Page 1
Helios Large Display Pulse Input Batch Controller
Instruction Manual PD2-6310
Batch Controller
USB Install
• 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)
• Pulse, Open Collector, NPN, PNP, TTL, Switch Contact,
Sine Wave (Coil), Square Wave Inputs
• Start/Pause/Stop, Change Batch with Front Panel Buttons
• Automatic Overrun Correction
• Input Power Options Include 85-265 VAC or 12-24 VDC
• Isolated 24 VDC Transmitter Power Supply
• Count Up or Down with Each Batch
• 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
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Helios Large Display Pulse Input Batch Controller Instruction Manual PD2-6310
Caution: Read complete
instructions prior to installation and
operation of the controller.
Warning: Risk of electric shock or
personal injury.
Warning!
This product is not recommended for life support
applications or applications where malfunctioning
could result in personal injury or property loss. Anyone
using this product for such applications does so at their
own risk. Precision Digital Corporation shall not be held
liable for damages resulting from such improper use.
!
Disclaimer
The information contained in this document is subject to change without notice. Precision
Digital makes no representations or warranties with respect to the contents hereof and
specifically disclaims any implied warranties of merchantability or fitness for a particular
purpose.
Limited Warranty
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.
Registered Trademarks
MeterView® Pro is a registered trademark of Precision Digital Corporation. All other
trademarks mentioned in this document are the property of their respective owners.
© 2018 Precision Digital Corporation. All rights reserved.
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Helios Large Display Pulse Input Batch Controller Instruction Manual PD2-6310
Table of Contents
Table of Contents .................................................... 3
Table of Figures ...................................................... 4
Introduction.............................................................. 4
Ordering Information ............................................... 5
Specifications .......................................................... 5
General ....................................................................... 5
Pulse Input .................................................................. 6
Batch Controller Rate/Totalizer Display ...................... 6
Relays ......................................................................... 7
Isolated 4-20 mA Transmitter Output .......................... 7
Serial Communications ............................................... 8
Modbus® RTU Serial Communications........................ 8
Digital Input & Output Terminal ................................... 8
Compliance Information .......................................... 9
Safety .......................................................................... 9
Safety Information .................................................10
Installation .............................................................10
Unpacking ................................................................. 10
Wall Mounting Instructions ........................................ 11
Mounting Dimensions ............................................ 11
Pipe Mounting Instructions ........................................ 12
Transmitter Supply Voltage Selection (P+, P-) .......... 13
Connections .............................................................. 13
Connectors Labeling ............................................. 14
Power Connections ............................................... 14
Signal Connections ............................................... 15
Modbus RTU Serial Communications ................... 15
Relay Connections ................................................ 15
Switching Inductive Loads ..................................... 16
RS485 Output Connections................................... 17
Digital I/O Connections ......................................... 19
F4 Digital Input Connections ................................. 19
4-20 mA Output Connections ................................ 20
Analog Output Transmitter Power Supply ............. 20
Interlock Relay Feature ......................................... 20
Basic Operation and Programming .......................21
Overview ................................................................... 21
Programming Buttons and Status LED Indicators ..... 22
MeterView® Pro Software .......................................... 23
MeterView Pro Installation..................................... 23
Controller Operation .................................................. 24
Default Batch Control Operation ........................... 24
Batch Control Operation Example ......................... 25
Display Functions & Messages ................................. 27
Main Menu ................................................................ 30
Setting Numeric Values ............................................. 30
Setting up the Batch Controller (setup) .................... 31
Setting the Input Signal (Input) ............................ 31
Setting the Totalizer and Batching Features (total)
.............................................................................. 31
Setting the Input Units or Custom Tags (units) ... 32
Setting the Decimal Point (dEc pt) ....................... 32
Programming the Batch Controller (prog) ............. 33
Setting the Display Parameter & Intensity (dsplay)
.............................................................................. 37
Setting the Relay Operation (relay) ......................... 38
Relay Assignment (Assign) .................................. 39
Setting the Relay Action ........................................ 39
Setting Batch Control Relays ................................. 39
Programming Set and Reset Points ...................... 40
Setting Fail-Safe Operation ................................... 40
Programming Time Delay ...................................... 40
Relay and Alarm Operation Diagrams ....................... 40
High Alarm Operation (Set > Reset) ...................... 40
Low Alarm Operation (Set < Reset) ....................... 40
High Alarm with Fail-Safe Operation (Set > Reset)41
Low Alarm with Fail-Safe Operation (Set < Reset) 41
Relay Sampling Operation ..................................... 41
Total Relay Sampling Operation ............................ 41
Signal Loss or Loop Break Relay Operation .......... 42
Time Delay Operation ............................................ 42
Relay Operation Details ............................................. 42
Overview ............................................................... 42
Relays Initialization ................................................ 43
Fail-Safe Operation ............................................... 43
Front Panel LEDs .................................................. 43
Automatic Reset (Auto) ......................................... 43
Pump Alternation Control Applications (Altern) ... 43
Setting up the Interlock Relay (Force On) Feature 44
Sample Relay Operation ....................................... 44
Scaling the 4-20 mA Analog Output (Aout) ............... 45
Reset Menu (reset) .................................................. 45
Control Menu (Contrl) .............................................. 45
Setting up the Password (pass) ................................ 46
Protecting or Locking the Meter ............................. 46
Total Reset Password & Non-Resettable Total ..... 46
Making Changes to a Password Protected Meter.. 47
Disabling Password Protection .............................. 47
Advanced Operation and Programming ............... 48
Function Key Operation ............................................. 48
Digital Input Operation ........................................... 48
Advanced Setup and Calibration ............................... 48
Multi-Point Calibration & Scaling ........................... 48
Maximum/Minimum Readings ................................... 48
Advanced Features Menu ......................................... 49
Advanced Features Menu & Display Messages .... 49
Gate Function (Gate) ............................................. 50
Contact De-Bounce Filter (FiLter) ....................... 51
Rounding Feature (round) ..................................... 52
Modbus RTU Serial Communications (serial) .... 52
Select Menu (SElect) ........................................... 53
Signal Input Conditioning (Functn) ....................... 53
Low-Flow Cutoff (CutofF) ..................................... 53
Total and Grand Total Count Direction (Count) ..... 53
Analog Output Programming (AoutPr) .................. 54
Programmable Function Keys User Menu (user) .. 54
Troubleshooting .................................................... 56
Diagnostics Menu (diag) ........................................... 56
Determining Software Version ............................... 56
Reset Controller to Factory Defaults .......................... 56
Factory Defaults & User Settings........................... 57
Troubleshooting Tips ................................................. 59
3
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Helios Large Display Pulse Input Batch Controller Instruction Manual PD2-6310
Table of Figures
Figure 1. Meter Mounting Holes .......................... 11
Figure 2. Controller Dimensions - Side View ...... 11
Figure 3. Controller Dimensions – Front View .... 11
Figure 4. Vertical Pipe Mount Assembly ............. 12
Figure 5. Horizontal Pipe Mount Assembly ......... 12
Figure 6. Transmitter Supply Voltage Selection.. 13
Figure 7. Connector Labeling for Fully Loaded
PD2-6310 ............................................................ 14
Figure 8. Power Connections .............................. 14
Figure 9: Flowmeter Powered by Internal Power
Supply ................................................................. 15
Figure 10: Flowmeter Powered by External Supply
............................................................................ 15
Figure 11: Self-Powered Magnetic Pickup Coil
Flowmeter............................................................ 15
Figure 12: NPN open Collector Input .................. 15
Figure 13: PNP Sensor Powered by Internal
Supply ................................................................. 15
Figure 14: Switch Input Connections .................. 15
Figure 15. Relay Connections ............................. 15
Figure 16. AC and DC Loads Protection ............. 16
Figure 17. Low Voltage DC Loads Protection ..... 16
Figure 18. RS-422 or RS-485 Wiring .................. 17
Figure 19. RS-485 Two-Wire Multi-Drop Wiring . 18
Figure 20. Connections for RS485 Connector to
Serial Converter .................................................. 18
Figure 21. Three-Wire RS485 Connection .......... 18
Figure 22. Digital Input and Output Connections 19
Figure 23. F4 Digital Input Connections .............. 19
Figure 24. 4-20 mA Output Connections ............ 20
Figure 25. Interlock Connections ........................ 20
Introduction
The Helios PD2-6310 is a multi-purpose, easy to use, large-display pulse input batch controller
ideal for simplifying independent batch control operations where local control is preferred to
expensive plant operation systems. It features large 1.8 inch superluminous LED digits, which
can be read in sunlight from up to 100 feet away. It is housed in a water-resistant, field
mountable NEMA 4X/IP65 rated enclosure for convenient indoor and outdoor installation.
