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PRECISION DIGITAL ProtEX-MAX PD8-6310 Instruction Manual

Explosion-proof pulse input batch controller
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ProtEX-MAX PD8-6310 Explosion-Proof
Pulse Input Batch Controller Instruction Manual
• Pulse, Open Collector, NPN, PNP, TTL, Switch Contact,
Sine Wave (Coil), Square Wave Inputs
• 5, 10, or 24 V Flowmeter Power Supply
• K-Factor, Internal Scaling, or External Calibration
• 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 4 Relays
• Automatic Overflow Protection
• Manual Control or Automatic Batching
• Modern, Sleek and Practical Enclosure
• Display Mountable at 0°, 90°, 180°, & 270° Degrees
• Explosion-Proof, IP68, NEMA 4X Enclosure
• SafeTouch
®
Through-Glass Button Programming
• Flanges for Wall or Pipe Mounting
• Superluminous Sunlight Readable Display
• Free USB Programming Software & Cable
PRECISION DIGITAL CORPORATION
233 South Street • Hopkinton MA 01748 USA
Tel (800) 343-1001 • Fax (508) 655-8990
USB Install
Batch Controller
www.predig.com

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Summary of Contents for PRECISION DIGITAL ProtEX-MAX PD8-6310

  • Page 1 ProtEX-MAX PD8-6310 Explosion-Proof Pulse Input Batch Controller Instruction Manual USB Install Batch Controller • Pulse, Open Collector, NPN, PNP, TTL, Switch Contact, Sine Wave (Coil), Square Wave Inputs • 5, 10, or 24 V Flowmeter Power Supply • K-Factor, Internal Scaling, or External Calibration •...
  • 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

    ProtEX-MAX PD8-6310 Explosion-Proof Pulse Input Batch Controller Instruction Manual Table of Contents Input Calibration Method (InCAL) ------------------ 33 Table of Contents ----------------------------------------- 3 K-Factor Calibration (Factor) ---------------------- 33 Table of Figures ------------------------------------------- 4 Scaling the Controller (SCALE) ---------------------- 34 Introduction ------------------------------------------------- 4 Time Base, Total Conversion Factor &...

  • Page 4: Table Of Figures

    Section View ............60 Introduction The ProtEX-MAX PD8-6310 offers all the functionality of the ProVu PD6310 as a fully FM, CSA, ATEX, and IECEx approved explosion-proof product. It is a pulse input (NPN, PNP, TTL, switch contact, sine wave, etc.) digital batch controller specifically designed for single and multi-stage batching applications.

  • Page 5: Ordering Information

    ProtEX-MAX PD8-6310 Explosion-Proof Pulse Input Batch Controller Instruction Manual Ordering Information SunBright Display Models 85-265 VAC Model 12-24 VDC Model Options Installed PD8-6310-6H7 PD8-6310-7H7 4 relays & 4-20 mA output WARNING - Cancer and Reproductive Harm - www.P65Warnings.ca.gov Accessories Model...

  • Page 6: Pulse Input

    ProtEX-MAX PD8-6310 Explosion-Proof Pulse Input Batch Controller Instruction Manual Environmental T6 Class operating temperature range Ta = Calibration May be calibrated using K-factor, internal -40 to 60°C calibration, or by applying an external calibration signal. T5 Class operating temperature range Ta = -40 to 65°C...

  • Page 7: Relays

    ProtEX-MAX PD8-6310 Explosion-Proof Pulse Input Batch Controller Instruction Manual 1. Automatic reset only (non-latching), Programmabl 0.1 and 999.9 seconds; applied to the first when the input passes the reset point e Delay on relay assigned or total is reset to zero.

  • Page 8: Serial Communications

    ProtEX-MAX PD8-6310 Explosion-Proof Pulse Input Batch Controller Instruction Manual Serial Communications Digital Inputs & Outputs Channels 4 digital inputs & 4 digital outputs Compatibility EIA-485 Digital Input 3 to 5 VDC Connectors Removable screw terminal connector Logic High Max Distance 3,937' (1,200 m) max Digital Input 0 to 1.25 VDC...

  • Page 9: Product Ratings And Approvals

    ProtEX-MAX PD8-6310 Explosion-Proof Pulse Input Batch Controller Instruction Manual Product Ratings and Approvals; Enclosure: Type 4X; IP66 Class I, Division 1, Groups B, C, D Class II, Division 1, Groups E, F, G Class III, Division 1, T5/T6 Class I, Zone 1, AEx d, IIC Gb T5/T6 Zone 21, AEx tb IIIC T90°C;...

