dixell universal controller manual
Overall Safety Precautions
Never expose the controller to water or moisture․ Operate within specified limits and avoid abrupt temperature shifts that could cause condensation․ Disconnect all power before maintenance․ Mount the probe in a location inaccessible to end users․ Do not open the unit return it for service if malfunctioning․
Environmental Limitations
All Dixell Universal controllers are designed for use in controlled industrial environments․ The operating temperature range is 0 °C to 50 °C (32 °F to 122 °F)․ Exposure to temperatures outside this range can cause internal component failure or inaccurate readings․ Relative humidity must not exceed 85 % RH; condensation may form when the device is moved between environments with high humidity and dry air․ The enclosure is not water‑proof; therefore, the controller must be kept dry and protected from splashes, steam, or accidental immersion․ Dust and other airborne particulates should be kept to a minimum; the device is not rated for dusty or sandy conditions․ The unit must be mounted in a location where it is not subject to vibration, shock, or mechanical impact․ Electrical supply must be stable and within the specified voltage range; transient spikes or surges can damage the power supply and control circuitry․ The controller should not be exposed to corrosive atmospheres, strong chemicals, or extreme pressure․ In case of accidental exposure to water or moisture, the device should be powered off, disconnected from the mains, and allowed to dry completely before re‑installation․ If condensation is detected inside the enclosure, the unit should be inspected for damage and, if necessary, sent back to the distributor for repair․ All maintenance must be performed only by qualified personnel, and the device must remain sealed during operation to preserve its environmental integrity․ All units should be stored in a drycool place for performance․
Electrical Safety
All electrical connections to the Dixell Universal controller must follow the manufacturer’s specifications and local codes․ The device is rated for a maximum input voltage of 240 V AC and a maximum current of 10 A․ Over‑voltage, under‑voltage, or current spikes can damage the power supply and internal circuitry․ Before any maintenance or component replacement, disconnect the controller from the mains and verify that the voltage is zero with a multimeter․ Do not open the enclosure while the unit is powered or when any terminals are live․ The controller’s input terminals are not insulated against accidental contact; therefore, all wiring must be insulated and secured to prevent short circuits or arcing․ Grounding is mandatory: connect the device’s grounding terminal to a reliable earth point to ensure safe dissipation of fault currents․ When connecting the TTL or RS485 communication lines, observe the correct polarity and shielding to avoid cross‑talk and electromagnetic interference․ The controller’s internal relays can generate high voltage spikes; use snubbers or varistors as recommended․ In case of a fault, immediately isolate the controller from the network and check for overheating, smoke, or unusual smells․ If the device has been exposed to water or moisture, do not power it until it has been inspected and dried thoroughly․ All personnel working with the controller should wear insulated gloves and use insulated tools․ Keep the area around the controller free of conductive debris and avoid vibration or shock․ Adhering to these electrical safety practices protects both the equipment and the operators from injury and damage․
Product Overview
XR02CX, XR01-02CX, XR80CX, and Universal‑XR series are digital controllers designed for precise temperature regulation․ Each model supports probe wiring, auto‑recognition, and TTL/RS485 communication, enabling flexible integration into dairy and industrial systems․ 24‑hour uptime․
XR02CX Family
The XR02CX family comprises compact, dual‑channel digital controllers engineered for precise temperature management in dairy and food processing applications․ Each unit features a rugged, sealed housing that protects internal electronics from dust and limited moisture exposure, yet the manufacturer explicitly advises against immersion or prolonged contact with water․ Operating the controller within its specified temperature envelope is essential; sudden ambient temperature shifts or high atmospheric humidity can induce condensation on internal circuitry, potentially leading to short circuits or degraded performance․ Therefore, install the device in a controlled environment and avoid rapid temperature fluctuations during operation or maintenance․