The controller comes programmed for easy start, pause, stop, and batch size (preset) changes.
Display line two (2) can be programmed to display rate, grand total, batch count, or preset by
cycling the Stop (F3) button. Digital inputs come standard.
Single and multi-stage batching is possible with up to four (4) on-board relays. Each batch
control relay may have a unique preclose amount when used for multi-stage batching. Manual
start batching is default, but automatic batching with a restart after a programmed time delay
from the completion of the last batch is also possible.
Overrun correction adjusts the closing of the batch control relays to adjust for inaccuracies from
batch to batch. This increases accuracy over time as systems wear out. The overrun correction
feature is capable of compensating for inaccuracies of up to 10% of the programmed preset
value.
The controller accepts pulse (e.g. ±40 mV to ±8 V), square wave (0-5 V, 0-12 V, or 0-24 V),
open collector, NPN, PNP, TTL or switch contact signals. Three of the programming buttons can
be set for custom operation. A fully loaded PD2-6310 batch controller comes with four (4) SPDT
relays, a 4 20 mA output, two 24 VDC power supplies, five (5) digital inputs and four (4) digital
outputs, and RS485 serial communications, making it an excellent addition to any system.
4
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Page 5
Helios Large Display Pulse Input Batch Controller Instruction Manual PD2-6310
85-265 VAC Model
12-24 VDC Model
Options Installed
PD2-6310-6H2
PD2-6310-7H2
2 relays
PD2-6310-6H7
PD2-6310-7H7
4 relays & 4-20 mA output
Model
Description
PDA6260
Pipe Mounting Kit
PDA7485-I
RS-232 to RS-422/485 isolated converter
PDA7485-N
RS-232 to RS-422/485 non-isolated converter
PDAPLUG2
Plastic Conduit Plug
PDX6901
Suppressor (snubber): 0.01 µF/470 , 250 VAC
Display
Main display: 1.8" (46 mm) high, red
LEDs
6 digits per line (-99999 to 999999),
with lead zero blanking
Display
Intensity
Eight user selectable intensity levels
Display
Update Rate
5/second (200 ms)
Overrange
Display flashes 999999
Underrange
Display flashes -99999
Display
Assignment
Display lines 1 & 2 may be assigned
to rate, total, grand total, batch
count, preset, set points, units
(lower display only), alternating R &
T, R & GT, preset & rate, max &
min, or a Modbus display register.
Any rate/total/grand total display
may be programmed to alternate
with a custom unit or tag.
Alternating
Display
Displays alternate every 10 seconds
when display is selected or batch is
paused.
Programming
Methods
Four programming buttons, digital
inputs, PC and MeterView Pro
software, or Modbus registers.
Noise Filter
Programmable from 2 to 199 (0 will
disable filter)
Filter Bypass
Programmable from 0.1 to 99.9% of
calibrated span
Recalibration
All ranges are calibrated at the
factory. Recalibration is
recommended at least every
12 months.
Max/Min
Display
Max/min readings reached by the
process are stored until reset by the
user or until power to the controller
is turned off.
Password
Three programmable passwords
restrict modification of programmed
settings.
Pass 1: Allows use of function keys
and digital inputs
Pass 2: Allows use of function keys,
digital inputs and editing set/reset
points
Pass 3: Restricts all programming,
function keys, and digital inputs
Total: Prevents resetting the total
manually
Gtotal: Prevents resetting the grand
total manually.
Power Options
85-265 VAC 50/60 Hz, 90-265 VDC,
20 W max or 12-24 VDC 10%, 15
W max
Powered over USB for configuration
only.
Isolated
Transmitter
Power Supply
Terminals P+ & P-: 24 VDC 10%.
12-24 VDC powered models
selectable for 24, 10, or 5 VDC supply
(internal P+/P- switch).
85-265 VAC models rated @ 200 mA
max, 12-24 VDC powered models
rated @ 100 mA max, @ 50 mA max
for 5 or 10 VDC supply.
Non-Volatile
Memory
All programmed settings are stored
in non-volatile memory for a
minimum of ten years if power is
lost.
Ordering Information
Standard Models
Accessories
Specifications
Except where noted all specifications apply to operation at +25°C.
General
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Helios Large Display Pulse Input Batch Controller Instruction Manual PD2-6310
Fuse
Required external fuse: UL
Recognized, 5 A max, slow blow; up
to 6 controllers may share one 5 A
fuse
Normal Mode
Rejection
Greater than 60 dB at 50/60 Hz
Isolation
4 kV input/output-to-power line;
500 V input-to-output or output-to-P+
supply
Overvoltage
Category
Installation Overvoltage Category II:
Local level with smaller transient
overvoltages than Installation
Overvoltage Category III.
Environmental
Operating temperature range: 40 to 65°C
Storage temperature range: -40 to
85°C
Relative humidity: 0 to 90% noncondensing
Connections
Removable and integrated screw
terminal blocks accept 12 to 22
AWG wire...
Enclosure
UL Type 4X, IP65 rated.
Polycarbonate & glass blended
plastic case, color: gray. Includes
four PG11 through-hole conduit
openings, with two factory installed
PG11, IP68, black nylon threaded
hole plugs with backing nuts.
Mounting
Wall Mounting: Four (4) mounting
holes provided for screwing
controller into wall. See Wall
Mounting Instructions on page 11
for additional details.
Pipe Mounting: Optional pipe
mounting kit (PDA6260) allows for
pipe mounting. Sold separately. See
Pipe Mounting Instructions on page
12 for additional details.
Tightening
Torque
Removable Screw Terminals: 5
lb-in (0.56 Nm)
Digital I/O and RS485 Terminals:
2.2 lb-in (0.25 Nm)
Overall
Dimensions
10.63" x 12.59" x 4.77" (270 mm x
319.7 mm x 121.2 mm) (W x H x D)
Weight
6.10 lbs (2.76 kg)
Warranty
3 years parts & labor
Inputs
Field selectable: Pulse or square
wave 0-5 V, 0-12 V, or 0-24 V @ 30
kHz; TTL; open collector 4.7 k
pull-up to 5 V @ 30 kHz; NPN or
PNP transistor, switch contact 4.7
k pull-up to 5 V @ 40 Hz; Modbus
PV (Slave)
Low Voltage
Mag Pickup
(Isolated)
Sensitivity: 40 mVp-p to 8Vp-p
Minimum
Input
Frequency
0.001 Hz
Minimum frequency is dependent
on high gate setting.
Maximum
Input
Frequency
30,000 Hz (10,000 for low voltage
mag pickup)
Input
Impedance
Pulse input: Greater than 300 k @
1 kHz.
Open collector/switch input: 4.7 k
pull-up to 5 V.
Accuracy
±0.03% of calibrated span ±1 count
Temperature
Drift
Rate display is not affected by
changes in temperature.
Multi-Point
Linearization
2 to 32 points
Low-Flow
Cutoff
0-999999 (0 disables cutoff
function)
Decimal Point
Up to five decimal places or none:
d.ddddd, d.dddd, d.ddd, d.dd, d.d, or
dddddd
Calibration
May be calibrated using K-factor,
internal calibration, or by applying
an external calibration signal.
K-Factor
Field programmable K-factor
converts input pulses to rate in
engineering units. May be
programmed from 0.00001 to
999,999 pulses/unit.
Calibration
Range
Input 1 signal may be set anywhere
in the range of the controller; input 2
signal may be set anywhere above
or below input 1 setting. Minimum
input span between any two inputs
is 10 Hz. An error message will
appear if the input 1 and input 2
signals are too close together.
Filter
Programmable contact de-bounce
filter: 40 to 999 Hz maximum input
frequency allowed with low speed
filter.
Time Base
Second, minute, hour, or day
Gate
Low gate: 0.1-99.9 seconds; High
gate: 2.0-999.9 seconds
F4 Digital
Input Contacts
3.3 VDC on contact. Connect
normally open contacts across F4 to
COM.
F4 Digital
Input
Logic Levels
Logic High: 3 to 5 VDC; Logic
Low: 0 to 1.25 VDC
Rate Display
Indication
-99999 to 999999, lead zero
blanking. “R” LED illuminates while
displaying rate.
Pulse Input
Batch Controller Rate/Totalizer Display
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Helios Large Display Pulse Input Batch Controller Instruction Manual PD2-6310
Batch Total &
Grand Total
Display
0 to 999,999; automatic lead zero
blanking. “T” LED is illuminated while
displaying batch total. “GT” LEDs are
illuminated while displaying grand
total. Up to 999,999 for batch
total/preset. Up to 999,999,999 with
grand total-overflow feature. “oF” is
displayed to the left of grand total
overflow and ▲ LED is illuminated.
