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PRECISION DIGITAL PROVU PD6210 Instruction Manual

Analog input batch controller
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Instruction Manual
 0-20 mA, 4-20 mA, 0-5 V, 1-5 V, and ±10 V Inputs
 Isolated 24 VDC @ 200 mA Transmitter Power Supply
 Start, batch, pause, & stop with front panel buttons
 Display batch total + rate, grand total, batch count or preset
 Single or multi-stage batching with up to 8 relays
 Automatic overflow protection
 Manual control or automatic batching
 Dual-Line Display
 NEMA 4X and IP65 Rated Front Panel
 UL Listed & CE Marked
 Display Features 0.6" & 0.46" Digits
 Six Full Digits on Each Line
 Optional Superluminous Sunlight Readable Display
 Free USB Programming Software & Cable
 2 or 4 Relays + Isolated 4-20 mA Output Options
 External 4-Relay & Digital I/O Expansion Modules
 Universal 85-265 VAC, or 12-24 VDC Input Power Models
 Isolated 24 VDC @ 200 mA Transmitter Power Supply
 Modbus® RTU Communication Protocol Standard
PRECISION DIGITAL CORPORATION
233 South Street • Hopkinton MA 01748 USA
Tel (800) 343-1001 • Fax (508) 655-8990
PD6210 Analog Input Batch Controller
USB Install
Batch Controller
Order from:
C A Briggs Company
622 Mary Street; Suite 101
Warminster, PA 18974
Phone: 267-673-8117 - 800-352-6265
Fax: 267-673-8118
Sales@cabriggs.com - www.cabriggs.com
www.predig.com

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Summary of Contents for PRECISION DIGITAL PROVU PD6210

  • Page 1  Universal 85-265 VAC, or 12-24 VDC Input Power Models  Isolated 24 VDC @ 200 mA Transmitter Power Supply  Modbus® RTU Communication Protocol Standard PRECISION DIGITAL CORPORATION 233 South Street • Hopkinton MA 01748 USA Tel (800) 343-1001 • Fax (508) 655-8990...
  • Page 2 Precision Digital Corporation warrants this product against defects in material or workmanship for the specified period under “Specifications” from the date of shipment from the factory. Precision Digital’s liability under this limited warranty shall not exceed the purchase value, repair, or replacement of the defective unit.

  • Page 3: Table Of Contents

    PD6210 Analog Input Batch Controller Instruction Manual Table of Contents Relay Assignment (Assign) ---------------------------- 32 Table of Contents ----------------------------------------- 3 Setting the Relay Action --------------------------------- 32 Table of Figures ------------------------------------------- 3 Setting Batch Control Relays --------------------------- 32 Introduction ------------------------------------------------- 4 Programming Alarm Set and Reset Points --------- 33 Ordering Information ------------------------------------ 5 Setting Fail-Safe Operation ----------------------------- 33...

  • Page 4: Table Of Figures

    PD6210 Analog Input Batch Controller Instruction Manual Table of Figures Figure 1: 1/8 DIN Panel Mounting ...... 10 Figure 9: Voltage Input Connections ....13 Figure 2: Controller Dimensions - Side View ... 11 Figure 10: Relay Connections ......14 Figure 3: Controller Dimensions - Top View ..

  • Page 5: Ordering Information

    PD6210 Analog Input Batch Controller Instruction Manual Ordering Information Standard Models 85-265 VAC Model 12-24 VDC Model Options Installed PD6210-6R2 PD6210-7R2 2 relays (PD1102*) PD6210-6R4 PD6210-7R4 4 relays (PD1104*) PD6210-6R5 PD6210-7R5 2 relays & 4-20 mA output (PD1105*) PD6210-6R7 PD6210-7R7 4 relays &...

  • Page 6: Specifications

    PD6210 Analog Input Batch Controller Instruction Manual Specifications Except where noted all specifications apply to operation at +25°C. Power 85-265 VAC 50/60 Hz, 90-265 VDC, 20 W General max or 12-24 VDC  10%, 15 W max Options Display Line 1: 0.6" (15 mm) high, red LEDs Powered over USB for configuration only Line 2: 0.46"...

