PRECISION DIGITAL PD2-6210 Instruction Manual
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PRECISION DIGITAL PD2-6210 Instruction Manual

Helios large display analog input batch controller
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• Large 1.80" Digits
• Dual-Line 6-Digit Display
• Readable from up to 100 Feet (30 Meters) Away
• Superluminous Sunlight Readable Display
• NEMA 4X, IP65 Rated Field Mountable Enclosure
• Operating Temperature Range of -40 to 65°C (-40 to 150°F)
• Single or Multi-Stage Batch Control (up to 4 Relays)
• 0-20 mA, 4-20 mA, 0-5 V, 1-5 V, and ±10 V Inputs
• Input Power Options Include 85-265 VAC or 12-24 VDC
• Isolated 24 VDC Transmitter Power Supply
• Start/Pause/Stop, Change Batch with Front Panel Buttons
• Automatic Overrun Correction
• Count Up or Down with Each Batch
• 2 or 4 Relays + Isolated 4-20 mA Output Options
• Onboard USB & RS-485 Serial Communications
• Modbus
• Program the Meter from a PC with onboard USB and MeterView Pro
Precision Digital Corporation
1.888.610.7664
Helios Large Display Analog Input Batch Controller
Instruction Manual
®
RTU Communication Protocol Standard
www.calcert.com
15
10
20
5
25
0
30
PD2-6210
USB Install
Batch Controller
sales@calcert.com

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Summary of Contents for PRECISION DIGITAL PD2-6210

  • Page 1 • 2 or 4 Relays + Isolated 4-20 mA Output Options • Onboard USB & RS-485 Serial Communications • Modbus ® RTU Communication Protocol Standard • Program the Meter from a PC with onboard USB and MeterView Pro Precision Digital Corporation 1.888.610.7664 www.calcert.com sales@calcert.com...
  • 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

    PD2-6210 Helios Large Display Analog Input Batch Controller Instruction Manual Table of Contents Table of Contents ............ 3 Setting Batch Control Relays ......... 40 Programming Set and Reset Points ...... 41 Table of Figures ............4 Setting Fail-Safe Operation ........41 Introduction..............

  • Page 4: Table Of Figures

    Figure 22. Interlock Connections ......21 Introduction The Helios PD2-6210 is a multi-purpose, easy to use, large-display batch controller ideal for simplifying independent batch control operations where local control is preferred to expensive and expansive plant operation systems. It features large 1.8 superluminous inch LED digits, which can be read in sunlight from up to 100 feet away.

  • Page 5: Ordering Information

    PD2-6210 Helios Large Display Analog Input Batch Controller Instruction Manual Ordering Information Standard Models 85-265 VAC Model 12-24 VDC Model Options Installed PD2-6210-6H2 PD2-6210-7H2 2 Relays PD2-6210-6H7 PD2-6210-7H7 4 relays & 4-20 mA output Accessories Model Description PDA6260 Pipe Mounting Kit...

  • Page 6: Process Input

    Helios Large Display Analog Input Batch Controller Instruction Manual PD2-6210 Temperature 0.005% of calibrated span/C max Fuse Required external fuse: UL Drift from 0 to 65C ambient, Recognized, 5 A max, slow blow; 0.01% of calibrated span/C max up to 6 controllers may share one from -40 to 0C ambient...

  • Page 7: Relays

    PD2-6210 Helios Large Display Analog Input Batch Controller Instruction Manual High or Low User may program any alarm for Totalizer Calculates total based on rate and Alarm high or low trip point. field programmable multiplier to Unused alarm LEDs and relays display total in engineering units.

  • Page 8: Rs485 Serial Communications Terminal

    Helios Large Display Analog Input Batch Controller Instruction Manual PD2-6210 Temperature 0.4 µA/C max from 0 to 65C Data 8 bit (1 start bit, 1 or 2 stop bits) Drift ambient, Parity Even, Odd, or None with 1 or 2 0.8 µA/C max from -40 to 0C...

  • Page 9: Compliance Information

    PD2-6210 Helios Large Display Analog Input Batch Controller Instruction Manual Compliance Information Safety UL & C-UL Listed USA & Canada UL 508 Industrial Control Equipment (United States), C22.2 No. 142 (Canadian National Standard) UL File Number E160849 Front Panel UL Type 4X, NEMA 4X, IP65...

  • Page 10: Safety Information

    Helios Large Display Analog Input Batch Controller Instruction Manual PD2-6210 Safety Information Caution: Read complete instructions Warning: Risk of electric shock or prior to installation and operation of the personal injury. controller. Hazardous voltages exist within enclosure. Installation and service should be performed only by trained service personnel.