Prior to any servicing, disconnect all electrical connections to eliminate the risk of electric shock or inadvertent activation of the control logic․ The probe assembly is designed for secure, permanent mounting; it should be positioned in a location inaccessible to the end user to prevent accidental removal or damage․ The controller’s internal firmware is not user‑serviceable; opening the unit may void warranties and compromise safety․ If the device exhibits abnormal behavior or fails to respond, return it to the authorized distributor or to Dixell S․p․A․ for inspection and repair․
Key features of the XR02CX family include dual‑channel input capability, programmable set‑point ranges, and built‑in safety interlocks that trigger an alarm or shutdown in the event of over‑temperature or communication loss․ The digital interface supports both TTL and RS485 communication protocols, enabling integration with existing plant control systems․ Calibration and configuration are performed via a dedicated software suite, which allows operators to fine‑tune response curves, hysteresis, and alarm thresholds․ The controllers also support remote monitoring through standard industrial protocols, providing real‑time data logging and diagnostics․
Installation guidelines recommend using shielded, low‑noise cables for probe connections, and ensuring proper grounding to mitigate electromagnetic interference․ The device’s firmware automatically detects probe impedance and adjusts its measurement algorithm accordingly, ensuring accurate temperature readings across a wide range of sensor types․ For optimal performance, maintain a clean, dust‑free environment and periodically verify probe integrity through the software interface․
XR01-02CX Family
XR02CX controllers are sealed, dust‑tight units that must not be exposed to water or moisture․ Operate within specified temperature limits and avoid sudden changes or high humidity to prevent condensation․ Disconnect power before maintenance and mount the probe in a location inaccessible to end users․ Do not open the unit; return it for service if it fails․
Before any maintenance, disconnect all electrical connections to eliminate shock risk․ The probe should be permanently mounted in a location inaccessible to end users․ The firmware is not user‑serviceable; opening the unit may void warranties․ Return the controller to the distributor if it malfunctions․
Key features include dual‑channel input, programmable set‑point ranges, and built‑in safety interlocks that trigger alarms or shutdowns during loss․ The interface supports TTL and RS485s enabling integration with plant control systems․ Calibration is performed via software allowing tunes of response curves!
Installation guidelines recommend shielded, low‑noise cables for probe connections and proper grounding to mitigate electromagnetic interference․ Firmware auto‑detects probe impedance, adjusting measurement algorithms for accurate readings across sensor types․
XR80CX Milk Tank Controllers
The XR80CX series is designed for dairy processing, offering precise temperature control for milk tanks․ A key feature is the regulation inversion capability, allowing the controller to switch between cooling and heating modes with a single setting․ This flexibility supports both pasteurization and chilling processes without hardware changes․
Digital input handling is configurable through the i1P parameter․ When set to i1PCL, the controller activates the input upon contact closure, whereas i1PoP triggers activation on contact opening․ This allows integration with various safety or process interlocks that may require different logic․
Communication is supported via TTL or RS485 interfaces․ For industrial networks, the optional Dixell XJ485‑CX converter can be attached, enabling robust serial communication over long distances and shielding against electrical noise․
Installation requires mounting the probe in a secure, user‑inaccessible location․ Use shielded cables and ensure proper grounding to avoid interference․ The unit should be kept dry; avoid exposure to moisture or sudden temperature changes that could cause condensation․ Disconnect all power before performing any maintenance, and if the controller shows abnormal behavior, return it to the distributor for service․
All units are rated for industrial use and comply with IEC 61508 safety standards․ Routine checks of probe integrity and firmware updates are recommended fully to maintain performance!!!