  • Page 10: Compliance Information

    ProtEX-MAX PD8-6310 Explosion-Proof Pulse Input Batch Controller Instruction Manual Compliance Information Safety UL & c-UL Listed USA & Canada UL 508 Industrial Control Equipment UL File Number E160849 Front Panel UL Type 4X, NEMA 4X, IP65; panel gasket provided Low Voltage...

  • Page 11: Safety Information

    ProtEX-MAX PD8-6310 Explosion-Proof Pulse Input Batch Controller Instruction Manual Safety Information WARNINGS • Read complete instructions prior to installation and operation of the instrument. • Installation and service should be performed only by trained service personnel. Service requiring replacement of internal sub-components must be performed at the factory.

  • Page 12: Pre-Installed Conduit/Stopping Plug

    ProtEX-MAX PD8-6310 Explosion-Proof Pulse Input Batch Controller Instruction Manual Pre-Installed Conduit/Stopping Plug The PD8-6000 is supplied with two pre-installed conduit plugs for installations that do not require the use of all conduit entries. The conduit/stopping plugs include an internal 12mm hexagonal socket recess for removal.

  • Page 13: Connections

    ProtEX-MAX PD8-6310 Explosion-Proof Pulse Input Batch Controller Instruction Manual Connections • Static electricity can damage sensitive components. • Observe safe handling precautions for static-sensitive components. • Use proper grounding procedures/codes. • If the instrument is installed in a high voltage environment and a...

  • Page 14: Connectors Labeling

    ProtEX-MAX PD8-6310 Explosion-Proof Pulse Input Batch Controller Instruction Manual Connectors Labeling The connectors’ label, affixed to the controller, shows the location of all connectors available with requested configuration. Do not connect any equipment other than Precision Digital’s expansion modules, cables, or controllers to the RJ45 M-LINK connector.

  • Page 15: Pulse Signal Connections

    ProtEX-MAX PD8-6310 Explosion-Proof Pulse Input Batch Controller Instruction Manual Pulse Signal Connections Signal connections are made to a six-terminal connector labeled SIGNAL on Figure 7. The COM (common) terminal is the return for the input signals. The following figures show examples of signal connections.

  • Page 16: Three Wire Connections

    ProtEX-MAX PD8-6310 Explosion-Proof Pulse Input Batch Controller Instruction Manual Three Wire Connections In order to wire the 5 pins for use as a 3-wire half-duplex RS-485 connection, it is necessary to create a jumper connection between DI – DO and DI- – DO- as shown below.

  • Page 17: Using Pro Vu U Serial Adapters

    ProtEX-MAX PD8-6310 Explosion-Proof Pulse Input Batch Controller Instruction Manual Figure 14: RS-485 Two-Wire Multi-Drop Wiring Notes: 1. Termination resistors are optional and values depend on the cable length and characteristic im- pedance. Consult the cable manufacturer for recommendations. 2. Refer to RS-232 to RS-485 Converter documentation for further details.

  • Page 18: Relay Connections

    Figure 17: Low Voltage DC Loads Protection 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 19: F4 Digital Input Connections

    ProtEX-MAX PD8-6310 Explosion-Proof Pulse Input Batch Controller Instruction Manual F4 Digital Input Connections A digital input, F4, is standard on the meter. This digital input connected with a normally open closure across F4 and COM, or with an active low signal applied to F4.

  • Page 20: Digital I/O Connections

    ProtEX-MAX PD8-6310 Explosion-Proof Pulse Input Batch Controller Instruction Manual Digital I/O Connections The ProtEX-MAX has a 10 position terminal block for connecting digital inputs and outputs. DI 1-4 DO 1-4 5 VDC Figure 21: Digital I/O Connections The onboard digital inputs (1-4) are configured at the factory to function identically to the front panel pushbuttons (Menu, F1, F2, &...

  • Page 21: Basic Operation And Programming

    ProtEX-MAX PD8-6310 Explosion-Proof Pulse Input Batch Controller Instruction Manual Basic Operation and Programming The PD8-6310 has been factory calibrated to read input frequency in Hz (pulses/sec). The calibration equipment is traceable to NIST standards. Overview Setup and programming may be done through the infrared through-glass SafeTouch buttons, or using the mechanical buttons when uncovered.