  • Page 11: Wall Mounting Instructions

    PD2-6210 Helios Large Display Analog Input Batch Controller Instruction Manual Wall Mounting Instructions The meter can be mounted to any wall using the four provided mounting holes. Note that the bottom mounting holes are located underneath the front door panel. To mount the meter to a wall, follow these instructions.

  • Page 12: Pipe Mounting Instructions

    Helios Large Display Analog Input Batch Controller Instruction Manual PD2-6210 Pipe Mounting Instructions The meter can also be mounted to a pipe using the optional pipe mounting kit (PDA6260). This kit includes two mounting plates, two U-bolts, and the necessary nuts and bolts. To mount the meter to a pipe using the pipe mounting kit accessory, follow these instructions.

  • Page 13: Transmitter Supply Voltage Selection (P+, P-)

    PD2-6210 Helios Large Display Analog Input Batch Controller Instruction Manual Transmitter Supply Voltage Selection (P+, P-) All meters, 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 14: Connectors Labeling

    The connectors’ label, affixed to the inside of the lower door panel, shows the location of all connectors available with requested configuration. Do not connect any equipment other than Precision Digital’s expansion modules, cables, or meters to the RJ45 M-LINK connector.

  • Page 15: Signal Connections

    PD2-6210 Helios Large Display Analog Input Batch Controller Instruction Manual 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 4-20 mA and the 10 V input signals.

  • Page 16: Modbus Rtu Serial Communications

    Helios Large Display Analog Input Batch Controller Instruction Manual PD2-6210 INPUT SIGNAL INPUT SIGNAL Signal 3-Wire Voltage Voltage Transducer Signal Figure 11. Voltage Input Connections The meter is capable of accepting any voltage from -10 VDC to +10 VDC. Modbus RTU Serial Communications Serial communications connection can be made to the onboard RS485 terminal block or USB connector shown in Figure 7.

  • Page 17: Switching Inductive Loads

    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 18: Rs485 Output Connections

    Helios Large Display Analog Input Batch Controller Instruction Manual PD2-6210 RS485 Output Connections An RS-485 connector is provided for the use of advanced Modbus ® serial communications. This connector converts the serial output of the meter to balanced, full or half-duplex RS-485 signals. It has a...

  • Page 19: Figure 16. Rs-485 Two-Wire Multi-Drop Wiring

    PD2-6210 Helios Large Display Analog Input Batch Controller Instruction Manual Figure 16. RS-485 Two-Wire Multi-Drop Wiring Notes: 1. Termination resistors are optional and values depend on the cable length and characteristic impedance. Consult the cable manufacturer for recommendations. 2. Refer to RS-232 to RS-485 Converter documentation for further details.

  • Page 20: Digital I/O Connections

    Helios Large Display Analog Input Batch Controller Instruction Manual PD2-6210 Digital I/O Connections Digital inputs and outputs are provided in order to expand the functionality of the meter. Digital inputs are made via a push button or switch connection to the appropriate digital input connector block and the +5 VDC block.

  • Page 21: 4-20 Ma Output Connections

    PD2-6210 Helios Large Display Analog Input Batch Controller Instruction Manual 4-20 mA Output Connections Connections for the 4-20 mA transmitter output are made to the connector terminals labeled MA OUT. The 4-20 mA output may be powered internally or from an external power supply.

  • Page 22: Basic Operation And Programming

    Helios Large Display Analog Input Batch Controller Instruction Manual PD2-6210 Basic Operation and Programming The meter 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.

  • Page 23: Programming Buttons And Status Led Indicators

    PD2-6210 Helios Large Display Analog Input Batch Controller Instruction Manual Programming Buttons and Status LED Indicators The meter can be programmed using the buttons located behind the front door panel. Use the Menu button to enter or exit Programming Mode, the Up Arrow button to cycle through menu options, and the Enter button to select the menu item or option you want.

  • Page 24: Meterview ® Pro Software

    Helios Large Display Analog Input Batch Controller Instruction Manual PD2-6210 MeterView ® Pro Software The meter can also be programmed using the PC-based MeterView Pro software included with the meter. This software is can be installed on any Microsoft® Windows® (2000/XP/Vista/7/8/10) computer by connecting the meter’s onboard USB.

