3 Operation 3.1 Overview This section gives you all the information necessary to help you monitor and operate your controller including an Operator Interface overview, an explanation of the Displays, keys, and LEDs, and Mode access, and Operation Modes. 3.2 Operator Interface Overview Fig 3-1 is a view of the operator interface.

  • Page 28: Displays, Leds, And Keys

    Operation 3.2.1 Displays, LEDs, and Keys Table 3-1 Displays, LEDs, and Keys Displays Upper Display 4 digits dedicated to display the PV. In configuration mode, this display indicates the name of a parameter. 4 digits dedicated to display the SP. In configuration mode, this display Lower Display indicates the value of a parameter or the status of the parameter selected Bar graph*...

  • Page 29: Mode Access

    Operation 3.3 Mode Access Operation Operation Configuration 1 Configuration 1 Program Program Configuration 2 Configuration 2 Set Up Set Up Figure 3-2 Mode Access Diagram 3.3.1 How to move from one mode to another Refer to Figure 3-2 and Table 3-2 for instructions. Table 3-2 Mode Change Instructions Step Action...

  • Page 30: Operation Mode

    Operation 3.4 Operation Mode 3.4.1 Key Functions 3.4.1.1 Changing Parameter Value Press the SHIFT KEY to change the parameters. If the SHIFT KEY is pressed, the first digit begins blinking. Press the UP KEY or DOWN KEY to increase or decrease the value of this digit, and then press the SHIFT KEY again to go to the next digit.

  • Page 31: Operation Mode Prompts

    Operation 3.4.2 Operation Mode Prompts Table 3-3 Operation Mode Prompts Displays Parameter Description PV Display To change the setpoint value, see changing parameter values (paragraph 3.4.1.1). SP Display Press the “SET” key to save the value. Output Limit * For limiting the maximum value of Control Output Percentage (%) Range: 0 to 100%...

  • Page 32: Control Types

    Operation 3.4.3 Control Types 3.4.3.1 Manual Operation In the manual mode, the operator directly controls the controller output level. Press the “A/M”key until you see “OUTL” in the upper display and a fixed control output value in the lower display. It’s different with ‘OUTL’ for limitation of output. To change the value of the Output (%), refer to Paragraph 3.4.1.1 Changing Parameter Value.
  • Page 33 Operation Example: (1) General Mode(DC10XXCX-) SP=200ºC, ATVL=5, Auto tuning point is at 195ºC During auto tuning the PV value will oscillate around 195ºC. Hence the PV will not go over 200ºC. The control will be at SP=200 after Auto tuning. SP - 5 (2) Program model(DC10XXPX-) In programmable model, Auto tuning point is as followings.

  • Page 34: Changing Set Point

    Operation Overshoot/Undershoot Suppression: This logic observes the speed and direction of the PV signal as it approaches the setpoint and temporarily modifies the internal controller response action as necessary to avoid an overshoot/undershoot. There is no change to the PID algorithm, and this logic does not alter the PID tuning parameters. See “Configuration 2”...

  • Page 35: Alarm Functions And Associated Prompts

    • See ‘Operation” Mode (Table 3-3). Enter the deviation value or absolute value “HbAC / ” for prompts depending on the Alarm Code selected above. Setting Range : 0.0~80.0 Aac(additional rage, please ask Honeywell) (for details, refer to paragraph 4.3.6) 7/05 DC1010/1020/1030/1040 Product Manual...

  • Page 36: Configuration

    Configuration 4 Configuration 4.1 Introduction Configuration is a dedicated operation where you use straightforward keystroke sequences to select and establish (configure) pertinent control data best suited for your application. To assist you in the configuration process, there are prompts that appear in the upper and lower displays.

  • Page 37: Configuration 2

    Configuration Displays Parameter Description Default Value Shown Main Control (OUT 1) For On/Off Control (P1=0) (Range -100.0-100.0) ON: PV<= (SP – HYS1) Actuation of Hysteresis OFF: PV>= (SP + HYS1) Sub Control (OUT 2) * Same as P1 Configuration P Value (Proportional Band) Sub Control (OUT 2) * Same as I1 Configuration I Value (Integral Value)

