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Operating Instruction

Universal Controller


B_UC_12504_e_ohne_Klemmenplan.doc/pdf Oktober 04








Please read this instruction carefully before using this device!!



Operating Instruction Universal Controller






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Contents

1. Introduction.............................................................................................................................2
2. Functional Description ............................................................................................................2
Control.........................................................................................................................................2
Control-Characteristic .................................................................................................................2
Level-Monitoring ........................................................................................................................2
Release-Contact...........................................................................................................................3
Alarm Delay ................................................................................................................................3
Start-Up after Power Failure .......................................................................................................3
3. Description of Terms...............................................................................................................3
Output Signal / Controller Output ...............................................................................................3
Proportional Control....................................................................................................................3
Integral Part / Reset Time T
R
......................................................................................................3
Derivative Action Time T
V
.........................................................................................................4
Dosing Time Limit ....................................................................................................................4
Start-Up Delay.............................................................................................................................5
Flow-Control Time......................................................................................................................5
Minimum and Maximum Output ................................................................................................5
4. Operation.................................................................................................................................6
4.1. Operation-Mode and Main-Menu ........................................................................................6
4.2. Menu Controller Set-up........................................................................................................7
Set-point (+) ................................................................................................................................7
Set-point (-) .................................................................................................................................8
Alarm minimum..........................................................................................................................8
Alarm maximum.........................................................................................................................8
P-Range .......................................................................................................................................8
I-Reset-Time................................................................................................................................8
D-Action Time ............................................................................................................................8
Minimum Output.........................................................................................................................8
Maximum Output ........................................................................................................................8
4.3. Menu Controller Calibrate....................................................................................................9
4.4. Menu Controller Configuration..........................................................................................11
Maximum Dosing Time ............................................................................................................11
Start-Up Delay...........................................................................................................................12
Current Output...........................................................................................................................12
Controlled Variable...................................................................................................................12
Output........................................................................................................................................12
Alarm-Delay..............................................................................................................................13
Flow...........................................................................................................................................13
Minimum Relay.........................................................................................................................13
Maximum Relay........................................................................................................................13
Language ...................................................................................................................................13
A: Error-, Alarm- and Status-messages.....................................................................................14
B: Datasheet ..............................................................................................................................15
C: Configuration........................................................................................................................16
D: Start-Up of the Control-Loop...............................................................................................16
E: Controller Reset ....................................................................................................................17
F: Terminal Description ............................................................................................................18
G: Standards ..............................................................................................................................18

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1. Introduction
The 1-Channel-Controller / Universal-Controller is a measurement and control device for
many applications. All standard measurements like the treating of drinking water or
swimming-pool water, pH, ORP, Chlorine-/ Chlorine-dioxide-concentration, Ozone,
Hydrogenperoxide Peracetic acid and oxygen concentration can be done with this device.
All common dosing devices like solenoid valves, motor-valves, O3-generators, metering
pumps or 20 mA-controlled devices can be connected to the controller. The dosing device
and the measured value can be selected in the configuration menu.

The Universal-Controller has a PID characteristic
(which can be changed into single P-, PI-, or PD-characteristic)

2. Functional Description

Control
The Controller measures the selected value, compares the measured value to the preset
parameters and controls the dosing device to get the measured value between the set-points
and keep it there as accurate as possible.
The Universal-Controller is a two-in-one controller with different dosing goals.
One part of the controller can lower the measured value, the other one raises it. The PID-
characteristics, are the same for both parts of the controller only the set-points have to be
selected for each single part. The concept with the two set-points gives you the chance to
define a tolerance range. You can make only one part of the controller work, if it is
necessary to only dose into one direction, like it is with chlorine.

Control-Characteristic
The Controller can be configured as a P, PD, PI or PID-Controller, by setting the
parameters: P-range, I-reset time and D-action time.

P-Controller: the dosing depends on the momentary deviation from the set-point.
PI-Controller: the dosing depends on the momentary deviation from the set-point
and the total deviation since the start-up of the controller.
PD-Controller: the dosing depends on the momentary deviation from the set-point
and the modification run of the measured value.
PID-Controller: the dosing depends on the momentary deviation from the set-point,
the total deviation since the start-up of the controller and the
modification run of the measured value.

The PI-Controller is probably the best selection for most uses. It has a good control
performance and is quite easy to adjust. The PID-Controller even has a better control
performance, but is much more difficult to adjust.