  • Page 25: Controller Operation

    Helios Large Display Analog Input Batch Controller Instruction Manual Controller Operation The PD2-6210 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 26: Batch Control Operation Example

    Batch Control Operation Example The following example shows how two stage batch control functions with a PD2-6210 controller. 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 27 PD2-6210 Helios Large Display Analog Input Batch Controller Instruction Manual 1.888.610.7664 www.calcert.com sales@calcert.com...

  • Page 28: Display Functions & Messages

    Helios Large Display Analog Input Batch Controller Instruction Manual PD2-6210 Display Functions & Messages The meter 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 PD2-6210 Helios Large Display Analog Input Batch Controller Instruction Manual Display Parameter Action/Setting Description Grand total Assign relay to grand total G total Select to display Modbus input or to assign Modbus input as the Modbus m bus analog output source...
  • Page 30 Helios Large Display Analog Input Batch Controller Instruction Manual PD2-6210 Reset Press Enter to access the Reset menu reset Press Enter to reset max display Reset high Rst Hi Press Enter to reset min display Reset low Rst Lo Reset high &...

  • Page 31: Main Menu

    PD2-6210 Helios Large Display Analog Input Batch Controller Instruction Manual Main Menu The main menu consists of the most commonly used functions: Setup, Reset, Control, and Password. • Press Menu button to enter Programming Mode then press the Up arrow button to scroll main menu.

  • Page 32: Setting Up The Batch Controller (Setup)

    Helios Large Display Analog Input Batch Controller Instruction Manual PD2-6210 Setting up the Batch Controller (setup) The Setup menu is used to select: 1. Input signal the controller will accept 2. Totalizer and batching features 3. Display units/tags 4. Decimal point position 5.

  • Page 33: Setting The Input Units Or Custom Tags (Units)

    PD2-6210 Helios Large Display Analog Input Batch Controller Instruction Manual Setting the Input Units or Custom Tags (units) Enter the input unit or custom tag that will be displayed if d unit is selected as the little display parameter. See the flow chart on page 38 to access the display menu to show the unit or tag on the little display.

  • Page 34: Programming The Batch Controller (Prog)

    Helios Large Display Analog Input Batch Controller Instruction Manual PD2-6210 Programming the Batch Controller (prog) It is very important to read the following information, before proceeding to program the meter: • The meter is factory calibrated prior to shipment to read in milliamps and volts depending on the input selection.
  • Page 35 PD2-6210 Helios Large Display Analog Input Batch Controller Instruction Manual Input Calibration Method ( InCAL There are two methods of calibrating (or scaling) the display to show the correct engineering units. Use the Scale menu to enter the scaling without a signal source.
  • Page 36 Helios Large Display Analog Input Batch Controller Instruction Manual PD2-6210 Error Message (Error) An error message indicates that the calibration or scaling process was not successful. After the error message is displayed, the meter reverts to the input prior to the failure during calibration or scaling and to input 1 during internal calibration, allowing the appropriate input signal to be applied or programmed.
  • Page 37 PD2-6210 Helios Large Display Analog Input Batch Controller Instruction Manual Batch Mode, 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 38: Setting The Display Parameter & Intensity (Dsplay)

    Helios Large Display Analog Input Batch Controller Instruction Manual PD2-6210 Setting the Display Parameter & Intensity (dsplay) The main display (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 39: Setting The Relay Operation (Relay)

    PD2-6210 Helios Large Display Analog Input Batch Controller Instruction Manual Setting the Relay Operation (relay) This menu is used to set up the operation of the relays. 1. Relay assignment During setup, the relays do not follow the input a. Rate for low and high alarm and they will remain in the state found prior to b.

  • Page 40: Relay Assignment (Assign)

    Helios Large Display Analog Input Batch Controller Instruction Manual PD2-6210 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 alarm indication 3. Grand total for alarm indication 4.

  • Page 41: Programming Set And Reset Points

    PD2-6210 Helios Large Display Analog Input Batch Controller Instruction Manual Programming 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.

  • Page 42: Relay And Alarm Operation Diagrams

    Helios Large Display Analog Input Batch Controller Instruction Manual PD2-6210 Relay and Alarm Operation Diagrams The following graphs illustrate the operation of the relays, status LEDs, and ACK button. High Alarm Operation (Set > Reset) Low Alarm Operation (Set < Reset)

  • Page 43: Total Relay Sampling Operation

    PD2-6210 Helios Large Display Analog Input Batch Controller Instruction Manual Total Relay Sampling Operation When the batch total reaches 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 value is added to the batch total.