  • Page 38: Table 4-2 Configuration 2 Mode

    Configuration 4.2.1 Configuration 2 To access ‘Configuration 2’ mode, press the ‘SHIFT’ key for 3 seconds WHILE pressing ‘SET’ key FIRST when in ‘Operation’ or ‘Configuration 1’ mode. Table 4-2 Configuration 2 Mode Displays Parameter Description Default Value shown except for examples Input 1 (INP1) Defines the Input type and Input range...
  • Page 39 Configuration Displays Parameter Description Default Value shown except for examples Time set for Alarm 2 * Range: 0-99 min, 59 seconds 0= flickering alarm, 99:59= continual alarm Other = Time delay for alarm Alarm Code for Alarm 3 * Refer to Table 4-3 for Alarm Codes. Time set for Alarm 3 * Range: 0-99 min, 59 seconds 0= flickering alarm, 99:59= continual alarm...
  • Page 40 Configuration Displays Parameter Description Default Value shown except for examples Motor Time Three Position Step Control - This is the time it takes the motor to travel from 0 to 100% (fully closed to fully open). This time can usually be found on the nameplate of the motor.
  • Page 41 Configuration Displays Parameter Description Default Value shown except for examples SP Compensation Range: -1000 to 1000 PV Compensation Range: -1000 to 1000 Used to Bias Process Variable Unit of PV and SP Selection: C, F, and A (linear) PV Filter(Digital Filter) Adjusts PV response time (Range: 0.01 to 5.00) Default=0.10 *PV will response faster if PVFT is smaller.

  • Page 42: Alarms Configuration

    Configuration 4.3 ALARMS CONFIGURATION 4.3.1 Alarm Function Selections These Alarm Function Selections are entered in “Configuration 2”. See Section 4.2.1. Table 4-3 Alarm Function Selections Code Description Hold-ON Refer to None Deviation high alarm Figure 4-3 Deviation high alarm Figure 4-4 Deviation low alarm Figure 4-5 Deviation low alarm...

  • Page 43: Deviation Alarm Overview

    Configuration 4.3.2 Deviation Alarm Overview The Alarm SP (Set Point) is to be changed as the SP moves. In this case, the Alarm SP preserves a certain deviation value with the SP. When an alarm is set, a certain deviation value with the preset SP should be defined.

  • Page 44: Figure 4-5 Lower Limit Deviation Alarm (Alarm Code 02)

    Configuration Figure 4-5 Lower Limit Deviation Alarm (Alarm Code 02, Alarm release in the first alarming situation) Figure 4-6 Lower Limit Deviation Alarm (Alarm Code 12, No alarm release in the first alarming situation) Figure 4-7 Dev. Band Breakaway Alarm [Hold On = Yes] (Alarm Code 03, Alarm release in the first alarming situation) Figure 4-8 Dev.

  • Page 45: Absolute Value Alarm Overview

    Configuration 4.3.3 Absolute Value Alarm Overview The Alarm SP (Set Point) is to be fixed even though the SP or PV moves. When an alarm is set, the absolute value of the Alarm SP should be defined. Absolute value LOW Absolute value High HYSA HYSA...

  • Page 46: Program Alarm

    Configuration 4.3.4 Program Alarm 4.3.4.1 Segment Run Alarm (Alarm Code 07) Once the selected segment is started to run, the alarm becomes activated - ALD1 – ALD3 Set the Alarm Code 07 - AL1 – AL3 Configure Segment No. for alarm - ALT1 –...

  • Page 47: Hba (Heater Break Alarm)

    Configuration 4.3.6 HBA (Heater Break Alarm) - HBA(Heater Break Alarm) detects ac current by CT and it is actuated though Alarm1. When OUT1 is ON and CT input value is less than HBA set point for 20 seconds, Alarm 1 is activated. - The heater break alarm function can use in output type of Relay(OUT1=1) and Voltage pulse output(OUT1=2).

  • Page 48: Figure 4-20 Hba Wiring Diagram

    Configuration [Wiring Diagram] Figure 4-20 HBA Wiring diagram DC1010/1020/1030/1040 Product Manual 7/05...

  • Page 49: Function Lock

    Configuration 4.4 Function Lock According to the status of the parameter “LCK” in ‘Configuration 1’ mode, ‘access to modes’ and ‘change of values’ can be prohibited. MODE ACCESS-Access to ‘Operation’, Configuration1 & 2’ modes allowed (* Default) MODE ACCESS-Access to ‘Operation’ & ‘Configuration 1’ mode allowed VALUE CHANGE-Every value change in each mode allowed MODE ACCESS-Access to ‘Operation’...

  • Page 50: Parameter Display Set (Hide Or Display)

    Configuration 4.5 Parameter Display SET (Hide or Display) 4.5.1 Overview You can choose to hide or display some parameters by selecting the set mode of each. See Figure 4-21 Display Status for an interpretation of the Status of the ‘SET’s. Refer to Table 4-4 for Functions of the ‘SET’s.
  • Page 51 Configuration Function Remarks Number 0 = Not repeat 1 = Program Repeat Programmer Model Only 0 = No power failure option See Section 5. 1 = With power failure option 0 = Program starts at 0 (Note 1) 1 = Program starts from PV DO NOT USE SET 8.4.