Batch Total
Decimal
Point
Up to five decimal places or none:
d.ddddd, d.dddd, d.ddd, d.dd, d.d, or
dddddd
Total decimal point is independent of
rate decimal point.
Totalizer
Calculates total based on rate and
field programmable multiplier to
display total in engineering units.
Time base must be selected
according to the time units in which
the rate is displayed.
Grand
Totalizer
Rollover
Grand totalizer rolls over when
display exceeds 999,999,999. Relay
status reflects display.
Grand Total
Alarms
Up to seven, user selectable under
setup menu. Any set point can be
assigned to grand total and may be
programmed anywhere in the range
of the controller for grand total alarm
indication. Relay 1 should always be
assigned to batch.
Programmabl
e Delay
On Release
0.1 and 999.9 seconds; applied to
the first relay assigned to total or
grand total.
If the controller is programmed to
reset total to zero automatically when
the preset is reached, then a delay
will occur before the total is reset.
Grand Total
Reset
Via front panel button, external
contact closure on digital inputs,
automatically via user selectable
preset value and time delay, or
through serial communications.
Grand Total
Reset
Password
Grand total passwords may be
entered to prevent resetting the
grand total from the front panel.
NonResettable
Grand Total
The grand total can be programmed
as a non-resettable total by entering
the password “050873”.
Caution!
Once the Grand Total has
been programmed as
“non-resettable” the
feature cannot be
disabled.
Rating
2 or 4 SPDT (Form C) internal
and/or 4 SPST (Form A) external;
rated 3 A @ 30 VDC and 125/250
VAC resistive load; 1/14 HP (≈ 50
W) @ 125/250 VAC for inductive
loads
Noise
Suppression
Noise suppression is recommended
for each relay contact switching
inductive loads; see page 16 for
details.
Deadband
0-100% of span, user
programmable
High or Low
Alarm
User may program any alarm for
high or low trip point.
Unused alarm LEDs and relays may
be disabled (turn off).
Relay
Operation
Primary Functions:
Batch Control
Automatic (non-latching)1
Sampling (based on time)
Off (disable unused relays and
enable Interlock feature)
Manual on/off control mode
Secondary Functions2:
Pump alternation control (2 to 4
relays)
Latching (requires manual
acknowledge)
Relay Reset
User selectable via front panel
buttons or digital inputs
1. Automatic reset only (nonlatching), when the input
passes the reset point.
2. Automatic + manual reset at any
time (non-latching)
3. Manual reset only, at any time
(latching)
4. Manual reset only after alarm
condition has cleared (latching)
Note: Front panel button or digital
input may be assigned to
acknowledge relays
programmed for manual
reset.
Alarm Time
Delay
0 to 999.9 seconds, on & off relay
time delays
Programmable and independent for
each relay
Fail-Safe
Operation
Programmable and independent for
each relay.
Note: Relay coil is energized in non-
alarm condition. In case of
power failure, relay will go to
alarm state.
Alarm Auto
Initialization
When power is applied to the
controller, relays will reflect the
state of the input to the controller.
Output
Source
Process variable (PV), max, min, set
points 1-8, Modbus input, or manual
control mode
!
Relays
Isolated 4-20 mA Transmitter Output
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2
These functions are not functional when the unit is
being used as a batch controller with total set to yes.
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Helios Large Display Pulse Input Batch Controller Instruction Manual PD2-6310
Scaling
Range
1.000 to 23.000 mA for any display
range
Calibration
Factory calibrated: 4.000 to 20.000 =
4-20 mA output
Analog Out
Programming
23.000 mA maximum for all
parameters:
Overrange, underrange, max, min,
and break
Accuracy
± 0.1% of span ± 0.004 mA
Temperature
Drift
0.4 µA/C max from 0 to 65C
ambient,
0.8 µA/C max from -40 to 0C
ambient
Note: Analog output drift is separate
from input drift.
Isolated
Transmitter
Power
Supply
Terminals I+ & R: 24 VDC 10%. May
be used to power the 4-20 mA output
or other devices. Refer to Figure 24
on page 20.
All models rated @ 40 mA max.
External
Loop Power
Supply
35 VDC maximum
Output Loop
Resistance
Power supply
Minimum
Maximum
24 VDC
10
700
35 VDC
(external)
100
1200
Compatibility
EIA-485
Connectors
Removable screw terminal connector
Max Distance
3,937' (1,200 m) max
Status
Indication
Separate LEDs for Power (P),
Transmit (TX), and Receive (RX)
Slave Id
1 – 247 (Controller address)
Baud Rate
300 – 19,200 bps
Channels
4 digital inputs & 4 digital outputs
Digital Input
Logic High
3 to 5 VDC
Digital Input
Logic Low
0 to 1.25 VDC
Digital
Output Logic
High
3.1 to 3.3 VDC
Digital
Output Logic
Low
0 to 0.4 VDC
Source
Current
10 mA maximum output current
Sink Current
1.5 mA minimum input current
+5 V
Terminal
To be used as pull-up for digital
inputs only.
Connect normally open pushbuttons
across +5 V & DI 1-4.
WARNING!
DO NOT use +5 V
terminal to power
external devices.
Serial Communications
Transmit
Time Delay
Data 8 bit (1 start bit, 1 or 2 stop bits)
Parity Even, Odd, or None with 1 or 2 stop
Byte-To-Byte
Timeout
Turn Around
Delay
Note: Refer to the Modbus Register Tables
for details.
Programmable between 0 and 199
ms
bits
0.01 – 2.54 second
Less than 2 ms (fixed)
Digital Input & Output Terminal
Modbus® RTU Serial Communications
8
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Helios Large Display Pulse Input Batch Controller Instruction Manual PD2-6310
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
Low Voltage Directive
EN 61010-1:2010
Safety requirements for measurement, control, and laboratory use
Compliance Information
Safety
9
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Helios Large Display Pulse Input Batch Controller Instruction Manual PD2-6310
Caution: Read complete instructions
prior to installation and operation of the
controller.
Warning: Risk of electric shock or
personal injury.
Warning!
Hazardous voltages exist within enclosure.
Installation and service should be performed only by trained
service personnel.
!
Safety Information
Installation
There is no need to open the clear plastic front cover in order to complete the installation, wiring,
and setup of the controller. All programming is done through the buttons and switches located
under the lower door panel and are accessible by removing the single securing screw. Wires
should be run through the knockout holes located on the bottom of the controller.
There are a total of four pre-drilled conduit entry holes located at the bottom of the controller. If
the need to drill additional holes arises, make sure you will have the clearance necessary for
conduit mounting hardware.
Do not disconnect the RJ45 connector found on the right side of the controller wiring board. Doing
so will disable the onboard digital I/O, RS-485 serial communications, and M-Link functionality.
Instructions are provided for changing the transmitter power supply to output 5 or 10 VDC instead
of 24 VDC, see page 12.
Unpacking
Remove the controller from box. Inspect the packaging and contents for damage. Report
damages, if any, to the carrier. If any part is missing or the controller malfunctions, please contact
your supplier or the factory for assistance.
10
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Helios Large Display Pulse Input Batch Controller Instruction Manual PD2-6310
Figure 2. Controller
Dimensions - Side View
Figure 3. Controller Dimensions – Front View
2.63" (67 mm)
4.77"
(121.2 mm)
Mounting Hole Mounting Hole
Front Door
Panel Sc rew
10.63" (270 mm)
12.59" (319. 7 mm)
10.43" (265 mm)
9.8" (249 mm)
11.14" (283 mm)
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.
1. Prepare a section of wall
approximately 11” x 13” (280 mm x
330 mm) for controller mounting by
marking with a pencil the mounting
holes (shown in the image to the
right) on the wall.
2. Using a drill bit slightly smaller than
the girth of the mounting screws,
pre-drill holes at the mounting
locations previously marked.
3. Insert mounting screws into the four
mounting holes and screw them into
the pre-drilled holes. Do not
overtighten the mounting screws
as it is possible that the enclosure
could crack and become damaged.
Figure 1. Meter Mounting Holes
Mounting Dimensions
11
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Helios Large Display Pulse Input Batch Controller Instruction Manual PD2-6310
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.
1. Secure the mounting plates to the top
and bottom (for vertical pipes) or left and
right (for horizontal pipes) of the reverse
side of the meter enclosure using the
provided fasteners. Do not overtighten
the fasteners as it could cause damage
to the enclosure.
2. Using the provided nuts and U-bolts,
secure the mounting plates to the pipe
enough torque such that the meter
cannot be moved up or down (or side to
side).