  • Page 22: Front Buttons And Status Led Indicators

    ProtEX-MAX PD8-6310 Explosion-Proof Pulse Input Batch Controller Instruction Manual Front Buttons and Status LED Indicators Button Symbol Description Status Relay 1 – 8 indicators Menu START Rate indicator (Right arrow/F1) BATCH Batch Total indicator (Up arrow/F2) STOP Grand Total indicator...

  • Page 23: Controller Operation

    ProtEX-MAX PD8-6310 Explosion-Proof Pulse Input Batch Controller Instruction Manual Controller Operation The PD8-6310 accepts pulses (e.g. ±40mV to ± 8V), square wave (0-5, 0-12V, or 0-24V), open collector NPN, PNP, TTL, or switch contact signals. These signals are scaled to represent rate in engineering units from -99999 to 999999. They may be scaled with a K-factor to represent a total for the batch, and grand total.

  • Page 24: Batch Control Operation Example

    ProtEX-MAX PD8-6310 Explosion-Proof Pulse Input Batch Controller Instruction Manual Batch Control Operation Example The following example shows how two stage batch control functions with a PD8-6310. 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 25 ProtEX-MAX PD8-6310 Explosion-Proof Pulse Input Batch Controller Instruction Manual...

  • Page 26: Meterview Pro Software

    ProtEX-MAX PD8-6310 Explosion-Proof Pulse 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 27: Display Functions And Messages

    ProtEX-MAX PD8-6310 Explosion-Proof Pulse 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.
  • Page 28 ProtEX-MAX PD8-6310 Explosion-Proof Pulse Input Batch Controller Instruction Manual Display Parameter Action/Setting Display Parameter Action/Setting Description Description Lt-CLr Out 1 Latching- Set relay for latching Output 1 Program output 1 value cleared operation with manual reset (e.g. 4.000 mA) only after alarm condition...

  • Page 29: Setting Numeric Values

    ProtEX-MAX PD8-6310 Explosion-Proof Pulse 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 30: Setting Up The Batch Controller (Setup)

    ProtEX-MAX PD8-6310 Explosion-Proof Pulse 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 31: Scaling And Calibration

    ProtEX-MAX PD8-6310 Explosion-Proof Pulse 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 32: Setting The Decimal Point (Dec Pt)

    ProtEX-MAX PD8-6310 Explosion-Proof Pulse Input Batch Controller Instruction Manual Setting the Decimal Point (dEc pt) The decimal point may be set with up to five decimal places or with no decimal point at all. The rate, total, and grand total decimal points are independent.

  • Page 33: Input Calibration Method (Incal)

    ProtEX-MAX PD8-6310 Explosion-Proof Pulse Input Batch Controller Instruction Manual Input Calibration Method (InCAL) There are three methods of calibrating (or scaling) the display to show the correct engineering units. • Use the Factor menu to enter a K-Factor. (Pulse input models only.) •...

  • Page 34: Scaling The Controller (Scale)

    ProtEX-MAX PD8-6310 Explosion-Proof Pulse 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 35: Batch Start Mode (Mode)

    ProtEX-MAX PD8-6310 Explosion-Proof Pulse Input Batch Controller Instruction Manual Batch Start Mode (mode) The batch controller may operate in manual or automatic mode. In manual mode, the controller operates as defined in Controller Operation as described on page 23. In automatic mode, the batch process will automatically begin after a completed batch.

  • Page 36: Setting The Display Parameter & Intensity (Dsplay)

    ProtEX-MAX PD8-6310 Explosion-Proof Pulse 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 37: Setting The Relay Operation (Relay)

    ProtEX-MAX PD8-6310 Explosion-Proof Pulse 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 38: Relay Assignment (Assign)

    ProtEX-MAX PD8-6310 Explosion-Proof Pulse 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...

  • Page 39: Programming Alarm Set And Reset Points

    ProtEX-MAX PD8-6310 Explosion-Proof Pulse 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 40: Relay Operation Details

    ProtEX-MAX PD8-6310 Explosion-Proof Pulse 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.

  • Page 41: Automatic Reset (Auto)

    ProtEX-MAX PD8-6310 Explosion-Proof Pulse 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...

  • Page 42: Sample Relay Operation

    ProtEX-MAX PD8-6310 Explosion-Proof Pulse 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...