  • Page 7: Batch Controller Rate/Totalizer Display

    PD6210 Analog Input Batch Controller Instruction Manual Programmabl 1.0001 to 2.9999 Grand Total Via front panel button, external contact e Exponent Reset closure on digital inputs, automatically via user selectable preset value and time delay, Low-Flow 0-999999 (0 disables cutoff function) or through serial communications.

  • Page 8: Isolated 4-20 Ma Transmitter Output

    PD6210 Analog Input Batch Controller Instruction Manual ® Modbus RTU Serial Communications Fail-Safe Programmable and independent for each Operation relay. 1 – 247 (Controller address) Slave Id Note: Relay coil is energized in non-alarm condition. Baud Rate 300 - 19,200 bps In case of power failure, relay will go Transmit Programmable between 0 and 199 ms...

  • Page 9: Compliance Information

    PD6210 Analog Input Batch Controller Instruction Manual Compliance Information Safety UL & c-UL Listed USA & Canada UL 508 Industrial Control Equipment UL File Number E160849 UL Type 4X, NEMA 4X, IP65; panel gasket provided Front Panel Low Voltage EN 61010-1:2010 Directive Safety requirements for measurement, control, and laboratory use Electromagnetic Compatibility...

  • Page 10: Safety Information

    PD6210 Analog Input Batch Controller Instruction Manual Safety Information CAUTION: Read complete WARNING: Risk of electric shock instructions prior to installation and or personal injury. operation of the controller. Hazardous voltages exist within enclosure. Installation and service should be performed only by trained service personnel.

  • Page 11: Mounting Dimensions

    PD6210 Analog Input Batch Controller Instruction Manual Mounting Dimensions Figure 2: Controller Dimensions - Side Figure 3: Controller Dimensions - Top View View Transmitter Supply Voltage Selection (P+, P-) All controllers, including models equipped with the 12-24 VDC power option, are shipped from the factory configured to provide 24 VDC power for the transmitter or sensor.

  • Page 12: Connections

    PD6210 Analog Input Batch Controller Instruction Manual Connections All connections are made to removable screw terminal connectors located at the rear of the controller. Use copper wire with 60°C or 60/75°C insulation for all line voltage connections. Observe all safety regulations. Electrical wiring should be performed in accordance with all applicable national, state, and local codes to prevent damage to the Caution!

  • Page 13: Signal Connections

    PD6210 Analog Input Batch Controller Instruction Manual Signal Connections Signal connections are made to a six-terminal connector labeled SIGNAL on Figure 6. The COM (common) terminal is the return for the 4-20 mA and the 10 V input signals. Current and Voltage Connections The following figures show examples of current and voltage connections.

  • Page 14: Modbus Rtu Serial Communications

    PD6210 Analog Input Batch Controller Instruction Manual Modbus RTU Serial Communications Serial communications connection is made to an RJ45 connector labeled M-LINK on Figure 7. Use the PDA1232 for RS-232 interfacing, or the PDA1485 for RS-485 interfacing. The same port is used for interfacing with all expansion modules (e.g.

  • Page 15: F4 Digital Input Connections

    PD6210 Analog Input Batch Controller Instruction Manual RC Networks Available from Precision Digital RC networks are available from Precision Digital and should be applied to each relay contact switching an inductive load. Part number: PDX6901. Note: Relays are de-rated to 1/14th HP (50 watts) with an inductive load.

  • Page 16: External Relay & Digital I/O Connections

    PD6210 Analog Input Batch Controller Instruction Manual External Relay & Digital I/O Connections The relay and the digital I/O expansion modules PDA1004 & PDA1044 are connected to the controller using a CAT5 cable provided with each module. The two RJ45 connectors on the expansion modules are identical and interchangeable;...

  • Page 17: Basic Operation And Programming

    PD6210 Analog Input Batch Controller Instruction Manual Basic Operation and Programming The PD6210 is factory calibrated prior to shipment to read in milliamps and volts depending on the input selection. The calibration equipment is certified to NIST standards. Overview Most setup and programming is done through the front panel buttons. Jumper J4 located inside the controller, behind the input signal connector, is used to select the excitation voltage (24 V [Default Setting], 10 V or 5 V) which is supplied to the P+ and P- wiring terminals.