  • Page 44: Relay Operation Details

    Helios Large Display Analog Input Batch Controller Instruction Manual PD2-6210 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 45: Automatic Reset (Auto)

    PD2-6210 Helios Large Display Analog Input Batch Controller Instruction Manual Automatic Reset (Auto) Automatic reset only In this application, the controller is set up for automatic Condition Relay reset (non-latching relay). Acknowledging the alarm while it Normal is still present has no effect on either the LED or the relay.

  • Page 46: Sample Relay Operation

    Helios Large Display Analog Input Batch Controller Instruction Manual PD2-6210 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.

  • Page 47: Setting Up The Password (Pass)

    PD2-6210 Helios Large Display Analog Input Batch Controller Instruction Manual Setting up the Password (pass) The Password menu is used for programming three levels of security to prevent unauthorized changes to the programmed parameter settings. Pass 1: Allows use of function keys and digital inputs...

  • Page 48: Making Changes To A Password Protected Meter

    Helios Large Display Analog Input Batch Controller Instruction Manual PD2-6210 Making Changes to a Password Protected Meter If the meter is password protected, the meter will display the message Locd (Locked) when the Menu button is pressed. Press the Enter button while the message is being displayed and enter the correct password to gain access to the menu.

  • Page 49: Advanced Operation And Programming

    PD2-6210 Helios Large Display Analog Input Batch Controller Instruction Manual Advanced Operation and Programming In addition to the functions described in Controller Operation on page 25, 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 50: Advanced Features Menu

    Helios Large Display Analog Input Batch Controller Instruction Manual PD2-6210 Advanced Features Menu To simplify the setup process, functions not needed for most applications are located in the Advanced Features menu. Press and hold the Menu button for three seconds to access the advanced features of the meter. This cannot be done during a batch process as all functions other than STOP are disabled during a batch process, including the Menu button.
  • Page 51 PD2-6210 Helios Large Display Analog Input Batch Controller Instruction Manual Display Parameter Action/Setting Set total and grand total count direction Count Count Total Count Set total to count up or down Tot C Set grand total to count up or down...

  • Page 52: 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 meters to the RJ45 M-LINK connector. Otherwise damage will occur to the equipment and the meter.

  • Page 53: Select Menu (Select)

    PD2-6210 Helios Large Display Analog Input Batch Controller Instruction Manual Select Menu (SElect) The Select menu is used to select the signal input conditioner applied to the input (linear, square root, programmable exponent, or round horizontal tank), low- flow cutoff, and analog output programming.

  • Page 54: Low-Flow Cutoff (Cutoff)

    Helios Large Display Analog Input Batch Controller Instruction Manual PD2-6210 Low-Flow Cutoff (CutofF) The low-flow cutoff feature allows the meter to be programmed so that the often-unsteady output from a differential pressure transmitter, at low flow rates, always displays zero on the meter.
  • Page 55 PD2-6210 Helios Large Display Analog 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 Disable the selected function key or...

  • Page 56: Internal Source Calibration (Ical)

    Helios Large Display Analog Input Batch Controller Instruction Manual PD2-6210 Internal Source Calibration (ICAL) The meter 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.

  • Page 57: Troubleshooting

    PD2-6210 Helios Large Display Analog Input Batch Controller Instruction Manual Troubleshooting Due to the many features and functions of the meter, it’s possible that the setup of the meter does not agree with what an operator expects to see. If the meter is not working as expected, refer to the Diagnostics menu and recommendations below.

  • Page 58: Factory Defaults & User Settings

    Helios Large Display Analog Input Batch Controller Instruction Manual PD2-6210 Factory Defaults & User Settings The following table shows the factory setting for most of the programmable parameters on the meter. Parameter Display Default Setting Input type 4-20 mA Input...
  • Page 59 PD2-6210 Helios Large Display Analog Input Batch Controller Instruction Manual Parameter Display Default Setting Relay 2 action Automatic Act 2 Relay 2 set point 200.0 Set 2 Relay 3 action Automatic Act 3 Relay 3 set point 3.000 Set 3 Relay 3 reset point 2.500...

  • Page 60: Troubleshooting Tips

    Helios Large Display Analog Input Batch Controller Instruction Manual PD2-6210 Troubleshooting Tips Symptom Check/Action No display at all Check power at power connector Not able to change setup or Meter is password-protected, enter correct six-digit password to programming, Locd is displayed...

This manual is also suitable for:

Pd2-6210-7h7Pd2-6210-7h2Pd2-6210-6h7Pd2-6210-6h2

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