  • Page 43: Rate Relay Sampling Operation

    ProtEX-MAX PD8-6310 Explosion-Proof Pulse 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 44: Time Delay Operation

    ProtEX-MAX PD8-6310 Explosion-Proof Pulse 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 45: Reset Menu (Reset)

    ProtEX-MAX PD8-6310 Explosion-Proof Pulse 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 46: Grand Total Reset Password & Non-Resettable Total

    ProtEX-MAX PD8-6310 Explosion-Proof Pulse 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”.

  • Page 47: Advanced Operation And Programming

    ProtEX-MAX PD8-6310 Explosion-Proof Pulse Input Batch Controller Instruction Manual Advanced Operation and Programming In addition to the functions described in Controller Operation on page 23, 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.
  • Page 48 ProtEX-MAX PD8-6310 Explosion-Proof Pulse Input Batch Controller Instruction Manual Display Parameter Action/Setting Display Parameter Action/Setting Tot C Calib Total count Set the batch to count up Calibrate Calibrate 4-20 mA to or down from the output (internal preset reference source used...

  • Page 49: Function Keys Operation

    ProtEX-MAX PD8-6310 Explosion-Proof Pulse 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 50: Noise Filter (Filter)

    ProtEX-MAX PD8-6310 Explosion-Proof Pulse Input Batch Controller Instruction Manual Noise Filter (filter) The noise filter is available for unusually noisy signals that cause an unstable process variable display. The noise filter averages the input signal over a certain period. The filter level determines the length of time over which the signal is averaged.

  • Page 51: Serial Communications Overview

    ProtEX-MAX PD8-6310 Explosion-Proof Pulse Input Batch Controller Instruction Manual Serial Communications Overview RS-232 and RS-485 are standard interfaces approved by the Electronic Industries Alliance (EIA) for con- necting serial devices. In EIA terms, the device (e.g. meter) that connects to the interface is called a Data Communications Equipment (DCE) and the device to which it connects (e.g.

  • Page 52: Select Menu (Select)

    ProtEX-MAX PD8-6310 Explosion-Proof Pulse 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 53: Analog Output Programming (Aoutpr)

    ProtEX-MAX PD8-6310 Explosion-Proof Pulse Input Batch Controller Instruction Manual Analog Output Programming (AoutPr) The Analog Output Programming menu is used to program the behavior of the 4-20 mA output. The following parameters and functions are programmed in this menu: 1. Source: Source for generating the 4-20 mA output (e.g. PV) 2.
  • Page 54 ProtEX-MAX PD8-6310 Explosion-Proof Pulse Input Batch Controller Instruction Manual Function Keys & Digital I/O Available Settings Refer to the following table for descriptions of each available function key or digital I/O setting. Display Description Display Description disabl Start Disable the selected function key or...

  • Page 55: Troubleshooting

    ProtEX-MAX PD8-6310 Explosion-Proof Pulse 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.

  • Page 56: Factory Defaults & User Settings

    ProtEX-MAX PD8-6310 Explosion-Proof Pulse 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...

  • Page 57: Troubleshooting Tips

    ProtEX-MAX PD8-6310 Explosion-Proof Pulse Input Batch Controller Instruction Manual Parameter Display Default Setting Parameter Display Default Setting Display 2 Parity Parity Even Dis 2 1000.0 analog out Byte-to-byte t-byt 010 (0.1 sec) Output 2 timeout Out 2 20.000 mA value...
  • Page 58 ProtEX-MAX PD8-6310 Explosion-Proof Pulse Input Batch Controller Instruction Manual 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 59: Service

    ProtEX-MAX PD8-6310 Explosion-Proof Pulse Input Batch Controller Instruction Manual Service WARNINGS • Installation and service should be performed only by trained service personnel. Service requiring replacement of internal sub-components must be performed at the factory. • Disconnect from supply before opening enclosure. Keep cover tight while circuits are alive.

  • Page 60: Mounting Dimensions

    ProtEX-MAX PD8-6310 Explosion-Proof Pulse Input Batch Controller Instruction Manual Mounting Dimensions All units: inches (mm) Figure 24: Enclosure Dimensions – Front View Figure 25: Enclosure Dimensions – Side Cross Section View...

  • Page 61: Eu Declaration Of Conformity

    SIRA 10 ATEX M462 ATEX Notified Body for Quality Assurance: Sira Certification Service, NB 0518 Unit 6, Hawarden Industrial Park Hawarden, Deeside, CH5 3US, UK Signed for and on behalf of Precision Digital Corporation: Name: Jeffrey Peters Company: Precision Digital Corporation...
  • Page 62 ProtEX-MAX PD8-6310 Explosion-Proof Pulse 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...

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