Universal-XR Series
The Universal‑XR family offers a versatile platform for a wide range of industrial processes․ Each unit is engineered to support up to sixteen input channels, allowing operators to monitor multiple sensors simultaneously․ Next, connect the required number of probes, ensuring that each probe is wired to the correct terminal and that the cable is shielded to reduce electromagnetic interference․
Once the probes are connected, the controller can be powered on․ Within one minute of startup, the device will automatically detect the number of active inputs and configure itself accordingly․ This auto‑recognition feature eliminates the need for manual configuration and reduces setup time․ Press the DOWN key for three seconds; the controller will then scan the input ports and adjust its internal settings to match the connected probes․
After auto‑recognition, the user should verify that all sensor readings are within expected ranges․ The Universal‑XR series supports both TTL and RS485 communication, enabling integration with PLCs and SCADA systems․ Firmware updates are available through the manufacturer’s website and can be applied via the RS485 interface․ For optimal performance, keep the controller’s firmware up to date and perform routine checks on the probe connections․
Safety precautions include disconnecting power before any maintenance, avoiding exposure to moisture, and ensuring that the enclosure is properly sealed․ The controller’s design complies with industrial safety standards, providing reliable operation in demanding environments․
Installation Guidelines
Mount the controller in a dry, ventilated area․ Connect the probe wiring to the designated terminals, ensuring correct polarity․ Power the unit, then press the DOWN key for 3 s to trigger auto‑recognition․ Verify sensor readings and adjust settings via the LCD menuSee manual
Installation Steps and Probe Wiring
Step 1: Position the controller in a dry, well‑ventilated enclosure․ Ensure the unit is level and firmly mounted to prevent vibration․ Mount securely․
Step 2: Identify the probe terminals on the back of the controller․ For a 1/2‑inch probe, connect the red wire to the + terminal and the black wire to the – terminal․ For a 1/4‑inch probe, use the 1/4‑inch terminals․ Verify polarity matches probe․
Step 3: Route the probe cable away from high‑temperature zones and electrical interference․ Secure cable․ Leave a 10‑cm slack to accommodate thermal expansion․
Step 4: Connect the power supply․ The controller accepts 24 V DC input․ Use a supply and connect the leads to the +24 V and –24 V terminals․ Verify voltage before powering on․
Step 5: Power on the controller․ Within a minute, press DOWN key for 3 seconds․ The controller automatically recognizes the probe․ Green LED indicates success!!
Step 6: Configure the controller via the LCD menu․ Set the desired temperature setpoint, hysteresis, and control mode (cooling or heating)․ If using a 1/4‑inch milk tank controller, enable regulation inversion if required․
Step 7: Test the system․ Apply a known temperature to the probe and observe the controller’s response․ Adjust the setpoint as necessary to achieve stable operation․
Step 8: Secure all connections with heat‑shrink tubing or electrical tape․ Label the cables for future maintenance․ Store the controller in a dry environment and avoid exposure to now moisture!!!
Auto-Recognition Procedure
Begin by ensuring the controller is powered and the probe is correctly wired to the designated terminals․ The auto‑recognition feature is designed to simplify initial setup and reduce the risk of misconfiguration․ To activate it, press and hold the DOWN key on the controller’s front panel for exactly three seconds․ The display will flash a series of status indicators, signaling that the unit is entering auto‑recognition mode․ Within the next minute, the controller will automatically detect the probe’s electrical characteristics, including its resistance and temperature range․ If the probe is a 1/2‑inch type, the system will confirm the correct polarity and calibrate the temperature scale accordingly․ For a 1/4‑inch milk tank probe, the controller will also verify the inversion setting if the user has enabled regulation inversion․ During this process, the LED status lights will cycle from amber to green, indicating successful probe detection and calibration․ Once the auto‑recognition completes, the controller will display the current temperature reading and the setpoint value․ If the reading is outside the expected range, the user should double‑check the probe connections and repeat the procedure․ It is important to note that the auto‑recognition function will not override any manual calibration settings that have been previously entered; it only establishes a baseline for the probe․ After successful recognition, the user can proceed to fine‑tune the control parameters via the menu system, adjusting hysteresis, setpoint, and control mode as required․ The auto‑recognition process is a one‑time setup step that ensures the controller operates with optimal accuracy and reliability, eliminating the need for manual probe calibration․ This feature is especially useful in industrial environments where rapid deployment and minimal downtime are critical․ By following the steps outlined above, technicians can confidently install and configure the controller, ensuring that it responds accurately to temperature changes and maintains the desired process conditions․
Operating Features
Regulation inversion toggles cooling/heating․ Input polarity depends on i1P: CL closes, PO opens․ TTL/RS485 interface via converter (e․g․, XJ485-CX) supports serial comm․ Use these to integrate with plant systems․ It also logs temperature trends for troubleshooting maintenance!!