  • Page 18: Controller Operation

    PD6210 Analog Input Batch Controller Instruction Manual Controller Operation The PD6210 controller is capable of accepting current (0-20 mA, 4-20 mA) and voltage signals (0-5 V, 1-5 V, 0-10 V,  10 V). These signals are scaled to represent rate in engineering units from -99999 to 999999. The default configuration displays batch total on the upper display, and a selection of rate, grand total, batch count, and preset on the lower display.

  • Page 19: Batch Control Operation Example

    PD6210 Analog Input Batch Controller Instruction Manual Batch Control Operation Example The following example shows how two stage batch control functions with a PD6210. This setup will establish a 55 gallon preset for the batch, with a main valve (high flow) that will close at 50 gallons, and a trickle valve (low or restricted flow) that will close at 55 gallons.
  • Page 20 PD6210 Analog Input Batch Controller Instruction Manual...

  • Page 21: Meterview Pro Software

    PD6210 Analog Input Batch Controller Instruction Manual ® MeterView Pro Software The meter can also be programmed using the PC-based MeterView Pro software included with the meter. This software can be installed on any Microsoft® Windows® (XP/Vista/7/8/10) computer by connecting the meter’s onboard USB.

  • Page 22: Display Functions And Messages

    PD6210 Analog Input Batch Controller Instruction Manual Display Functions and Messages The controller displays various functions and messages during setup, programming, and operation. The following table shows the main menu functions and messages in the order they appear in the menu. Display Parameter Action/Setting...
  • Page 23 PD6210 Analog Input Batch Controller Instruction Manual Display Parameter Action/Setting Display Parameter Action/Setting Description Description Altern Out 1 Alternate Set relay for pump Output 1 Program output 1 value alternation control (relays (e.g. 4.000 mA) assigned to rate) Dis 2 Program display 2 value Display 2 Sampl...

  • Page 24: Setting Numeric Values

    PD6210 Analog Input Batch Controller Instruction Manual Main Menu Map The main menu consists of the most commonly used functions: Setup, Reset, Control, and Password.  Press Menu button when a batch is not running to enter Programming Mode then press the Up arrow button to scroll main menu.

  • Page 25: Setting Up The Batch Controller (Setup)

    PD6210 Analog Input Batch Controller Instruction Manual Setting Up the Batch Controller (setup) The Setup menu is used to select: 1. Input signal the controller will accept 2. Enable or disable totalizer and batching features 3. Select the display units/tags 4.

  • Page 26: Scaling And Calibration

    PD6210 Analog Input Batch Controller Instruction Manual Scaling and Calibration It is very important to read the following information, before proceeding to program the controller:  There is no need to recalibrate the controller when first received from the factory. ...

  • Page 27: Programming The Batch Controller (Prog)

    PD6210 Analog Input Batch Controller Instruction Manual Programming the Batch Controller (prog) It is very important to read the following information, before proceeding to program the controller:  The PD6210 is factory calibrated prior to shipment to read in milliamps and volts depending on the input selection.
  • Page 28 PD6210 Analog Input Batch Controller Instruction Manual Scaling the Controller (SCALE) The process inputs (4-20 mA and 10 VDC) and frequency inputs can be scaled to display the process variable in engineering units. A signal source is not needed to scale the controller; simply program the inputs and corresponding display values.

  • Page 29: Batch Start Mode (Mode)

    PD6210 Analog Input Batch Controller Instruction Manual Time Base, Total Conversion Factor & Total Reset The time base, total conversion factor, and total reset menus are located in the Program menu. The total and grand total have their own independent settings. This means that one can be displaying the value in gallons while the other displays in million gallons, liters, m , etc.

  • Page 30: Setting The Display Parameter & Intensity (Dsplay)

    PD6210 Analog Input Batch Controller Instruction Manual Setting the Display Parameter & Intensity (dsplay) Display line 1 (line 1) can be programmed to display: 1. Display total 2. Display grand total 3. Toggle rate and total 4. Toggle rate and grand total 5.

  • Page 31: Setting The Relay Operation (Relay)

    PD6210 Analog Input Batch Controller Instruction Manual Setting the Relay Operation (relay) This menu is used to set up the operation of the relays. During setup, the relays do not follow the input and they will remain in the state found prior to entering the Relay menu.

