Adding second controller fails and states entry is already there in DB.

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-Verify that controller components  are cleanly removed and no entries there in registry or in DB.

-DB should show only one active controller.

-Find out the stale entries for other controller using below script and remove the entries.

-Now freshly add the controller.

    DECLARE @SQL VARCHAR(MAX) 
    DECLARE @SearchString VARCHAR(100) 
    SET @SQL='' 
     
    -- ------------------------------------------ 
    -- Enter the string to be searched for here : 
    -- 
    SET @SearchString='%searchstring%' 
    -- ------------------------------------------ 
     
    SELECT   @SQL = @SQL + 'SELECT CONVERT(VARCHAR(MAX),COUNT(*)) + '' matches in column ''+'''
             + C.name + '''+'' on table '' + ''' + SC.name + '.' + T.name + 
             ''' [Matches for '''+@SearchString+''':] FROM ' + 
             QUOTENAME(SC.name) + '.' + QUOTENAME(T.name) + ' WHERE ' + QUOTENAME(C.name) + 
             ' LIKE ''%' + @SearchString + 
             '%'' HAVING COUNT(*)>0 UNION ALL ' +CHAR(13) + CHAR(10) 
    FROM     sys.columns C 
    JOIN     sys.tables T 
    ON       C.object_id=T.object_id 
    JOIN     sys.schemas SC 
    ON       SC.schema_id=T.schema_id 
    JOIN     sys.types ST 
    ON       C.user_type_id=ST.user_type_id 
    JOIN     sys.types SYST 
    ON       ST.system_type_id=SYST.user_type_id 
    AND      ST.system_type_id=SYST.system_type_id 
    WHERE    SYST.name IN ('varchar','nvarchar','text','ntext','char','nchar') 
    ORDER BY T.name, C.name 
     
    -- Strip off the last UNION ALL 
    IF LEN(@SQL)>12 
      SELECT @SQL=LEFT(@SQL,LEN(@SQL)- 12) 
     
    EXEC(@SQL) 
     
    --PRINT @SQL
 

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Problem Cause

Stale entries in Database.