  • Page 52: Input Codes

    Table 4-6 RTD Inputs TYPE CODE RANGE -199.9~850.0C -199.9~999.9F -199~850C -326~1562F Pt100 0~850C 32~1562F * The default of Input Code is ‘ ’ for the model of RTD input type. (DC10X0XR-XXX-XXX-X) * Regarding JPT100, please contact Honeywell. DC1010/1020/1030/1040 Product Manual 7/05...

  • Page 53: Table 4-7 Linear Inputs

    Configuration Table 4-7 Linear Inputs CODE SIGNAL INPUT TYPE RANGE 0-20mA, 0-1V, 0-5V, 0-10V 0 - 50mV -1999~9999 4-20mA, 1-5V, 2-10V 10 - 50mV -1999~9999 *The default of Input Code is ‘AN4’ (4-20mA) for the model of linear input type. (DC10X0XL-XXX-XXX-X) CAUTION DO NOT change the input type without technical assistance because it requires...

  • Page 54: Programmer (Optional)

    Programmer (Optional) 5 Programmer (Optional) 5.1 Overview 5.1.1 Introduction The term “programming” is used here to identify the process for selecting and entering the individual ramp and soak segment data needed to generate the required setpoint versus time profile (also called a program). A segment is a ramp or soak function which together make up a setpoint program.

  • Page 55: Segment Runing Alarm

    Programmer (Optional) 5.4.2 Segment Runing Alarm ALD1 (Alarm Code for Alarm 1)= 07 (Segment Run Alarm) AL1 (Alarm Condition)= 2 (‘2’ means Segment No.) When seg#2 start, AL1 will act. ALT1 (Alarm Time) = 00.10 Alarm Operation Example: Once Segment 2 is completed, Alarm 1 will become actuated and will be on for 10 seconds 5.4.3 END Function...

  • Page 56: Other Functions

    Programmer (Optional) 5.4 Program Functions (continued) 5.4.6 Other Functions These other functions [Program Repeat, Power Failure Option, and Program Start from PV] are set through the SETs function (Refer to Table 4-4 Functions of Sets). Table 5-2 Associated Program Functions Function Remarks 0 = No Program Repeat...

  • Page 57: Program Configuration Prompts

    Programmer (Optional) Program Configuration Prompts 5.5.1 Overview The prompts to configure the programs will appear after the operation mode prompts. See Table 3-3. Also see Table 5-2 for Associated program functions. 5.5.2 Configuration Table 5-3 Program Configuration Prompts Displays Parameter Description Start from Operation Mode –...
  • Page 58 Programmer (Optional) Displays Parameter Description Output Limit for Segment 2 Range: 0 to 100% Setpoint for Segment 3 Range: LSPL (Lower Setpoint Limit) to USPL (Upper Setpoint Limit) See Table 4-2 for Limit settings Time Setting for Segment 3 Range: END, 0-99 hrs:59 minutes Ramp segment* = Changing Setpoint time Soak segment** = Fixed Setpoint time Output Limit for Segment 3...
  • Page 59 Programmer (Optional) Displays Parameter Description Output Limit for Segment 6 Range: 0 to 100% Setpoint for Segment 7 Range: LSPL (Lower Setpoint Limit) to USPL (Upper Setpoint Limit) See Table 4-2 for Limit settings Time Setting for Segment 7 Range: END, 0-99 hrs:59 minutes Ramp segment* = Changing Setpoint time Soak segment** = Fixed Setpoint time Output Limit for Segment 7...

  • Page 60: Program Example

    Programmer (Optional) 5.5.3 Program Example Profile Segment Setpoint Time Number Values Settings value SP 1 = 20 T 1 = 00:01 100.0 SP 2 = 50 T 2 = 09:00 100.0 SP 3 = 50 T 3 = 00:02 100.0 SP 4 = 90 T 4 = 00:02 100.0...

  • Page 61: Error Codes

    Error Codes 6 Error Codes Overview Introduction Instrument performance can be adversely affected by installation and application problems as well as by hardware problems. We recommend that you investigate the problems in the following order: Table 6-1 Error Codes ERROR CODE DESCRIPTION SOLUTION Open the circuit of ‘INPUT 1’...

  • Page 62: Index

    7 Index A, B, C, D Absolute Value Alarm Overview Installation Alarm 1 Integral Value 28, 29 Alarm 2 Key Functions Alarm 3 Alarm Code for Alarm 1 L, M Alarm Code for Alarm 2 Alarm Code for Alarm 3 Linear Inputs Alarm Function Selections Linking Function...
  • Page 63 Program Pattern Setpoint for Segment Program Repeat Setpoint Limit Program Repeats Soak Segment Program RUN Alarm SP Compensation Program Running Alarm SP Display Program Segment Display Specifications Program Start from PV System Alarm Program starts from PV System Error Alarm Program timer display Terminal Connections Programmer...

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