  • Page 32: Relay Assignment (Assign)

    PD6210 Analog Input Batch Controller Instruction Manual Relay Assignment (Assign) The relays can be assigned to any of the following parameters: 1. Rate for low or high alarm indication 2. Total for batch control relays 3. Grand total for alarm indication Assign preclose if multiple relays are assigned.

  • Page 33: Programming Alarm Set And Reset Points

    PD6210 Analog Input Batch Controller Instruction Manual Programming Alarm Set and Reset Points High alarm indication: program set point above reset point. Low alarm indication: program set point below reset point. The deadband is determined by the difference between set and reset points. Minimum deadband is one display count.

  • Page 34: Relay Operation Details

    PD6210 Analog Input Batch Controller Instruction Manual Relay Operation Details Overview The relays of the controller can serve three roles, as batch control relays for single or multi-stage batching, as rate, or grand total alarm, or as a sampling relay based on grand total or rate alarm. These capabilities include front panel alarm status LEDs and 2 or 4 internal relays and/or 4 external relays expansion module.

  • Page 35: Automatic Reset (Auto)

    PD6210 Analog Input Batch Controller Instruction Manual Automatic Reset (Auto) Automatic reset only In this application, the controller is set up for automatic reset Condition Relay (non-latching relay). Acknowledging the alarm while it is still Normal present has no effect on either the LED or the relay. When the Alarm alarm finally goes away, the relay automatically resets and the Ack (No effect)

  • Page 36: Sample Relay Operation

    PD6210 Analog Input Batch Controller Instruction Manual Sample Relay Operation The sampling function allows the operator to set a set point for a “sampling” relay. This can be done for the rate, total, or grand total. Each time the relay reaches the set point, it will close that relay’s contacts for a programmed period of time A rate sampling relay will activate for the sample time (sam t), up to 600.0 seconds, every time the set point rate is reached.

  • Page 37: Rate Relay Sampling Operation

    PD6210 Analog Input Batch Controller Instruction Manual Rate Relay Sampling Operation When the signal crosses the set point, the relay trips and the sample time starts. After the sample time has elapsed, the relay resets. The cycle repeats every time the set point is crossed, going up for high alarms and going down for low alarms.

  • Page 38: Time Delay Operation

    PD6210 Analog Input Batch Controller Instruction Manual Time Delay Operation The following graphs show the operation of the time delay function. When the signal crosses the set point, the On time delay timer starts and the relay trips when the time delay has elapsed.

  • Page 39: Reset Menu (Reset)

    PD6210 Analog Input Batch Controller Instruction Manual Reset Menu (reset) The Reset menu is used to reset the total, grand totals, batch count, maximum, or minimum reading (peak or valley) reached by the process; both maximum and minimum may be reset at the same time by selecting “reset high &...

  • Page 40: Grand Total Reset Password & Non-Resettable Total

    PD6210 Analog Input Batch Controller Instruction Manual Grand Total Reset Password & Non-Resettable Total The grand total can be password-protected to prevent unauthorized total resets. The grand total can be programmed as a non-resettable total by entering the password “050873”. Once the Grand Total has been programmed as “non-resettable”...

  • Page 41: Advanced Operation And Programming

    PD6210 Analog Input Batch Controller Instruction Manual Advanced Operation and Programming In addition to the functions described in Controller Operation on page 18, the following advanced operation and display features may be programmed. Configuring these features may disable some default batch controller features, or make running a batch operation impossible. These functions should only be used by users who are sure of their need in their application.

  • Page 42: Advanced Features Menu & Display Messages

    PD6210 Analog Input Batch Controller Instruction Manual Advanced Features Menu & Display Messages The following table shows the functions and messages of the Advanced Features menu in the order they appear in the menu. Display Parameter Action/Setting Display Parameter Action/Setting Douwn Lo G Down...
  • Page 43 PD6210 Analog Input Batch Controller Instruction Manual Display Parameter Action/Setting Display Parameter Action/Setting C Hi F4 function Assign F4 function Current Calibrate high current (digital input) high input (e.g. 20 mA) Assign digital input 1 – 8, dI I Digital input v CAL Voltage Calibrating voltage input...