Figure 4. Vertical Pipe Mount Assembly
Figure 5. Horizontal Pipe Mount Assembly
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Helios Large Display Pulse Input Batch Controller Instruction Manual PD2-6310
Caution
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 meter and
ensure personnel safety.
MENU START
F1
BATCH
F2
STOP
F3
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.
If the transmitter requires 5 or 10 VDC excitation, the switch labeled P+/P- must be configured
accordingly.
To access the voltage selection jumper:
1. Unplug the meter power.
2. Unscrew and open the front door panel.
3. Locate the P+/P- switch located in the center of the connections board (see diagram below).
4. Flip this switch into the appropriate position for the required transmitter excitation.
Figure 6. Transmitter Supply Voltage Selection
Connections
All connections are made to screw terminal connectors located under the front door panel. Remove the
single securing screw in order to access the wiring terminals.
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Helios Large Display Pulse Input Batch Controller Instruction Manual PD2-6310
Warning!
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.
Do not disconnect the RJ45 connector located to the left of the power
terminal block. Doing so will disable the onboard digital I/O, RS-485
serial communications, and M-Link functionality.
MA OUT
21 3
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RELA Y4RELA Y3
43 6521
RELA Y2RELA Y1
MENU STARTF1BATCHF2STOP
F3
AC or DC
POWER
Required External Fuse:
5 A max, 250 V Slow Blow
POWER
+
-
Connectors Labeling
The connectors’ label, affixed to the inside of the lower door panel, shows the location of all connectors
available with requested configuration.
Figure 7. Connector Labeling for Fully Loaded PD2-6310
Power Connections
Power connections are made to a two-terminal connector labeled POWER on Figure 7 on page 14. The
meter will operate regardless of DC polarity connection. The + and - symbols are only a suggested wiring
convention.
Figure 8. Power Connections
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Helios Large Display Pulse Input Batch Controller Instruction Manual PD2-6310
Figure 9: Flowmeter Powered by Internal
Power Supply
Figure 10: Flowmeter Powered by External
Supply
Figure 11: Self-Powered Magnetic Pickup
Coil Flowmeter
Figure 12: NPN open Collector Input
Figure 13: PNP Sensor Powered by
Internal Supply
Figure 14: Switch Input Connections
43 6521
RELAY4RELAY3
43 6521
RELAY2RELAY1
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.
Setup and programming is performed through the front panel buttons.
Modbus RTU Serial Communications
Serial communications connection can be made to the onboard RS485 terminal block or USB connector
shown in Figure 7. If RS232 is required, an RS485 to RS232 adapter (PDA7485) may be used. See
Ordering Information on page 5 for additional information.
Relay Connections
Relay connections are made to two six-terminal connectors labeled
RELAY1 – RELAY4 on Figure 7. Each relay’s C terminal is common only to the normally open (NO) and
normally closed (NC) contacts of the corresponding relay. The relays’ C terminals should not be confused
with the COM (common) terminal of the INPUT SIGNAL connector.
Figure 15. Relay Connections
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Helios Large Display Pulse Input Batch Controller Instruction Manual PD2-6310
C
R
C
R
Use a diode with a reverse breakdown
voltage two to three times the circuit
voltage and forward current at least as
large as the load current.
Switching Inductive Loads
The use of suppressors (snubbers) is strongly recommended when switching inductive loads to prevent
disrupting the microprocessor’s operation. The suppressors also prolong the life of the relay contacts.
Suppression can be obtained with resistor-capacitor (RC) networks assembled by the user or purchased
as complete assemblies. Refer to the following circuits for RC network assembly and installation:
Figure 16. AC and DC Loads Protection
Choose R and C as follows:
R: 0.5 to 1 Ω for each volt across the contacts
C: 0.5 to 1 µF for each amp through closed contacts
Notes:
1. Use capacitors rated for 250 VAC.
2. RC networks may affect load release time of solenoid loads. Check to confirm proper operation.
3. Install the RC network at the meter's relay screw terminals. An RC network may also be installed
across the load. Experiment for best results.
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.
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Helios Large Display Pulse Input Batch Controller Instruction Manual PD2-6310
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
removable screw terminal connector for the RS-485 terminals which
includes Transmit Data (DO) and (/DO), Receive Data (DI) and (/DI),
and Signal Ground. Baud rates are adjustable and handled by the
meter (see Modbus RTU Serial Communications on page 52 for
more information).
The RS-485 connector has three diagnostic LEDs: a Power (PWR)
LED to show when the adapter is powered properly, a Transmit Data (TX) LED to show when the adapter
is sending data out from the PC side, and a Receive Data (RX) LED to show when the adapter is
receiving data from the meter.
Installation
Figure 18 shows the connection of a meter to a PC using the RS485 output connector and a PDA7485
RS-232 to RS-422/485 converter in an RS-422 network. Figure 19 shows the connection of several
meters to a PC using a PDA7485 RS-232 to RS-422/485 converter in an RS-485 network.
When using more than one meter in a multi-drop mode, each meter must be provided with its own unique
address. The meter address (Slave ID) may be programmed between 1 and 247. The transmit delay may
be set between 0 and 199 ms. The parity can be set to even, odd, or none with 1 or 2 stop bits.
To change the meter address:
1. Press and hold the Menu button for three seconds to access Advanced Features menu of the meter.
2. Press Up arrow until Serial (SEriaL) menu is displayed and press Enter, Addres is displayed.
3. Press Enter to change meter address using Right and Up arrow buttons. Press Enter to accept.
4. Press Menu button to exit and return to Run Mode.
Figure 18. RS-422 or RS-485 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-422/485 Converter documentation for further details.
3. Use shielded cable, twisted-pairs plus ground. Connect ground shield only at one location.
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Helios Large Display Pulse Input Batch Controller Instruction Manual PD2-6310
RS485 Connector to RS-422/485 Serial
Converter Connections
RS-422/485 Serial
Converter
PDA1485 RS-485
Adapter
DO DI
DO DI
DI DO
DI DO
Figure 20. Connections for RS485
Connector to Serial Converter
Figure 19. 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.
3. Use shielded cable, twisted-pair plus ground. Connect ground shield only at one location.
Connections
Figure 20 details the wiring connections from the RS-485
connector to an RS-422/485 serial converter (such as the
PDA7485 or PDA8485) for a four-wire network.
Three Wire Connection
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.
Figure 21. Three-Wire RS485 Connection
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Helios Large Display Pulse Input Batch Controller Instruction Manual PD2-6310
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. Digital output connections are made by wiring from the appropriate digital output block to the
grounding terminal block.
Figure 22. Digital Input and Output Connections
F4 Digital Input Connections
Digital input F4 is also available on the meter. This digital input is connected with a normally open contact
across F4 and COM, or with an active low signal applied to F4.
Figure 23. F4 Digital Input Connections
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Helios Large Display Pulse Input Batch Controller Instruction Manual PD2-6310
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.
Figure 24. 4-20 mA Output Connections
Analog Output Transmitter Power Supply
The internal 24 VDC power supply powering the analog output may be used to power other devices, if the
analog output is not used. The I+ terminal is the +24 V and the R terminal is the return.
Interlock Relay Feature
As the name implies, the interlock relay feature reassigns one, or more, alarm/control relays for use as
interlock relay(s). Interlock contact(s) are wired to digital input(s) and trigger the interlock relay. This
feature is enabled by configuring the relay, and relative digital input(s) (see page 44). In one example, dry
interlock contacts are connected in series to one digital input which will be used to force on (energize) the
assigned interlock power relay when all interlock contacts are closed (safe). The interlock relay front
panel LED flashes when locked out. The interlock relay would be wired in-series with the load (N/O
contact). See below.
Figure 25. Interlock Connections
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Helios Large Display Pulse Input Batch Controller Instruction Manual PD2-6310
The meter has been factory calibrated to read input
frequency in Hz (pulses/sec). The calibration equipment is
certified to NIST standards.
Basic Operation and Programming
Overview
There are no jumpers to set for the meter input selection. The controller has one switch located to the
right of the input connector, which must be configured according to the input level and type.
Setup and programming is done through the programming buttons located under the front door panel.
After power and input signal connections have been completed and verified, apply power to the meter.
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Helios Large Display Pulse Input Batch Controller Instruction Manual PD2-6310
Button Symbol
Description
LED
Status
Menu
1-4
Alarm 1-4 indicator
START
Right arrow/F1
R
Rate Indicator
BATCH
Up arrow/F2
T
Batch total indicator
STOP
Acknowledge (Enter)/F3
G T
Grand total indicator
Note:
F4 – F8 are digital inputs.
▲
Total overflow indicator
M
Flashing: Manual control of flashing
relays. M flashing alone indicates manual
analog output. Indicators flash every 10
seconds.
