PRECISION DIGITAL ProtEX-MAX PD8-6210 Instruction Manual
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PRECISION DIGITAL ProtEX-MAX PD8-6210 Instruction Manual

Explosion-proof analog input batch controller
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• 0-20 mA, 4-20 mA, 0-5 V, 1-5 V, and ±10 V Inputs
• 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
• Isolated 24 VDC @ 25 mA Transmitter Power Supply
• Input Power Options Include 85-265 VAC or 12-24 VDC
• SafeTouch
• Flanges for Wall or Pipe Mounting
• Superluminous Sunlight Readable Display
• Free USB Programming Software & Cable
• 4 Relays + Isolated 4-20 mA Output
PRECISION DIGITAL CORPORATION
1.800.561.8187
ProtEX-MAX PD8-6210 Explosion-Proof
Analog Input Batch Controller Instruction Manual
®
Through-Glass Button Programming
www.
Batch Controller
information@itm.com
.com
USB Install

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Summary of Contents for PRECISION DIGITAL ProtEX-MAX PD8-6210

  • Page 1 ProtEX-MAX PD8-6210 Explosion-Proof Analog Input Batch Controller Instruction Manual USB Install Batch Controller • 0-20 mA, 4-20 mA, 0-5 V, 1-5 V, and ±10 V Inputs • Start, Batch, Pause, & Stop with Front Panel Buttons • Display Batch Total + Rate, Grand Total, Batch Count or Preset •...
  • 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 PD8-6210 Explosion-Proof Analog Input Batch Controller Instruction Manual Table of Contents Table of Contents ----------------------------------------- 3 Programming the Batch Controller (prog) ---------- 33 Input Calibration Method (InCAL) ------------------ 33 Table of Figures ------------------------------------------- 4 Scaling the Controller (SCALE) ---------------------- 34 Introduction ------------------------------------------------- 4 Time Base, Total Conversion Factor &...

  • Page 4: Table Of Figures

    Section View ............61 Introduction The ProtEX-MAX PD8-6210 offers all the functionality of the ProVu PD6210 as a fully FM, CSA, ATEX, and IECEx approved explosion-proof product. It is an analog input (4-20 mA, 0-5 V, 1-5 V, etc.) digital batch controller specifically designed for single and multi-stage batching applica- tions.

  • Page 5: Ordering Information

    ProtEX-MAX PD8-6210 Explosion-Proof Analog Input Batch Controller Instruction Manual Ordering Information SunBright Display Model 85-265 VAC Model 12-24 VDC Model Options Installed PD8-6210-6H7 PD8-6210-7H7 4 relays & 4-20 mA output WARNING - Cancer and Reproductive Harm - www.P65Warnings.ca.gov Accessories Model...

  • Page 6: Specifications

    ProtEX-MAX PD8-6210 Explosion-Proof Analog Input Batch Controller Instruction Manual Specifications Except where noted all specifications apply to operation at +25°C. General Fuse Required external fuse: UL Recognized, 5 A max, slow blow; up to 6 controllers may share one 5 A fuse Display Line 1: 0.6"...

  • Page 7: Batch Controller Rate/Totalizer Display

    ProtEX-MAX PD8-6210 Explosion-Proof Analog Input Batch Controller Instruction Manual Signal Input Linear, square root, or programmable Grand Total Up to seven, user selectable under setup Conditioning exponent Alarms menu. Any set point can be assigned to grand total and may be programmed...

  • Page 8: Isolated 4-20 Ma Transmitter Output

    ProtEX-MAX PD8-6210 Explosion-Proof Analog Input Batch Controller Instruction Manual Serial Communications High or Low User may program any alarm for high or low Alarm trip point. Compatibility EIA-485 Unused alarm LEDs and relays may be disabled (turn off). Connectors Removable screw terminal connector...

  • Page 9: Product Ratings And Approvals

    ProtEX-MAX PD8-6210 Explosion-Proof Analog 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 PD8-6210 Explosion-Proof Analog 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 PD8-6210 Explosion-Proof Analog 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 PD8-6210 Explosion-Proof Analog 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 PD8-6210 Explosion-Proof Analog 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 PD8-6210 Explosion-Proof Analog 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: Signal Connections

    ProtEX-MAX PD8-6210 Explosion-Proof 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.