Level-Monitoring
The controller has two level-switch-inputs for monitoring the levels of the chemicals for
dosing. In case of low level, the level-switch closes, and an alarm is set and dosing for the
corresponding channel is stopped (run dry protection).
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Release-Contact
The controller has one release-contact to attach a flow-control or any external controller.
The activity of the release-contact can be delayed, by setting a start-up-delay. With every
contact of the release-contact the start-up-delay will be active. The flow-control-time
delays the stopping of the controller, when no flow is registered.

Alarm Delay
The release of an alarm can be delayed from 0 to 7200 seconds.

Start-Up after Power Failure
All settings will be stored in case of a power failure. Only the part of the data of the PI-
Controller is lost, in which the total deviation since the start-up of the Controller is stored.
The controller will start up again with the last settings, the dosing will be delayed until the
start-up-delay-time has passed. If the Controller was stopped by the menu-command
controller stop, the Controller will still be stopped after the main power is back on.

3. Description of Terms

Output Signal / Controller Output
The output signal (controller output) is the output quantity, which is being calculated by
the Controller, to each a given set-point. Depending on the dosing device it can be a pulse
width modulated signal with variable ON / OFF intervals for motor pumps, a variable
frequency for frequency controlled metering pumps or an aperture angle for motor valves.

Proportional Control
To control a variable, e.g. the concentration of free chlorine in water, the proportional
Controller generates an output signal, meaning here the amount of added chlorine, which is
proportional to the deviation between the measurement and the set-point.

In this context the proportional band (P-range) is specified as the deviation from the set-
point where the maximum output signal is generated.

Example: A chlorine Controller having a proportional band (P-range) of 0.1 ppm and a
set-point of 0.4 ppm regulates a frequency controlled dosing pump with a
maximum of 6000 strokes per hour (st/h). At a measurement of 0.3 ppm the
output signal will be 6000 st/h. At a measurement of 0.35 ppm the output
signal will be 3000 st/h.

Integral Part / Reset Time T
R

For the regulation of an output quantity the integral controller generates an output signal
that is proportional to the sum of the past deviations from the set-point. The output signal
of the integral controller increases at a constant deviation from the set-point and decreases
only after the set-point has been passed. The integral controller is adjusted with the
parameter I-Reset Time. The Reset-Time is the time span, which is needed by the integral
controller to generate the same output signal as the one being immediately generated by the
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proportional controller. The longer the Reset-Time, the smaller is the influence of the
integral controller to the entire Proportional-Integral (PI) regulation.

Example: A chlorine controller having a proportional band of 0.1 ppm and a set-point
of 0.4 ppm regulates a frequency controlled dosing pump with a maximum
of 6000 strokes per hour (st/h). At a measurement of 0.35 ppm the output
signal from the P-Controller will be 3000 st/h. Having a reset time of 10
minutes, the Integral Controller will, at a constant deviation of 0.05 ppm,
generate an output signal of 3000 st/h after 10 minutes. The entire PI
regulation will then generate an output signal of 6000 st/h.

The output signal of the Integral Controller will only decrease when the measurement
passes the set-point. With such a summing (integrating) property, the Integral Controller
can determine e.g. the actual chlorine consumption and the necessary base dosing, making
sure that the set-point will be maintained with a high accuracy.




Derivative Action Time T
V
The derivative control unit (D-unit) of the controller generates an output signal that is
proportional to the variation speed of the controlled variable. The derivative control unit
acts against the variation of the controlled variable. The derivative action time is the time
that a P-Controller would need for a constant variation speed to generate the same output
as the D-unit generates immediately.

Example: The PD-Chlorine Controller of a swimming pool has a set-point of 0.4 ppm,
a P-range of 0.1 ppm and a derivative action time of 30 seconds. 30 children
jump into the water for a swimming lesson and immediately the chlorine
concentration decreases, lets pretend about 0.03 ppm/10 seconds. A P-
Controller generates a small control-output that increases only with the
decrease of free chlorine. Within 33 seconds, the chlorine concentration has
fallen to 0.3 ppm. That means the P-Controller needs 33 seconds to generate
ist maximum output. In this case the D-unit would generate an output of
almost 100%, as long as the chlorine falls with a variation speed of
0.03ppm/10 seconds and acts against the decrease of the chlorine
concentration.