Front Door
Panel
MA OUT
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43 6521
RELAY4RELA Y3
43 6521
RELA Y2RELA Y1
MENU STARTF1BATCHF2STOP
F3
MENU
START
F1
BAT CH
F2
ST OP
F3
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. The Right Arrow button is used during numeric
and decimal point programming.
• Press the Menu button to enter or exit the Programming Mode at any time.
• Press the Right arrow button to move to the next digit during digit or decimal point programming.
• Press or hold the Up arrow button to scroll through the menus, decimal point, or to increment the
value of a digit.
• Press the Enter button to access a menu or to accept a setting.
• Press and hold the Menu button for three seconds to access the advanced features of the meter.
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Helios Large Display Pulse Input Batch Controller Instruction Manual PD2-6310
Note: If you decide to update your MeterView Pro software, once the installation has completed, you
will be asked if you want to update the setup files located on the meter itself. This way, you will always
have the most current version on the meter for future installs.
Warning
Do not unplug the meter while the new installation files are being written to it. The
meter will display
uwrite
during the process and you will receive an onscreen
notification once the process is complete.
Front Door
Panel
MENU
RESET
F1
MAX
F2
ENTER
F3
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. The meter is powered by the USB connection, so there is no need
to wire anything prior to programming the meter, though USB is intended only for meter configuration.
MeterView Pro Installation
1. Connect one end of the provided USB cable to the meter and the other end to the computer. The
computer will automatically install the driver software it needs to talk to the meter.
Only one meter may be connected at a time. Attaching multiple meters will cause a conflict
with the meter software. Disconnect other meters before performing these steps.
2. Once the driver is installed, an AutoPlay dialog should appear
for the drive “MAINSTAL.” Click “Open folder to view files.”
If the computer does not display an AutoPlay dialog for the
drive “MAINSTAL,” you should open My Computer and doubleclick on the drive labeled “MAINSTAL.”
3. Double-click on the file named “MAStart.” The program will
open a few windows and install two programs on your
computer. Simply follow the onscreen instructions until you see
one of the dialogs below. If you receive a “User Account
Control” warning, click “Yes.”
4. If there is an update available, click the “Update” button to
install the new version. Otherwise, click “Configure” to begin
programming your meter.
Data logging for one meter at a time is available with MeterView Pro software. More advanced data
acquisition may be accomplished by using any Modbus RTU compliant software. Additional information
regarding configuration and monitoring of the meter using MeterView Pro software is available online.
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Helios Large Display Pulse Input Batch Controller Instruction Manual PD2-6310
Only STOP Button Enabled if a Batch is Running
During a batch process, only the pause/stop
functions of the STOP button will function. No other
buttons will be functional.
!
Controller Operation
The PD2-6210 controller is capable of accepting 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. The pulse signals may be scaled with a Kfactor to represent a total for the batch, and grand total.
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.
When in pause or stop mode, the display will alternate the numeric value with the run status in the upper
display and the display label for the lower display.
The controller has up to 4 relays on board which are used to either control the batch process in single or
multi-stage batch control, or as alarms that will be active when the batch process is running. A 4-20 mA
output option is also available for retransmitting the process variable analog signal.
Default Batch Control Operation
The following describes the operation of the three operating buttons as programmed with default settings.
START Button
Press the START button to begin a new batch process.
BATCH Button
Press the Batch button to access the Preset (batch amount) menu. Program the batch with the arrow
keys, and confirm with the Enter key.
STOP Button
Press the STOP key once during a batch to pause. Press the STOP key while paused to stop and
cancel the batch. Press the STOP key while in stop/ready mode cycle lower display values of rate (or
other lower display programmed parameter), grand total, batch count, and preset.
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Helios Large Display Pulse Input Batch Controller Instruction Manual PD2-6310
Parameter
Setting
Function
Relay
Assign
Press Enter to enter the relay assignment parameters.
Asign1
total
Assign relay 1 to batch total control.
Asign2
total
Assign relay 2 to batch total control.
Precls
Total
Press Enter to access preclose
selection for multi-stage control.
Precls
Yes
Yes to enable a preclose value for relay 2.
Yes
00005..0
Set the preclose value to 5 for closing the valve controlling
relay 2 five gallons before reaching the preset.
… Assignment for optional relays 3-4.
Rly 1
relay
Select relay 1 setup.
Act 1
rly 1
Configure activation of relay 1.
Act 1
Auto
Always set to Auto for batch control function.
Rly 1
Preset
Set the preset value for batch control.
Preset
00055.0
Set 55 gallons as the preset.
… Setup for optional relays 3-4.
Batch Control Operation Example
The following example shows how two stage batch control functions with a PD2-6310 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. After the batch, the preset
will be changed to 100 gallons.
Two-Stage Batch Control Setup Using Relays 1 & 2
The following table shows the parameters as they appear within the Setup menu entry relay.
The operation of relay 2 has already been assigned for multi-stage control preclose, and will not appear
as a selection in the relay menu.
If only one stage batch control was desired, with one relay for control, then one would set the assignment
of relay 2, assign2, to off, rate, or grand total.
The following pages show an illustration of how the above settings control the batch operation. The
display assignment is the default.
Batch Control Operation
1. A new container is prepared for the batch. Both valves are closed. Note that the upper display may
show the batch total from the last batch.
2. The START button is pressed. Both valves open. The barrel begins to fill as the total being dispensed
is displayed in the big window. The lower window shows the rate and units, alternating.
3. When the batch total reaches 50 gallons, the preset (55) minus the preclose amount (5) for relay 2,
relay 2 deactivates to close the main valve. The barrel fills more slowly as a result, improving
accuracy.
4. When the batch total equals the preset, relay 1 deactivates, closing valve 1. Filling stops.
5. The BATCH button is pressed, and a new preset is entered, 100 gallons, and the enter/STOP button is
pressed to confirm it.
6. The new batch begins when the START button is pressed, so both relays activate and both valves
open.
Additional Features
At any time during the batch, the STOP button may be pressed to pause the batch. When paused, the
START button will continue the batch, and pressing the STOP button again will cancel the batch.
When in STOP mode, the STOP button may be pressed to cycle through alternative parameters to be
displayed on the lower display, including the grand total, batch count, and preset.
The grand total and batch count may be reset in the reset menu by pressing the MENU button and
entering the reset menu. It may also be reset with digital inputs.
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Helios Large Display Pulse Input Batch Controller Instruction Manual PD2-6310
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Helios Large Display Pulse Input Batch Controller Instruction Manual PD2-6310
Display
Parameter
Action/Setting Description
setup
Setup
Enter Setup menu
Input
Input
Enter Input selection menu
Total
Total
Enable or disable totalizer features
units
Units
Select the display units/tags
rate
Rate
Select the display units for rate
total
Total
Select the display units for total
Gtotal
Grand Total
Select the display units for grand total
Dec pt
Decimal point
Set decimal point
prog
Program
Enter the Program menu
InCAL
Input Calibration
Enter the Input Calibration menu
factor
K-factor Scaling
Programs unit to convert input pulse to rate in engineering units
SCALE
Scale
Enter the Scale menu
Cal
Calibrate
Enter the Calibration menu
Inp 1
Input 1
Calibrate input 1 signal or program input 1 value
Dis 1
Display 1
Program display 1 value
Inp 2
Input 2
Calibrate input 2 signal or program input 2 value (up to 32 points)
Dis 2
Display 2
Program display 2 value (up to 32 points)
Error
Error
Error, calibration not successful, check signal or programmed value
T tb
Total time base
Program total time base
T CF
Total conversion
factor
Program total conversion factor
mode
Batch mode
Automatic or manual batch control
T dly
Time delay
Set time delay for automatic batch restart
GT tb
Grand total time
base
Program grand total time base
GT CF
Grand total
conversion factor
Program grand total conversion factor
GT rst
Grand total reset
Program grand total rest mode: auto or manual
Auto
Automatic
Press Enter to set automatic total reset
T dly
Time delay
Program time delay for total auto reset
mAn
Manual
Press Enter to reset total manually
dsplay
Display
Enter the Display menu
Line 1
Display Line 1
Press Enter to assign the display line 1 parameter (default: PV)
Line 2
Display Line 2
Press Enter to assign the display line 2 parameter (default:
engineering units)
d-Inty
Display intensity
Set display intensity level from 1 to 8
RELaY
Relay
Enter the Relay menu
Assign
Assignment
Assign relays to rate, total, or grand total
Asign1
Assign 1
Relay 1 assignment
totAL
Total
Assign relay to total
G total
Grand total
Assign relay to grand total
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.