  • Page 44: Function Keys Operation

    PD6210 Analog Input Batch Controller Instruction Manual Function Keys Operation During operation, the programmable function keys operate according to the way they have been programmed in the Advanced Features – User menu. The following table shows the default setting for each of the function keys.

  • Page 45: Noise Filter (Filter)

    RS-232, or RS-485 option is required; see Ordering Information on page 5 for details. Do not connect any equipment other than Precision Digital’s expansion modules, cables, or controllers to the RJ45 M-LINK connector.

  • Page 46: Select Menu (Select)

    PD6210 Analog Input Batch Controller Instruction Manual Select Menu (SElEct) The Select menu is used to select the signal input conditioning applied to the input (linear, square root, or programmable exponent, low-flow cutoff, and analog output programming. The multi-point linearization is part of the linear function selection.
  • Page 47 PD6210 Analog Input Batch Controller Instruction Manual Total and Grand Total Count Direction (Count) By default, the batch total and grand total count up during batch processes. Count parameter allows this to change. When set to count down, the batch total will count down from the preset to 0. When set to count down, the grand total will count down from a set value to zero.

  • Page 48: Programmable Function Keys User Menu (User)

    PD6210 Analog Input Batch Controller Instruction Manual Programmable Function Keys User Menu (user) Changing the programming of the F1-F3 function keys will disable the default batch operation of these keys, and is not recommended for batch control applications. The User menu allows the user to assign the front panel function keys F1, F2, and F3, the digital input F4 (a digital input located on the signal input connector), and up to eight additional digital inputs to access most of the menus or to activate certain functions immediately (e.g.

  • Page 49: Internal Source Calibration (Ical)

    PD6210 Analog Input Batch Controller Instruction Manual Internal Source Calibration (ICAL) Note: The PD6210 is factory calibrated prior to shipment to read in milliamps and volts depending on the input selection. The calibration equipment is certified to NIST standards. The use of a calibrated signal source is necessary to calibrate the internal source of the meter. The meter’s internal source is what allows the user to scale the meter without applying a signal.

  • Page 50: Troubleshooting

    PD6210 Analog Input Batch Controller Instruction Manual Troubleshooting Due to the many features and functions of the controller, it’s possible that the setup of the controller does not agree with what an operator expects to see. If the controller is not working as expected, refer to the Diagnostics menu and recommendations below. Diagnostics Menu (diag) The Diagnostics menu is located in the Advanced Features menu, to access Diagnostics menu see Advanced Operation and Programming, page 41.

  • Page 51: Factory Defaults & User Settings

    PD6210 Analog Input Batch Controller Instruction Manual Factory Defaults & User Settings The following table shows the factory setting for the major programmable parameters on the controller. Parameter Display Default Setting Parameter Display Default Setting Input Relay 1 Input type 4-20 mA Act 1 Automatic...
  • Page 52 PD6210 Analog Input Batch Controller Instruction Manual Parameter Display Default Setting Parameter Display Default Setting baud Loop break Baud rate 9600 ignore Ignore relay 3 Transmit Tr dly 50 ms Loop break delay ignore Ignore relay 4 Parity Parity Even Display 1 Byte-to-byte Dis 1...

  • Page 53: Troubleshooting Tips

    PD6210 Analog Input Batch Controller Instruction Manual Troubleshooting Tips Symptom Check/Action Check power at power connector No display at all Controller is password-protected, enter correct six-digit password Not able to change setup or to unlock programming, Locd is displayed Check: Controller displays error 1.
  • Page 54 PD6210 Analog Input Batch Controller Instruction Manual This Page Intentionally Left Blank...

  • Page 55: Eu Declaration Of Conformity

    EN 55022:2010, EN 61000-6-2:2005, EN 61010-1:2010, and EN 61326:2013 and there were no major technical changes affecting the latest technical knowledge for the products listed above. Product Markings: Signed for and on behalf of Precision Digital Corporation: Name: Jeffrey Peters Company:...
  • Page 56 PD6210 Analog Input Batch Controller Instruction Manual How to Contact Precision Digital  For Technical Support please Call: (800) 610-5239 or (508) 655-7300 Fax: (508) 655-8990 Email: support@predig.com  For Sales Support or to place an order please contact your local distributor or...

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