Dosing Time Limit
In order to prevent dangerous over-dosing or even wrong dosing due to electrode failure, it
is possible to limit the maximum dosing-time of the controller. The maximum dosing-time
is the time span in which the set-point has to be reached. If the set-point is not reached
within the maximum time, an error in the dosing system is assumed (e.g. dosing pump
failure, dosing
tube failure, electrode failure, cable disconnected) and dosing is stopped.
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Start-Up Delay
If the flow of measurement water is stopped, the properties of the water are not the same as
those of the pool water, meaning that the measurement is not representative. When the
measurement flow starts up again, it will take some time until the water in the
measurement circle is representative for the pool water again. The purpose of the start-up
delay is to prevent a wrong dosing during this time span.
The start-up delay is activated at every start, no matter how the controller was started
(manual start, switching the controller ON, external start by release-contact).

Flow-Control Time
In some dosing systems, the pressure of the measurement water can vary. This could be
mistaken by the flow-control as no flow. To prevent the Controller from stopping, a time
can be set in which the flow should be normal again. That means that the Controller will
only set an alarm, when the flow is down for a longer time than the flow-control time is
set.


Minimum and Maximum Output
The minimum and maximum controller output can be set as a percentage from the
maximum effective dosing of the dosing system. These parameters can be used to adjust a
dosing system to a control loop.

Example: A 10 L/h pump is attached to a chlorine control loop. The pump is too big
for this application. You may use the maximum output parameter to reduce
the maximum output to 60% which turns the pump effectively into a 6 L/h
pump.

The minimum output is very important when using the pulse-width-modulated output. A
motor pump might need a certain ON-time before it starts to pump effectively. In this case
you will need a minimum ON-time or minimum controller output.

Example: The cycle time for pulse-width-modulation is 30 seconds. A minimum
output of 10% will result in a minimum ON-time of 3 seconds. That means,
whenever the controller will generate an output signal, it will be at least 3
seconds long, giving the connected pump enough time to dose some volume.
If the Universal-Controller is used as a pure P-Controller and you have a
constant disturbance e.g. chlorine-loss, the set-point can never be reached
because the P-Controller needs a deviation to produce any output. You may
use the minimum output-parameter in this case to increase the dosing
beneath the set-point.
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4. Operation

Overview

The Universal-Controller has two major operating modes:

a) measure and control (operation-mode)
b) set-up and configure (menu-mode)

Use the MODE key to change between the operation-mode and the menu-mode. Within the
menu-mode you can choose a menu-item with the UP and DOWN keys. You enter a
selected sub-menu or a parameter setting by pressing the OK key. You also use the OK key
to store a modified parameter value and exit the setting. The MODE key is used to abort a
setting and leave a sub-menu.
In the operation-mode the OK key is used to restart the Controller, reset alarms and skip
the start-up delay.

4.1. Operation-Mode and Main-Menu
In the operation mode there are three display modes. You can toggle between them with
the UP and DOWN keys. The first mode shows the actual Controller output s a percentage,
the second one as a bar graph. The dosing direction is shown as a + or sign, the third one
showes the time and dafe.



pH: 7.23 (23.1)
dosing 83% +
pH: 7.23 (23.1)
(+)

Controller
stop
Controller
Set up
Controller
calibrate
Controller
configuration
Mode Mode
ph: 7,23
08:15

Switch from the operation-mode to the menu-mode with the MODE key. The display
shows CONTROLLER / STOP. You can choose one of the four main-menu items with the
UP and DOWN keys.

1. Controller stop: stops the Controller, all dosing outputs are disabled,
measurement continues.

2. Controller set-up: sub-menu with all parameters for the control characteristic

3. Controller calibrate: sub-menu for calibration

4. Controller configuration: sub-menu for the configuration of the Controller
(measured values, output type, start-up delay)
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You enter any sub-menu by pressing the OK key.

If you select the menu-item CONTROLLER / STOP with the OK key, all dosing outputs
will be disabled and the Controller will turn back to the operation-mode. It is just
measuring not controlling now!
You can restart the Controller by pressing OK. The start-up delay will be initiated, but you
can skip the start-up delay by pressing OK a second time.
Within a sub-menu you can choose a parameter with the UP and DOWN keys. If you want
to modify a parameter value, press OK. A little star (*) appears in the upper right corner of
the display, that shows you that you can modify the parameter now.
You can increase the value with the UP key and decrease it with the DOWN key. You can
abort by pressing the MODE key. All modifications will then be lost. To end the setting
and store the new value press OK.
Some menu-items like CONFIGURATION / SIGNAL OUTPUT make several settings
available. The general rule for these settings is: OK confirms / accepts and let you
continue.
MODE aborts without storing new values!

