Digital Industrial Controller 1 General Safety Instructions

DIGITAL INDUSTRIAL CONTROLLER
GENERAL SAFETY INSTRUCTIONS

To ensure that the device functions correctly, and will have a long service life, please
comply with the information in these Operating Instructions, as well as in the
application conditions and the additional data given in the data sheet:
When planning the application of the device, and during its operation, observe
the general technical rules!
Installation and maintenance work should only be carried out by specialist staff
using the correct tools!
Observe the relevant accident prevention and safety regulations for electrical
equipment during the operation and maintenance of the unit!
If the controller is part of a complex automation system, a defined and controlled

re-start must be carried out following an interruption of operation.
Always switch off the voltage before carrying out work on the device!
Take suitable measures to prevent unintentional operation or impermissible

impairment.
If these instructions are ignored, no liability will be accepted from our side, and
the guarantee on the device and on accessory parts will become invalid!
1110 - 3
english

2
CHARACTERISTICS AND POSSIBILITIES OF USE

(OVERVIEW)
english
The digital industrial controller is designed as a PID controller for controlling tasks in
the process control technology. It represents a new controller generation based on a
microprocessor.
Either standard current/voltage and frequency-analog signals can be applied to the
scaleable controller inputs or resistance thermometers and thermocouples can be
connected.
Outputs for continuous standard signals or relay outputs can now be used as
controller outputs.
In addition, outputs for error reports and a binary input and output for additional
functions are available.
RS 232 or RS 485 / PROFIBUS serial interfaces are available as connection
options.
The following control tasks can be realised with the controller:
Fixed setpoint control (single control loop)

Fixed setpoint with feed forward control
Follow-up control (external set-value)
Ratio control
Cascade control
The controller is characterised by user-friendly operation and has a backlit, easily

legible LCD plain language display.
The following operator actions can be carried out with menu support in various
operator control levels:
Configuration (defining the controller structure),

Parameter definition (setting controller parameters),
Process operation (manual interventions).
Configuration and parameter definition data is stored in an EEPROM to protect

against power failures.
NOTE
4 - 1110
The digital industrial regulator complies with the 73/23/EWG

Low Voltage Regulations and the EMC 89/2338/EWG
Regulations.
Self-optimization algorithms (for self-adjustment and adaption) are implemented in

the controller and ensure automatic adaption of the controllers parameters to the
process in the closed control loop.
Figure 1 shows an overview of the controller.
Figure 1: Overview diagram
Mastercode for digital

industrial controller:
8575
1110 - 5
english
Unauthorized operation of the individual operator control levels can be rendered

impossible by a free choice of user codes. Regardless of this, a permanently
programmed and invariable master code exists which allows access to all levels.
This 4-digit master code can be found on the bottom margin of this page. It
can be cut out and stored separately from the instruction manual.

3
INSTALLING THE CONTROLLER
english
The controller was conceived for installation in switch panels. On the controller,
first of all remove the retaining elements engaged on both sides by swivelling in
anticlockwise direction. Insert the controller, including the enclosed rubber seal, into
the insertion opening from the front. Then again engage the two retaining elements
in the bolts on the sides of the housing and screw in the threaded pin inside from the
rear.
Switch panel insertion opening (W x H):
Outer controller dimensions (W x H x D):
Controller weight:
Degree of protection:
Operating temperature:
Storage temperature:
ATTENTION!
92 x 92 mm2 (+0,8 mm)

96 x 96 x 173 mm3
960 g
IP 65 (front when using the
enclosed seal)
0 bis +50 C
-20 bis +60 C
To ensure the electromagnetic compatibility (EMC) the screw

terminal TE (Technical Earth) must be connected to the earth
potential by a cable that is as short as possible (30 cm, 2.5 mm2)
CONNECTIONS
4.1
Pin assignments
TE connection
(Technical Earth)
Figure 2: Rear side of controller

6 - 1110

Controller input 2
Controller input 1
Relay 3
(Alarm)
Position acknowledgement
Controller output
Standard signal
Current
Standard signal
Voltage
Binary
output
Relay 1
(Output)
Relay 2
(Output)
Resistance
thermometer
PT100
Binary
input
Thermo
couples
Power
supply
Fig. 3: Allocation of the terminal strip

NOTE
4.2
When connecting the sensor lines:

Lay the lines separate from the power lines (lines in which large
currents flow) and high frequency lines. Never under any
circumstances use multi-pole cables to carry both power and
sensor lines.
When using screened cables, only connect the screen at one
end. Never under any circumstances connect the screen to both
the protective conductor and the earth of the regulator input.
Supply voltages
Power supply for the
controller:
Model 1:
Model 2:
Power supply for
transducers:
ATTENTION!
Connect to terminals 14
and 15.
115 / 230V 50 ... 60 Hz
12 / 24V 50 ... 60 Hz
24 V DC
Accessible on terminals 23
and 24.
To ensure the electro-magnetic compatibility (EMC), the screw

terminal TE (Technical Earth) must be connected to the earth
potential with a short cable (30 cm, 2.5 mm2).
1110 - 7
english
Relay 3
(Alarm)

4.2.1 115/230 V and 24/48 V Changeover
english
By means of a jumper inside the unit, the supply voltage can be changed from 230 V
to 115 V, or from 12 V to 24 V respectively. This adaptation must take place before
installing the unit.
Procedure:
Insert all connection and supply lines
Remove the connecting screw for the Technical Earth
Remove the optionally-installed interface card (if present)
Undo the four screws on the rear plate, and remove the rear plate
Pull the unit one third of the way out of the housing
The jumper is easily accessible on the power supply printed-circuit board,
positioned immediately in front of one of the relays and identified by the numbers
1-4 on the board.
At delivery, the connector is positioned between contacts 2 and 4
To change the unit to 115V or 12 V respectively, contacts 1 and 3 must be
bridged with the connector. Proceed identically when changing from 24V to 12V.
Finally, push the unit back into the housing, and screw on the rear plate.
NOTE
If the unit is to be set to the lower voltage, please ensure that the
voltage does not exceed the quoted tolerances, and make a note
on the wiring diagram.
4.2.2 24V DC/AC Converter for operation at 24 V DC

The 12/24V AC controller model can also be operated at 24 VDC using an optional
DC/AC converter. Up to 3 controllers can be supplied from a single converter. (Order
number: 19139J)
8 - 1110
Supply voltage
16V - 26V DC
Output voltage
16V-26V AC (50 Hz)
Efficiency
> 95%
Switch-on delay
max. 5 secs
Dimensions (WxHxD)
23 x 75 x 110 mm3

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DIGITAL INDUSTRIAL CONTROLLER

GENERAL SAFETY INSTRUCTIONS

If the controller is part of a complex automation system, a defined and controlled

Take suitable measures to prevent unintentional operation or impermissible