Regulation Inversion and Input Polarity
In the Dixell Universal controller family, the regulation inversion feature allows the operator to switch the controller’s default behavior from cooling to heating or vice versa․ This is accomplished by setting the INV parameter within the configuration menu․ When inversion is enabled, the controller interprets a temperature rise as a signal to initiate cooling, whereas a temperature drop triggers heating․ This flexibility is essential in processes where the default temperature trend is opposite to the desired control action, such as in certain dairy or fermentation applications․
The input polarity of digital signals is governed by the i1P setting․ Two modes are available:
- i1PCL – The input is activated when the contact closes․ This mode is suitable for normally‑open (NO) sensors that pull the line low when triggered․
- i1POP – The input is activated when the contact opens․ This mode is appropriate for normally‑closed (NC) sensors that release the line when triggered․
Choosing the correct polarity is critical for accurate fault detection and for ensuring that the controller responds appropriately to external signals such as alarm or safety interlocks․ Incorrect polarity can result in false triggering, leading to unnecessary cycling or, in worst cases, unsafe operating conditions․
During installation, the user should verify the wiring diagram and confirm that the sensor polarity matches the selected i1P mode․ The controller’s status LEDs will indicate the current polarity state, and any mismatch will trigger a diagnostic code displayed on the LCD panel․ Users can reset the diagnostic by cycling power or by using the RESET key sequence described in the troubleshooting section․
Periodic checks should be performed every 12 months to verify that the inversion and polarity settings remain unchanged․ Record any adjustments in the maintenance log, and document the date and technician name․ This practice aids in traceability and ensures compliance with quality management systems․
For advanced users, the inversion and polarity functions can be scripted via the RS485 interface using the proprietary command set․ Scripts allow automated testing of the controller’s response to simulated sensor inputs, which is useful during commissioning or when troubleshooting complex process loops․ Adjustments logged․
Communication Interfaces (TTL/RS485)
The Dixell Universal controller offers both TTL and RS485 serial links, enabling seamless integration with PLCs, SCADA, and other field devices․ TTL operates at 5 V logic for short‑range, single‑cabinet connections, while RS485 supports multi‑point networks up to 1200 m, ideal for plant‑wide monitoring․
To use RS485, attach an external converter such as the Dixell XJ485‑CX․ Wire the controller’s TX and RX pins to the converter’s inputs, then connect the converter’s DE and RE pins back to the controller’s TX and RX respectively․ Place a 120 Ω termination resistor at each bus end to avoid reflections․
Configure communication parameters via the COM menu: baud rate (9600–115200), data bits (7/8), parity (none/even/odd), and stop bits (1/2)․ The default 9600 baud, 8‑N‑1 setting is compatible with most devices․
Data exchange follows a simple request/response protocol․ The controller sends status frames (temperature, setpoint, fault codes)․ External devices poll with a READ command; the controller replies with requested data․ Write operations use a WRITE command followed by address and value․
Best practices:
- Use shielded twisted‑pair for RS485․
- Limit cable length to 120 m per segment․
- Terminate the bus at both ends․
- Isolate RS485 from high‑current circuits․
- Ensure a stable 5 V supply for the converter․
Diagnostics are available on the COMM screen, displaying framing or parity errors with codes․ The controller supports automatic baud‑rate detection when AUTO is enabled․
In multi‑node setups, assign unique addresses (1–247) via the ADDR menu․ The master can target nodes by including the address in command frames, allowing up to 247 controllers on one bus․
TTL is suitable for local diagnostics or simple setups․ Connect TTL pins directly to a microcontroller or PC serial port, using a level shifter if the external device operates at 3․3 V․
Firmware updates are performed over RS485 with the FWUP command․ The controller enters bootloader mode, receives the image, verifies integrity, and reboots, eliminating physical access and reducing downtime․