4.2. Menu Controller Set-up
The sub-menu CONTROLLER / SET-UP contains all parameters for the controller
characteristic, like set-points, P-range or minimum output. You enter the menu by choosing
it in the main menu with the UP and DOWN keys and pressing OK. Then you can choose a
parameter with the UP and DOWN keys. If you want to modify a parameter press OK. a
little star (*) appears in the upper right corner of the display that indicates that you are now
modifying the parameter value. You accept and store the new value by pressing OK or
abort with MODE.


Set-point (+)
The lower set-point. If the measured value falls below this set-point the dosing starts
(raise).

Example: setting the lower set-point
- the controller is in operation-mode
- press the MODE key to enter the menu-mode
- press the UP key once; the menu-item CONTROLLER / SET- UP is
displayed
- press OK to enter the CONTROLLER / SET-UP sub-menu
- the actual setting of the set-point (+) parameter is displayed
- press OK to modify the value; a little star (*) appears in the upper right
corner of the display that indicates that you are now modifying the
parameter value
- raise or lower the value with the UP or DOWN keys
- if you hold down the key for more than 1,5 seconds an auto-repeat
function is activated
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- to store the new value press OK; the little star (*) in the upper right
corner of the display disappears and your modification is now stored.
Pressing the MODE key instead of OK will abort and the new settings
will not be stored.
- you leave the sub-menu by pressing the MODE key
- you leave the main-menu by pressing the MODE key once again

Set-point (-)
The upper set-point. If the measured value raises above this set-point the dosing starts
(lower).

Alarm minimum
The lower alarm value. If the measured value falls below this value an alarm is raised.

Alarm maximum
The upper alarm value. If the measured value raises above this value an alarm is raised.

P-Range
Proportional band of the controller defines the gain of the controller. The P-range is
always set in the same unit as the measured variable, that means pH-steps for pH, millivolt
for ORP and ppm for Chlorine / Chlorine-dioxide measurement.
The smaller the P-range the higher is the gain of the controller.

I-Reset-Time
Integral reset time in seconds. The possible range is 1 to 3600 seconds. A reset time of 0
means infinite, meaning that the I-part of the controller is turned off. The influence of the
integral-part decreases with increased reset-time.

D-Action Time
Derivative-action time in seconds. The possible range is 1 to 3600 seconds. The D-part
increases with longer action times. A D-action time of 0 means that the D-part is
inactive.

Minimum Output
The minimum control output as percentage of the maximum dosing capability of the
dosing device.

Maximum Output
The maximum control output as percentage of the maximum dosing capability of the
dosing device.
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4.3. Menu Controller Calibrate
The sub-menu CONTROLLER / CALIBRATE contains menu-items for the calibration.
You enter the menu by choosing it in the main-menu with the UP and DOWN keys and
pressing OK.



Controller
calibrate
Calibrate
Temperature
Calibrate
Cal.-measurement
Setting up the temperature ( only needed while calibrating ph+
with manual tempeature compensation )
Calibration with measuring the
bufferfluid
Calibration with one
ore two points
Calibrate
Zeropoint
Zeropointcalibration-only for probs who needs to calibrate the
zeropoint



Display of the Raw-Measurement during Calibration
You can see the raw-measurement (the non-calibrated voltage level of the A/D converter)
during the calibration procedure by pressing the DOWN key. The non-calibrated voltage
will be displayed in the upper display line, as long as you hold the DOWN key down.

Temperature
You can choose between automatic and manual temperature-compensation of the pH
measurement. If you choose manual temperature-compensation you have to enter the
temperature of the liquid during normal operation.

Example: The operating-temperature of your control-loop is 50C. Enter this
temperature under the menu-item CALIBRATE / TEMPERATURE and the
controller will adjust the gain of the pH-sensor to the correct value for this
temperature.

