PC500 Chemical Controller
PC500 Chemical Controller

The PC500 system is a rugged microprocessor based control system designed for use in an industrial environment.  The system is rated to IP65 and all exposed parts are chemically resistant.

The scalability and flexibility of the system means that it can be used for a wide range of applications including:

  • Controlling chemical concentrations in metal cleaning, phosphating & treatment plants.
  • Acctive™ software for control of accelerator in Zinc Phosphating processes
  • Totalising liquid flow in water treatment plants.
  • Monitoring and analysing waste water contamination and flow for environmental reports.
  • Monitoring levels in bulk storage systems.

The control panel has a large touch-sensitive colour display giving process information in graphical format.  The display can be customised to match the layout of the plant.  A typical mimic shows process values, setpoints, pump status, operating modes and alarm conditions.  By pressing on-screen buttons, the operator can access screens to make adjustments and gain further information about a section of the process.  Trend graphs show 120-hour historical trends of measured process conditions. Chemical usage can be calculated by pump run time or flow measurement.

The system can be designed around several major PLC types, including Allen Bradley and Siemens. Depending on the PLC selection, the system can be configured with up to 32 analogue inputs.

The PC500 Display
The PC500 Display


Each control output has four operating modes - Auto, Timed, Off and Manual.

In Auto mode the system controls chemical dosing according to process conditions.  Inputs used to control dosing can be body count or measured chemical concentration. 

Timed mode is used in the event of a sensing failure.  In this mode the operator has manual control of the percentage on-time of the pump which allows control of the process to be retained. 

Off mode would be selected to monitor the chemical strength without dosing and is normally used while maintenance is being carried out on the pump. 

Selecting Manual mode causes the pump to run irrespective of process conditions and can be used to test pump operation after maintenance has been carried out.

Lineguard Compatability

The system has been designed as a replacement for ageing Lineguard-type systems and includes many features not found on older systems.


The PC500 trending screens allow a clear view of each process over a 24-hour period.  Historical data is stored enabling the operator to look back over the previous five days.  Trend data can be uploaded to a PC via RS232 and imported to a Microsoft® Excel spreadsheet or viewed using a custom-written windows application.

PC500 Trending
PC500 Trending

Alarm Handling

The PC500 has a comprehensive alarm handling system that logs both alarms and events.  The log records the occurrence, acknowledgement and clearing of the alarm.  Events such as changing a process setpoint, line stoppages and recalibration of a process value are also recorded.

Multi-language Support

The display can be created with up to 8 different languages which can be switched in real time via buttons on the touch screen.

Multiple languages are supported
Multiple languages are supported

Remote operation via a web browser
Remote operation via a web browser


The PC500 is available with DH485, DH+ or ethernet communications to permit remote interrogation and data logging.

With a standard printer connected to the RS232 port, the system can produce detailed shift reports including (but not restricted to):

  • Operator name, shift start and stop time.
  • Chemical usage and cost.
  • Stoppage time.
  • Frequency and results of manual checks.
  • Highest, lowest and average process readings.
  • System alarms with time on, time acknowledged and time off.

Sensor Technology

All of the PC500 sensing systems utilise two-wire 4-20 mA current loop transmitters for interference free signal transmission to the control panel.  Conductivity sensors are chosen to suit process conditions.  Inductive conductivity probes are used where conventional sensors may be susceptible to fouling.  Contacting conductivity probes are used in low conductivity situations, such as de-ionised water rinses.  A choice of pH sensors is available to suit a variety of process conditions.  All are rugged industrial probes that provide long and reliable service in the most demanding applications.  Fluoride measurement is achieved using an ACS industrial ion selective electrode with signal linearisation to give true ppm readout.  Other sensors are available such as redox, temperature, flow, level, & pressure.

Technical Details

110V AC, 50/60Hz, 10A typical.

Dimensions: 1200x600x300mm
Weight: 45kg typical
Ambient Temperature: 0° to 50°C
Humidity: 20% to 80% non-condensing

Analogue Inputs
4 to 32

Communication Options
DH485, DH+ or Ethernet

640x480 bright, wide angle CCFL TFT
32-bit processor
Accelerated graphics controller
200x200 resistive touchscreen


PC500 info pdf

PC500 information sheet
0.33MB pdf

Page reviewed: 18th December 2017