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Helios Large Display Pulse Input Batch Controller Instruction Manual PD2-6310
Display
Parameter
Action/Setting Description
m bus
Modbus
Select to display Modbus input or to assign Modbus input as the
analog output source
rate
Rate
Assign relay to rate
precls
Batch total relay
preclose
For relays beyond the first assigned to total, a preclose amount may
be entered.
RLY 1
Relay 1
Relay 1 setup
Act 1
Action 1
Set relay 1 action
Auto
Automatic
Set relay for automatic reset
A-nman
Auto-manual1
Set relay for automatic & manual reset any time
LatCH
Latching1
Set relay for latching operation
Lt-CLr
Latching-cleared1
Set relay for latching operation with manual reset only after alarm
condition has cleared
Altern
Alternate2
Set relay for pump alternation control
Sanmpl
Sampling
Set relay for sampling operation
OFF
Off
Disable relay and front panel status LED
(Select Off to enable Interlock feature)
Preset
Preset
Set batch preset
Set 1
Set 1
Program set point 1
RSt 1
Reset 1
Program reset point 1
RLY 2
Relay 2
Relays 2-4 setup
FaiLSF
Fail-safe
Enter Fail-safe menu
FLS 1
Fail-safe 1
Set relay 1 fail-safe operation
on
On
Enable fail-safe operation
off
Off
Disable fail-safe operation
FLS 2
Fail-safe 2
Set relays 2-8 fail-safe operation
DeLAY
Delay
Enter relay Time Delay menu
DLY 1
Delay 1
Enter relay 1 time delay setup
On 1
On 1
Set relay 1 On time delay
OFF 1
Off 1
Set relay 1 Off time delay
DLY 2
Delay 2
Enter relays 2-8 time delay setup
break
Loop break
Set relay condition if loop break detected
ignore
Ignore
Ignore loop break condition (Processed as a low signal condition)
On
On
Relay goes to alarm condition when loop break is detected
Off
Off
Relay goes to non-alarm condition when loop break is detected
Aout
Analog output
Enter the Analog output scaling menu
Dis 1
Display 1
Program display 1 value
Out 1
Output 1
Program output 1 value (e.g. 4.000 mA)
Dis 2
Display 2
Program display 2 value
Out 2
Output 2
Program output 2 value (e.g. 20.000 mA)
1. During operation, only the STOP button will function, to stop/pause the batch. As a result, relay
alarms cannot be manually reset.
2. This setting used for level control applications. It is not appropriate if using this controller for batching
applications.
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Helios Large Display Pulse Input Batch Controller Instruction Manual PD2-6310
Display
Parameter
Action/Setting Description
reset
Reset
Press Enter to access the Reset menu
Rst Hi
Reset high
Press Enter to reset max display
Rst Lo
Reset low
Press Enter to reset min display
Rst HL
Reset high &
low
Press Enter to reset max & min displays
Rst t
Reset total
Press Enter to reset total
Rst Gt
Reset grand
total
Press Enter to reset grand total
Rst bc
Reset batch
count
Press Enter to reset batch count
Contrl
Control
Enter Control menu
Auto
Automatic
Press Enter to set meter for automatic operation
mAn
Manual
Press Enter to manually control relays or analog output operation
pass
Password
Enter the Password menu
Pass 1
Password 1
Set or enter Password 1
Pass 2
Password 2
Set or enter Password 2
Pass 3
Password 3
Set or enter Password 3
Total
Total password
Set or enter password for manual reset
Gtotal
Grand total
password
Set or enter password for manual reset
nonrst
Non-resettable
Non-resettable grand total set after entering “050873” for Gtotal
password
unloc
Unlocked
Program password to lock meter
locd
Locked
Enter password to unlock meter
999999
-99999
Flashing
Over/under range condition
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Helios Large Display Pulse Input Batch Controller Instruction Manual PD2-6310
004.000
004.000
005.000
dis 1 dis 1 dis 1
Next
Setting
Select
Next
Digit
Increment
Digital
Value
Accept
Setting
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.
• Press Menu, at any time, to exit and
return to Run Mode. Changes made
to settings prior to pressing Enter are
not saved.
• Changes to the settings are saved to
memory only after pressing Enter/F3.
• The display moves to the next menu
every time a setting is accepted by
pressing Enter/F3.
Setting Numeric Values
The numeric values are set using the Right and Up arrow buttons. Press Right arrow to select next digit
and Up arrow to increment digit value.
The digit being changed is displayed brighter than the rest.
Press and hold up arrow to auto-increment the display value.
Press the Enter button, at any time, to accept a setting or Menu button to exit without saving changes.
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Helios Large Display Pulse Input Batch Controller Instruction Manual PD2-6310
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. Program menu for scaling or
calibration
6. Display parameter and
intensity
7. Relay operation
8. 4-20 mA analog output
scaling
Press the Enter button to access any
menu or press Up arrow button to
scroll through choices. Press the
Menu button to exit at any time.
Setting the Input Signal (Input)
There is a switch, located to the right
of the input connector, which must be
configured according to the input
level and type. Jumper J4 located
inside the controller, behind the input
signal connector, is used to select
the excitation voltage (24 V*, 10 V or
5 V) which is supplied to the P+ and
P- wiring terminals.
The controller may be calibrated
using the K-Factor function. Most
flowmeter manufacturers provide this information with the device. Enter the K-Factor (Factor) menu and
select the decimal point with highest resolution possible and program the K-factor value (i.e. pulses/gal).
The controller will automatically calculate the flow rate using the K-factor and the time base selected.
*Default setting
Setting the Totalizer and Batching Features (total)
To simply not display the total, select alternative display parameters in the display (dsplay) menu.
Enable or disable the totalizer and batching features by selecting “Yes” or “no” after the input type has
been set up. If the totalizer features are disabled, all the totalizer and batching features and functions are
hidden from the menus.
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Helios Large Display Pulse Input Batch Controller Instruction Manual PD2-6310
Display
Character
Display
Character
Display
Character
Display
Character
0
0
C
C
k
K
v V 1
1
c
c
l
L
uw
w
2
2
d
d
m
m
x X 3
3
e
E
N
n
y Y 4
4
f
F
O
O
z Z 5
5
g
G
o
o
- - 6
6
9
g
p
P
/ / 7
7
H
H
q
q
[ ] 8
8
h
h
r
r
] [ 9
9
I
I
s
S
= = A
A
I
i
t
t
!
Degree(<)
b
b
j
J
u
u
Space
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 37 to access the display menu to show the unit or tag on the little
display. The engineering units or custom legends can be set using the following 7-segment character set:
Notes:
Degree symbol represented by (<) if programming with MeterView® Pro.
The letters “m” and “w” use two 7-segment LEDs each; when selected the characters to the right are
shifted one position.
Press and hold up arrow to auto-scroll the characters in the display.
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.
Pressing the Right arrow moves the decimal point one place to the right until no decimal point is
displayed then it moves to the leftmost position. Pressing the Up arrow moves the decimal point one
place to the left.
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Helios Large Display Pulse Input Batch Controller Instruction Manual PD2-6310
Programming the Batch Controller (prog)
It is very important to read the following information, before proceeding to program the meter:
• The meter has been factory calibrated to read input frequency in Hz (pulses/sec). The calibration
equipment is certified to NIST standards.
• There is no need to recalibrate the controller when first received from the factory.
• Use the K-Factor menu to match the rate/totalizer with a flowmeter’s k-factor (pulse/unit of measure).
• Use the Scale menu to scale the pulse input (pulse/sec) without a signal source.
• Use Cal menu to calibrate the rate/totalizer using a signal source.
The Program menu contains the following menus:
1. K-Factor calibration
2. Scale without a signal source
3. Calibrate with a calibrated signal source
4. Total time base & conversion factor
5. Grand total time base & conversion factor
6. Total reset mode for total & grand total
Note: The Scale, Calibrate, and K-Factor functions are exclusive of each other. The meter uses the last
function programmed. Only one of these methods can be employed at a time. The Scale and Calibrate
functions can use up to 32 points (default is 2). The number of points should be set in the Advanced
Features menu under the Multi-Point Linearization (Linear) menu selection prior to scaling and
calibration of the meter, see page 53 for details.
The process input may be calibrated or scaled to any display value within the range of the meter.
Additional parameters, not needed for most applications, are programmed in the Advanced Features
menu; see Advanced Features Menu, page 49.
Multi-Point Calibration & Scaling
The meter is set up at the factory for 2-point linear calibration. The number of points for multi-point
calibration/scaling is set up in the Advanced Features menu. Up to 32 linearization points may be
selected. See page 53 for details.
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Page 34
Helios Large Display Pulse Input Batch Controller Instruction Manual PD2-6310
For instructions on how to program
numeric values see Setting Numeric
Values, page 30.
Input Calibration Method (
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.