Calibrating-Measurement
To calibrate the different sensors you need a reference-measurement. The calibration
procedures differ between the possible configurations:

pH-Probe
To calibrate a pH-probe you need two different buffer-solutions. One has to have pH 7 the
other one can be pH 4, 5, 6, 8, 9 or 10.
Select the menu-item and press OK. Take the probe out of the flow armature, dry it with a
clean cloth and dunk the probe into the first buffer. Stir at least 30 seconds in the buffer
solution, then press OK. Now enter the temperature of the buffer solution during the
calibration. The temperature is entered manually because in most cases it is much more
convenient to measure it manually than to dismantle the PT 100.
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As soon as you press OK again, the measurement will start. The measurement takes 15
seconds. After the measurement, the controller displays the estimated buffer value. You
can correct this value using the UP and DOWN keys. Press OK when finished.
Now take the probe out of the first buffer, dry it with a clean cloth and dunk it into the
second buffer solution. Stir at least 30 seconds and the press OK to start the second
measurement.
After 15 seconds the controller displays the estimated value. Again, you can correct the
value using the UP and DOWN keys. Press OK when finished.
After the calibration is done, offset and gain of the probe are calculated and displayed. In
case of a failure a message will be displayed.

Please be aware of the fact that the pH-probe might need up to one minute to get a stable
output for a buffer. In this case stir a little longer before pressing OK to start the
measurement.

ORP-Probe
A ORP-probe can not be calibrated.
You can only test it! Take the ORP-probe out of the flow armature and dry it with a clean
cloth. Dunk the probe into a buffer solution of 475mV for a few seconds. The measured
value will be displayed.

Chlorine / Chlorine Dioxide / Ozone / Hydrogenperoxide / Peracetic acid Probe
For calibrating such a probe you need an analytical measured value. Chlorine, chlorine
dioxide, or ozone concentration is to be determined with the DPD-method. Hydrogen
peroxide or peracetic acid is to be determined by a titration (see instruction manuall of the
sensor)

Example: - the controller is in operation mode.
- press the MODE key to enter the menu mode.
- press the UP key twice; the menu item CONTROLLER / CALIBRATE
is displayed.
- press OK to enter this sub menu.
- the display shows CALIBRATE / CAL.-MEASUREMENT.
- Press OK
- press OK to start the measurement. (count down of 15 sec) *1
- The Display shows MEASURE VALUE, adjust the displayed value with
the UP and DOWN keys to the value determined by the analytical
measurement.
- Press OK the new calibration is stored or press MODE to abort
- Display shows the slope of the sensor. If the slope is too high or too low
an error will be displayed.
- press OK and then twice the MODE key to get the operation mode (for a
short time software release number and other informations are
displayed.)

No zero point adjustment is possible.

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*1: If you press the key DOWN () during the count down, you see the original signal from the sensor in
Volts. A correct signal must be negative.

Zero-Point
Some controller-configuration need zero-point adjustment. At the menu-item ZERO-
POINT you can calibrate the zero-point of your measurement. The zero-point adjustment is
necessary when you get the measured value from a current input or when you use specific
measuring probes. You have to make a calibrating measurement at the zero-point of the
measuring probe.


4.4. Menu Controller Configuration
The sub-menu CONTROLLER CONFIGURATION contains the items to configure the
type and the options of the controller itself. You enter the menu by choosing it in the main
menu with the UP and DOWN keys and OK. You can now choose a parameter, if you want
to modify one, press OK. You accept and store a new value by pressing OK or abort with
MODE.

Example: - the controller is in operation-mode
- press the MODE key to enter the menu-mode
- press the DOWN key, the menu-item CONTROLLER /
CONFIGURATION is displayed
- press OK to enter the sub-menu
- the display shows the actual setting of the maximum dosing time
- press the UP key three times; the actual selection of the controlled
variable is displayed
- press OK to change this parameter: a little star (*) appears in the upper
right corner of the display. It indicates that you can change the variable
now
- choose the controll variable using the UP and DOWN keys. Press OK.
Then choose the decimal point (see measuring range of the sensor).
Press OK. Then choose the measuring unit (see measuring range of the
sensor). *2.
- to store the new setting press OK
- press MODE
- you are back in the sub-menu CONTROLLER / CONFIGURATION
- leave the sub-menu and return to the main-menu by pressing the MODE
key
- You should calibrate the controller for this new variable
-
*2 If you will change the decimal point or measuring unit without changing the controll variable, then you
must first select another controll variable and install this. Then start again this procedure and choose your old
controll variable. Now you can set the decimal point or respectively the measuring unit.