  • Page 16: Serial Communications Connections

    ProtEX-MAX PD8-6210 Explosion-Proof Analog Input Batch Controller Instruction Manual Serial Communications Connections The ProtEX-MAX has a 5 position terminal block for connecting RS-485 serial devices. Figure 8 details the wiring connections from the ProtEX-MAX to an RS-485 serial converter (such as the PDA7485 or PDA8485) for a four-wire network.

  • Page 17: Figure 10: Rs-485 Wiring

    ProtEX-MAX PD8-6210 Explosion-Proof Analog Input Batch Controller Instruction Manual Figure 10: RS-485 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: Using Pro V U Serial Adapters

    ProtEX-MAX PD8-6210 Explosion-Proof Analog Input Batch Controller Instruction Manual Figure 11: 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 19: Relay Connections

    Figure 14: 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 20: F4 Digital Input Connections

    ProtEX-MAX PD8-6210 Explosion-Proof Analog 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 21: Digital I/O Connections

    ProtEX-MAX PD8-6210 Explosion-Proof Analog Input Batch Controller Instruction Manual Digital I/O Connections The ProtEX-MAX has a 10 position terminal block for connecting digital inputs and outputs. 5 VDC DI 1-4 DO 1-4 Figure 18: 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 22: Basic Operation And Programming

    ProtEX-MAX PD8-6210 Explosion-Proof 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 traceable to NIST standards.

  • Page 23: Front Buttons And Status Led Indicators

    ProtEX-MAX PD8-6210 Explosion-Proof Analog Input Batch Controller Instruction Manual Front Buttons and Status LED Indicators Button Symbol Description Status Menu Relay 1 – 8 indicators START Rate indicator (Right arrow/F1) BATCH Batch Total indicator (Up arrow/F2) STOP Grand Total indicator...

  • Page 24: Controller Operation

    ProtEX-MAX PD8-6210 Explosion-Proof 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.

  • Page 25: Batch Control Operation Example

    ProtEX-MAX PD8-6210 Explosion-Proof 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 26 ProtEX-MAX PD8-6210 Explosion-Proof Analog Input Batch Controller Instruction Manual 1.800.561.8187 information@itm.com www. .com...

  • Page 27: Meterview ® Pro Software

    ProtEX-MAX PD8-6210 Explosion-Proof 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 28: Display Functions And Messages

    ProtEX-MAX PD8-6210 Explosion-Proof 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.
  • Page 29 ProtEX-MAX PD8-6210 Explosion-Proof Analog Input Batch Controller Instruction Manual Display Parameter Action/Setting Display Parameter Action/Setting Description Description Alternate Set relay for pump Display 2 Program display 2 value Altern Dis 2 alternation control (relays Output 2 Program output 2 value...

  • Page 30: Setting Numeric Values

    ProtEX-MAX PD8-6210 Explosion-Proof 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 31: Setting Up The Batch Controller (Setup)

    ProtEX-MAX PD8-6210 Explosion-Proof 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 32: Scaling And Calibration

    ProtEX-MAX PD8-6210 Explosion-Proof 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 33: Programming The Batch Controller (Prog)

    ProtEX-MAX PD8-6210 Explosion-Proof 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 34: Scaling The Controller (Scale)

    ProtEX-MAX PD8-6210 Explosion-Proof 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 35: Time Base, Total Conversion Factor & Total Reset

    ProtEX-MAX PD8-6210 Explosion-Proof 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 36: Setting The Display Parameter & Intensity (Dsplay)

    ProtEX-MAX PD8-6210 Explosion-Proof 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 37: Setting The Relay Operation (Relay)

    ProtEX-MAX PD8-6210 Explosion-Proof 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 38: Relay Assignment (Assign)

    ProtEX-MAX PD8-6210 Explosion-Proof 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...

  • Page 39: Programming Alarm Set And Reset Points

    ProtEX-MAX PD8-6210 Explosion-Proof 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 40: Relay Operation Details

    ProtEX-MAX PD8-6210 Explosion-Proof 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.