• Use the Calibrate menu to apply a signal from a signal source.
Note: The Scale and Calibrate functions are exclusive of each other. The meter uses the last function
programmed. Only one of these methods can be employed at a time. The Scale and Calibrate functions
can use up to 32 points (default is 2). The number of points should be set in Scale and Calibrate
accordingly under the Number of Points (nopts) menu selection prior to scaling and calibration of the
meter, see page 53 for details.
K-Factor Calibration (
The meter may be calibrated using the K-Factor function. Most flowmeter manufacturers provide this
information with the device. Enter the K-Factor (Factor) menu and select the decimal point with highest
resolution possible and program the k-factor value (i.e. pulses/gal). The meter will automatically calculate
the flow rate using the k-factor and the time base selected.
InCAL
Factor
)
)
Scaling the Meter (
The process inputs (4-20 mA and 10 VDC) can be scaled to display the process variable in engineering
units. A signal source is not needed to scale the meter; simply program the inputs and corresponding
display values.
SCALE
)
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Helios Large Display Pulse Input Batch Controller Instruction Manual PD2-6310
Input Range
Input 1 & Input 2 Span
4-20 mA
0.15 mA
10 VDC
0.01 VDC
Note: To scale the meter without a
signal source refer to K-Factor
Calibration (Factor), page 34.
Warm up the meter for at least 15 minutes
before performing calibration to ensure
specified accuracy.
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.
The error message might be caused by any of the following conditions:
1. Input signal is not connected to the proper terminals or it is connected backwards.
2. Wrong signal selection in Setup menu.
3. Minimum input span requirements not maintained.
4. Input 1 signal inadvertently applied to calibrate input 2.
Minimum Input Span
The minimum input span is the minimum difference between input 1 and input 2 signals required to
complete the calibration or scaling of the meter.
Calibrating the Meter with External Source (
Cal
)
The controller can be calibrated to display the process variable in engineering units by applying the
appropriate input signal and following the calibration procedure.
The use of a calibrated signal source is strongly recommended to calibrate the meter.
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Helios Large Display Pulse Input Batch Controller Instruction Manual PD2-6310
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, m3, etc.
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 24. In automatic mode, the batch process will
automatically begin after a completed batch. The time delay for the restart may be 0.1 to 999.9 seconds
(t dly). Automatic batch start will only occur after a successful batch. A manually stopped batch will
require a manual start to begin a new batch process.
Time Base
The time base is the amount of time over which the rate parameter should accrue. For example, if the
rate was ten and the time base was in minutes, then the total would increase by ten every one minute.
Total & Grand Total Conversion Factor
The total & grand total conversion factor is the amount by which the rate is multiplied before it is added to
the total or grand total. For Example, if the rate was ten per second and the total conversion factor was
100, the total would increase by 1000 every second. This is useful, for instance, if you want to show rate
in gallons and total in thousands of gallons.
Grand Total Reset
The grand total can be programmed for manual or automatic reset. In the automatic reset mode, a
programmable time delay is available to reset the total or grand total after the assigned preset is reached.
Non-Resettable Totalizer
The total and grand total can be password-protected to prevent unauthorized resets. The grand total can
be programmed as a non-resettable total, see page 46 for details.
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Helios Large Display Pulse Input Batch Controller Instruction Manual PD2-6310
4
4
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. Display batch count
6. Relay set points
7. Toggle preset and rate
8. Toggle rate and units
9. Toggle total and units
10. Toggle grand total and units
11. Display max and min values
12. Display Modbus input
13. Display rate value
The small display (Line 2) can be
programmed to display:
1. Toggle rate and units
2. Toggle total and units
3. Toggle grand total and units
4. Display max and min values
5. Display Modbus input
6. Off (no display)
7. Display rate units
8. Display rate
9. Display total
10. Display grand total
11. Toggle rate and total
12. Toggle rate and grand total
13. Display batch count
14. Relay set points
15. Toggle preset and rate
Display Intensity: The meter has eight display intensity levels to give the best performance under
various lighting conditions. Select intensity 8 for outdoor applications. The default intensity setting is 8.
After setting up the input and display, press the Menu button to exit programming and skip the rest of the
setup menu. Press the Menu button again and the Up arrow to reach the Program menu and complete
the scaling or calibration of the meter.
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Helios Large Display Pulse Input Batch Controller Instruction Manual PD2-6310
Rate Alarms Only Active During a Batch Process
The rate alarms are active only during a batch process. As a result, rate
alarms should not be programmed with manual reset, as they cannot be
manually reset during a batch process, the only time they are active.
!
Caution!
During setup, the relays do not follow the input
and they will remain in the state found prior to
entering the Relay menu.
!
Setting the Relay Operation (relay)
This menu is used to set up the operation of the relays.
1. Relay assignment
a. Rate for low and high alarm
b. Total for batch control relays
c. Grand total for grand total
alarms
d. Modbus input process variable
2. Relay action
a. Automatic reset only (non-latching)
b. Automatic + manual reset at any time (non-latching)
c. Latching (manual reset only)
d. Latching with Clear (manual reset only after alarm condition has cleared)
e. Pump alternation control (automatic reset only)
f. Sampling (the relay is activated for a user-specified time)
g. Off (relay state controlled by Interlock feature)
3. Set and reset points
4. Fail-safe operation
a. On (enabled)
b. Off (disabled)
5. Time delay
a. On delay (0-999.9 seconds)
b. Off delay (0-999.9 seconds)
6. Relay action for loss (break) of 4-20 mA input (ignore, on, off)
Note: Fail-safe should not be used for relays assigned to batch control.
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Helios Large Display Pulse Input Batch Controller Instruction Manual PD2-6310
Assign preclose
if multiple relays
are assigned.
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. Modbus input
Note: Relay 1 should always be assigned to “total” for batch control applications.
Setting the Relay Action
Operation of the relays is programmed in the Action menu.
The relays may be set up for any of the following modes of
operation:
1. Always set to Auto for Batch control operation. Also for
automatic reset (non-latching) of alarms.
2. Sampling (the relay is activated for a user-specified time)
3. Off (relay state controlled by Interlock feature)
In addition, the following relay actions may be programmed. These actions are not
appropriate for batch control applications, but may be used then the controller is in other
applications.
4. Automatic + manual reset when not in a batch process (non-latching)
5. Latching (manual reset only, when not in a batch process)
6. Latching with Clear (manual reset only when not in a batch process after alarm
condition has cleared)
7. Pump alternation control (automatic reset only, for level applications, unrelated to
batch control.)
The following graphic shows relay 1 action setup; relay 2-4 are set up in a similar fashion.
Setting Batch Control Relays
Operation of batch control relays are programmed in the Assign menu by selecting total
as the assignment. Relays set to total beyond the first will include a preclose parameter
(precls) option. Selecting yes for precls will enable multi-stage batching with preclose,
and the valve will close prior to the end of the batch at volume equal to the preset value
minus the preclose amount entered. Selecting no for precls will have the relay perform
identically to the first batch control relay set to total.
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Helios Large Display Pulse Input Batch Controller Instruction Manual PD2-6310
High Alarm Operation (Set > Reset)
For Manual reset mode, ACK can be pressed
anytime to turn "off" relay. To detect a new alarm
condition, the signal must go below the set point,
and then go above it.
Low Alarm Operation (Set < Reset)
For Manual reset mode, ACK can be pressed
anytime to turn "off" relay. For relay to turn back
“on”, signal must go above set point and then go
below it.
Reset
Set
Input
Relay
LED
energized
de-energized
on
off
Automatic (non-latching)
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.
Minimum deadband is one display count. If the set and reset points are
programmed with the same value, the relay will reset one count below the set
point.
Note: Changes are not saved until the reset point has been accepted.
Setting Fail-Safe Operation
In fail-safe mode of operation, the relay coil is energized when the process variable is within safe limits
and the relay coil is de-energized when the alarm condition exists. The fail-safe operation is set
independently for each relay. Select on to enable or select off to disable fail-safe operation.
Failsafe mode should not be used on batch relays assigned to total.
Programming Time Delay
The On and Off time delays may be programmed for each relay between 0 and 999.9 seconds. The
relays will transfer only after the condition has been maintained for the corresponding time delay.
The On time delay is associated with the set point.
The Off time delay is associated with the reset point.
Relay and Alarm Operation Diagrams
The following graphs illustrate the operation of the relays, status LEDs, and ACK button.
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Helios Large Display Pulse Input Batch Controller Instruction Manual PD2-6310
High Alarm with Fail-Safe Operation
(Set > Reset)
Note: Relay coil is energized in non-alarm condition.
In case of power failure, relay will go to alarm
state.