Maximum Dosing Time
The maximum dosing time in minutes. This is the maximum time that the controller has to
control a deviation. If the set-points are not reached within this time, the controller assumes
a failure, stops the dosing and raises an alarm. The alarm is automatically reset if the
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measured value gets into the range between the lower and upper set-points or if the alarm
is manually reset by pressing OK.

Start-Up Delay
Start-up delay time in minutes. This delay is initiated after each start of the controller and
disables the dosing outputs until this time is over. You can skip the start-up delay by
pressing OK.

Current Output
In the menu-item CONFIGURATION / CURRENT OUTPUT you can choose between 0-
20mA or 4-20mA output. Select the menu-item with the UP and DOWN keys and press
OK.

Controlled Variable
The type of measurement system to control. You can choose one of the following options:
(Potentiometric sensors): pH: with manual temperature compensation, pH (temp.-comp.):
with automatic temperature compensation, ORP: or any voltage system between 1.2V and
+1.2V, (amperometric sensors): chlorine or chlorine dioxide, ozone, hydrogen peroxide,
peracetic acid, and additionally you must choose the decimal point (2.000 / 20.00 /200.0
/2000) and the measuring unit (mg/L / ppm / %).
(PT100): Temp.: temperature controller

If the regulating variable is changed, all controller PID-parameters and the signal output
are set to defaults.

For chlorine, chlorine dioxide, ozone, hydrogen peroxide, peracetic acid and ORP the
controller function for reducing the concentration is automatically deactivated. The SET
POINT (-) is set to the upper end of the measuring range.

Output
Configuration of the used controller output. You can choose between the following
options:
Off: no dosing
Pulse: pulse-frequency output from reed-relay for metering pumps
Pulse-width: modified duty-cycle (ON-OFF time) of 230VAC relays within 30seconds
for motor-pumps
2-state: 230VAC relay turns ON for dosing 100% and turns OFF for dosing smaller
than 1%. The controller can be configured as a simple 2-state controller with
switching hysteresis: reset-time = 0 (infinite) and derivative action time= 0
and the proportional band is corresponding to the hysteresis
0-20mA(+): 0-20mA output rising direction
4-20mA(-): 4-20mA output rising direction
0-20mA(-) : 0-20mA output lowering direction
4-20mA(-): 4-20mA output lowering direction
valve (+): motor-valve with position-feedback
valve (-): motor-valve with position-feedback

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Network
For connecting the controller to a network or a PC, an address and code are required. At
this menu-item you can first enter the address then your code. The code has four figures
from 0 to 255 which are shown in the hexadecimal scheme. Enter the code with the UP and
DOWN keys. The network or pc function can only be use with a special software.

Alarm-Delay
Time-delay for minimum / maximum alarms in seconds. After appearing of an alarm
situation the response of the relays are delayed for the set time. If the alarm situation
disappears before the end of this time, no alarm will be set.

Flow
Control-time for the flow in seconds. The flow-control-time is the maximum time-span in
which the flow may be down, before an alarm is raised and the controller stops.

Minimum Relay
Never all relays are used. A relay that is not used, can be set as an additional minimum-
relay in this menu-item. Use this menu-item when you need an additional or a from the
other alarms separated minimum contact.

Maximum Relay
Never all relays are used. A relay that is not used, can be set as an additional maximum-
relay in this menu-item. Use this menu-item when you need an additional or a from the
other alarms separated maximum contact.

Language
The language of the menu of the controller. You can choose between German and English.

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A: Error-, Alarm- and Status-messages


start-up delay the start-up delay is still active, the dosing outputs are still disabled
controller stop the controller is stopped
dosing time the maximum dosing time has been exceeded: for security reasons
the dosing is stopped and an alarm is set
upper alarm the measured value is above the upper alarm level, the alarm relay
and the maximum relay are active
lower alarm the measured value is below the lower alarm level, the alarm relay
and the minimum relay are active
(+)-level-alarm the tank with the pH(+) chemical (alkaline solution) is empty, the
dosing for this chemical is stopped
(-)-level-alarm the tank with the pH(-) chemical (acid) is empty, the dosing for this
chemical is stopped
? manual control the OK key was pressed during dosing operation, the controller is
waiting for OK or MODE to be pressed
cal.-error a failure during calibration has occurred
equal buffers the same buffer solution has been used twice for calibration of the
pH-probe
no pH7 buffer no pH7 buffer solution was applied at the calibration. One of the two
solutions has to be pH7!
gain the gain of the sensor is not within the tolerance - the sensor might
be defective or the input of the buffer value was incorrect
offset the offset of the sensor is too big - the sensor might be defective or
the input of the buffer values were incorrect
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B: Datasheet