  • Page 41: Automatic Reset (Auto)

    ProtEX-MAX PD8-6210 Explosion-Proof 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...

  • Page 42: Sample Relay Operation

    ProtEX-MAX PD8-6210 Explosion-Proof 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...

  • Page 43: Rate Relay Sampling Operation

    ProtEX-MAX PD8-6210 Explosion-Proof 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 44: Time Delay Operation

    ProtEX-MAX PD8-6210 Explosion-Proof 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 45: Reset Menu (Reset)

    ProtEX-MAX PD8-6210 Explosion-Proof 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 46: Grand Total Reset Password & Non-Resettable Total

    ProtEX-MAX PD8-6210 Explosion-Proof 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”.

  • Page 47: Advanced Operation And Programming

    ProtEX-MAX PD8-6210 Explosion-Proof Analog Input Batch Controller Instruction Manual Advanced Operation and Programming In addition to the functions described in Controller Operation on page 24, 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: Advanced Features Menu & Display Messages

    ProtEX-MAX PD8-6210 Explosion-Proof 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...
  • Page 49 ProtEX-MAX PD8-6210 Explosion-Proof Analog Input Batch Controller Instruction Manual Display Parameter Action/Setting Display Parameter Action/Setting F4 function Assign F4 function Current Calibrate high current C Hi (digital input) high input (e.g. 20 mA) Assign digital input 1 – 4 Digital input...

  • Page 50: Function Keys Operation

    ProtEX-MAX PD8-6210 Explosion-Proof 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 51: Noise Filter (Filter)

    ProtEX-MAX PD8-6210 Explosion-Proof Analog 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 52: Serial Communications Overview

    ProtEX-MAX PD8-6210 Explosion-Proof Analog 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 53: Select Menu (Select)

    ProtEX-MAX PD8-6210 Explosion-Proof 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 54: Total And Grand Total Count Direction (Count)

    ProtEX-MAX PD8-6210 Explosion-Proof 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 55: Programmable Function Keys User Menu (User)

    ProtEX-MAX PD8-6210 Explosion-Proof 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.

  • Page 56: Internal Source Calibration (Ical)

    ProtEX-MAX PD8-6210 Explosion-Proof 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 traceable to NIST standards.

  • Page 57: Troubleshooting

    ProtEX-MAX PD8-6210 Explosion-Proof 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.

  • Page 58: Factory Defaults & User Settings

    ProtEX-MAX PD8-6210 Explosion-Proof 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 Relay 4 reset point 3.500...

  • Page 59: Troubleshooting Tips

    ProtEX-MAX PD8-6210 Explosion-Proof Analog Input Batch Controller Instruction Manual Parameter Display Default Setting Parameter Display Default Setting F3 function key Stop Password 1 000000 (unlocked) Pass 1 F4 function Start/Stop Password 2 000000 (unlocked) Pass 2 Digital input 1 Menu...

  • Page 60: Service

    ProtEX-MAX PD8-6210 Explosion-Proof Analog Input Batch Controller Instruction Manual Symptom Check/Action Check: Display does not respond to Display assignment, it might be displaying max, min, or set input changes, reading a fixed point. number Display alternates between Press Menu to exit max/min display readings.

  • Page 61: Mounting Dimensions

    ProtEX-MAX PD8-6210 Explosion-Proof Analog Input Batch Controller Instruction Manual Mounting Dimensions All units: inches (mm) Figure 21: Enclosure Dimensions – Front View Figure 22: Enclosure Dimensions – Side Cross Section View 1.800.561.8187 information@itm.com www. .com...
  • Page 62 ProtEX-MAX PD8-6210 Explosion-Proof Analog Input Batch Controller Instruction Manual This Page Intentionally Left Blank 1.800.561.8187 information@itm.com www. .com...

  • Page 63: Eu Declaration Of Conformity

    ATEX Quality Assurance Notification No.: 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 64 ProtEX-MAX PD8-6210 Explosion-Proof Analog Input Batch Controller Instruction Manual PRECISION DIGITAL CORPORATION LIM8-6210_D SFT039 Ver 4.010 & up 12/18 1.800.561.8187 information@itm.com www. .com...

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