processor: modern powerful CMOS -controller
control panel: LC-display with background light and four keys
measurement range: pH 0-14
ORP 1200mV to +1200mV
chlorine / chlorinedioxide / ozone / hydrogen peroxide / peracetic
acid
range: 2.000 / 20.00 / 200.0 / 2000, units: mg/L / ppm / %
Inputs: pH- and ORP probes (SN6)
chlorine, chlorine-dioxide, ozone, hydrogen peroxid, peracetic acid
(4-pole socket)
Outputs: 2 pulse-frequency with reed-relay (48VDC/40mA) for metering
dosing pumps
2 230VAC/2A Pulse lenght for motor-valves or motor-pumps
1 Limit contact 2A
0/4-20mA control output for current-controlled dosing devices
0/4-20mA signal output for recorders, remote displays
Controller: P, PI, PD or PID-Controller
Description: The Universal-Controller can be configured as a pH, ORP, chlorine,
chlorine dioxide, ozone, hydrogen peroxide, peracetic acid- or
temperature-controller by specific software..
The controller has two dosing-directions for pH: lower and raise.
when controlling chlorine, chlorine-dioxide or ORP the lowering
dosing-direction is disabled.
Dosing-outputs are reed-contacts for -metering pump , Relay
contacts for motor-pumps or motor-valves and a current-output. The
current-output can be adjusted for one dosing-direction.
Operating Instruction Universal Controller






Page 16

C: Configuration


There are many ways and options to configure the Universal-Controller. But not all
combination do make sense.
Configuration of 2-point-controller:
If the controller is configured to have an ON/OFF output-characteristic, it is very difficult
to use the PID parameters correctly. The ON/OFF output is intended to be used without
the I- and D-parts (integral-reset-time = 0 (infinite), derivative-action-time =0). The
minimum output has to be 0%, the maximum output has to be 100%, then the P-range is
the hysteresis for switching the contact. If you want to use a 230VAC contact and PID it
would be better to select a pulse-width-modulated output.
Pulse-width-modulation:
In control loops where the time-constants are shorter than 30 seconds, the pulse-width-
modulated outputs loose their continuity:






D: Start-Up of the Control-Loop


All controllers with an integrating part tend to overshoot. When starting up a control-loop,
the integral part might lead to a big overshot. It might be useful to start up the loop with a
pure P-controller and add the I- and D-units later or to reset the integral-sum manually by
pressing OK as soon as the measurement value approaches the set-point.



Operating Instruction Universal Controller






Page 17
E: Controller Reset





Operating Instruction Universal Controller






Page 18
F: Terminal Description


Terminal Description Terminal Description
1 230VAC or 110 VAC, 50/60 Hz
L / Phase
22 + 0/4..20mA Control output
2 0V N 23 - 0/4..20mA Control output
3 Protective earth PE 24 + 0/4..20mA Signal output
4 Contact direction + (230VAC/
2A)
25 - 0/4..20mA Signal output
5 0V N 26 Release contact
Input for open collector
6 Protective earth PE 27 Release contact
15 V
7 230VAC / 50Hz
or Common
28 Release contact
GND
8 Contakt direction - (230VAC/
2A)
29 Release contact
24V
9 0V N 30 Release contact / Input 24V
10 Protective earth PE 31 Level switch direction - /24V
11 230VAC / 50Hz
or Common
32 Level switch direction -
Input 24V
12 Alarmcontact norm. close 33 Level switch direction + /24V
13 Alarmcontact norm. open 34 Level switch direction +
Input 24V
14 Alarmcontact common 35 Position feedback valve + 5V
15 Reedrelay direction + 36 Position feedback - - pickoff
16 Reedrelay direction + 37 Position feedback - - GND
17 Reedrelay direction - 38 20VDC unstab. for 20mA Sensor
18 Reedrelay direction - 39 20mA Input
19 Rs232 RxD / Rs485 Line A 40 20mA GND
20 Rs232 Signal ground 41 Pt 100 Signal
21 Rs232 TxD / Rs485 Line B 42 Pt 100 GND



G: Standards

The Universal-Controller is CE-compliant.
The following european standards have been used:
EN 50 081-1
EN 50 082-2
EN 60 555-2
EN 60 555-3