Low Alarm with Fail-Safe Operation
(Set < Reset)
Note: Relay coil is energized in non-alarm condition.
In case of power failure, relay will go to alarm
state.
Reset
Set
Input
Relay
LED
Automatic (non-latching)
de-energized
energized
on
off
Set
Reset
Relay
LED
Input
Sample
Time
Sample
Time
Sample
Time
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.
The sample time can be programmed between 0.1 and 5999.9 seconds.
Total Relay Sampling Operation
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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.
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Helios Large Display Pulse Input Batch Controller Instruction Manual PD2-6310
Signal Loss or Loop Break Relay
Operation
The following graph shows the loop break relay
operation for a high alarm relay.
When the meter detects a break in the 4-20 mA
loop, the relay will go to one of the following
selected actions:
1. Turn On (Go to alarm condition)
2. Turn Off (Go to non-alarm condition)
3. Ignore (Processed as a low signal
condition)
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. If the signal drops below the
set point (high alarm) before the time delay has
elapsed, the On time delay timer resets and the
relay does not change state. The same principle
applies to the Off time delay.
Note: If “Automatic or Manual (
A-mAn
)” reset
mode is selected, the LED follows the reset
point and not the relay state when the relay
is acknowledged.
Relay
LED
Input
Loop Break = Ignore
de-energized energized
off on
Relay
LED
Loop Break = Off
Relay
LED
Loop Break = On
Set
Reset
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. The relays used for
batch control (total) are activated when the batching process starts, and deactivate when the batch total is
reached, minus any preclose amount programmed for batch (total) relays after the first.
For an example of batch control operation, see Batch Control Operation Example on page 25.
Typical applications for alarms are low and high flow alarms or grand total limit alarms. Note that rate
alarms are only enabled during a batching process, and deactivate when the processes is stopped.
The relays can also be set for sampling, where the relay will activate for a specific amount of time after a
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certain grand total has been reached (ie: 2 second sample relay activation every 100 gallons batched).
There are three basic ways the relays can be used:
1. Batch Control (Total)
2. High or Low Alarms for Rate or Grand Total
3. Sampling (Based on Grand Total and Sample Time)
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Helios Large Display Pulse Input Batch Controller Instruction Manual PD2-6310
Fail-Safe
Selection
Non-Alarm State
Alarm State
Power Failure
NO
NC
NO
NC
Off
Open
Closed
Closed
Open
Relays go to
non-alarm state
On
Closed
Open
Open
Closed
Relays go to
alarm state
LED
Status
1
Alarm 1
Relays Initialization
Batch control (total) relays will activate when the start function is enabled, such as when the START
button is pressed. Rate alarm relays will enable and initialize to their programmed states when the batch
process is started. Grand total alarm relays will initialize to their programmed state at controller power-up.
Fail-Safe Operation
The following table indicates how
the relays behave based on the failsafe selection for each relay:
Note: NO = Normally Open,
NC = Normally Closed.
This refers to the condition of
the relay contacts when the
power to the meter is off.
Front Panel LEDs
The LEDs on the front panel provide status indication for the following:
The controller is supplied with four alarm points that include front panel
LEDs to indicate alarm conditions. This standard feature is particularly
useful for alarm applications that require visual-only indication. The LEDs
are controlled by the set and reset points programmed by the user. When the display reaches a set point
for a high or low alarm, the corresponding alarm LED will turn on. When the display returns to the reset
point the LED will go off. Note that rate alarms are only enabled during a batching process, and
deactivate when the processes is stopped.
Latching relays, or relays with manual reset, are not recommended when using this controller for batch
control, as the manual reset will not be acknowledged during a batch process, when the rate alarms are
active. For information on latching and manual reset alarms, see the PD2-6200 instruction manuals
available.
2 Alarm 2
3 Alarm 3
4 Alarm 4
Automatic Reset (Auto)
In this application, the controller is set up for automatic
reset (non-latching relay). Acknowledging the alarm while it
is still present has no effect on either the LED or the relay.
When the alarm finally goes away, the relay automatically
resets and the LED also goes off.
Condition LED Relay
Normal Off Off
Alarm On On
Ack (No effect) On On
Normal Off Off
Automatic reset only
Pump Alternation Control Applications (Altern)
Pump alternation control is not recommended when using this controller for batch control, as it is used
only in level applications, and not with rate, total, or batching applications. For information on using pump
alternation control for level, see the PD2-6000 instruction manuals available.
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Helios Large Display Pulse Input Batch Controller Instruction Manual PD2-6310
SW1
SW2
Setting up the Interlock Relay (Force On) Feature
Relays 1-4 can be set up as interlock relays. To set up the relays for the interlock feature:
1. Access the Setup – Relay – Action menu and set the action to off.
2. In the Advanced features – User menu program any of the digital inputs to Force On any of the
internal relays (1-4).
3. Connect a switch or dry contact between the +5V terminal and the corresponding digital input (dI1 to dI-4) terminal.
Interlock Relay Operation Example
Relays 3 & 4 are configured to energize (their front panel LEDs are off) when SW1 & SW2 switches
(above) are closed. If the contacts to these digital inputs are opened, the corresponding front panel LEDs
flash indicating this condition. The processes being controlled by the interlock relay will stop, and will restart only after the interlock relay is re-activated by the digital inputs (switches).
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.
A total sampling relay will activate for the sample time (sam t), up to 600.0 seconds every time the
process has batched the amount programmed for the set point, and every time this amount has been
batched afterward. (See the diagram below for more details). The utility of this function can, of course, be
expanded beyond sampling and be used whenever a timed relay output closure is required when the
batch total interval reaches a certain set point.
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Helios Large Display Pulse Input Batch Controller Instruction Manual PD2-6310
For instructions on how to program
numeric values see Setting
Numeric Values, page 30.
Contrl
Auto
man a out
rly 1 rly 4
off on
Contrl
Contrl man man man
a out rly 1 rly 4
16.000
Scaling the 4-20 mA Analog Output (Aout)
The 4-20 mA analog output can be scaled to provide a 4-20 mA signal for any display range selected.
No equipment is needed to scale the analog output; simply program the display values to the
corresponding mA output signal.
The Analog Output menu is used to program the 4-20 mA output based on display values.
Reset Menu (reset)
The Reset menu is used to reset the maximum or minimum reading (peak or valley) reached by the
process; both may be reset at the same time by selecting “reset high & low” (rst HL). The tare value
used to zero the display may be reset by selecting “reset tare” (rst tr).
Control Menu (Contrl)
The Control menu is used to control
the 4-20 mA analog output and the
relays manually, ignoring the input.
Each relay and analog output can
be programmed independently for
manual control. Selecting automatic
control sets all relays and analog
output for automatic operation.
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Helios Large Display Pulse Input Batch Controller Instruction Manual PD2-6310
Pass 1: Allows use of function keys and digital inputs
Pass 2: Allows use of function keys, digital inputs and editing set/reset points
Pass 3: Restricts all programming, function keys, and digital inputs
Total: Prevents resetting the total manually
Gtotal: Prevents resetting the grand total manually.
Caution!
Once the Grand Total has been programmed as
“non-resettable” the feature cannot be disabled.
!
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.
Protecting or Locking the Meter
Enter the Password menu and program a six-digit password.
For instructions on how to program numeric values see Setting Numeric Values, page 30.
Total Reset Password & Non-Resettable Total
The total and 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”.
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Helios Large Display Pulse Input Batch Controller Instruction Manual PD2-6310
Did you forget the password?
The password may be disabled by entering a master
password once. If you are authorized to make changes,
enter the master password 508655 to unlock the meter.
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. After exiting the programming mode, the meter returns to its
password protected condition.
Disabling Password Protection
To disable the password protection, access the Password menu and enter the correct password twice, as
shown below. The meter is now unprotected until a new password is entered.
If the correct six-digit password is entered, the meter displays the message unLoc (unlocked) and the
protection is disabled until a new password is programmed.
If the password entered is incorrect, the meter displays the message Locd (Locked) for about two
seconds, and then it returns to Run Mode. To try again, press Enter while the Locked message is
displayed.
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Helios Large Display Pulse Input Batch Controller Instruction Manual PD2-6310
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.
!
Function Key/Button
Default Setting
Action
F1/START
Start
Start batch
F2/BATCH
preset
Change preset
F3/STOP
stop
Pause/stop batch
F4/Digital Input
Srtstp
Start/stop batch
Only STOP Operation Enabled if a Batch is Running.
During a batch process, the only function that can be
performed is the pause/stop functions of the STOP button;
the default programming of the F3 key. No other functions,
including min/max display, manual alarm reset, or total
reset, will function while a batch is running.
!
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. These functions should
only be used by users who are sure of their need in their application.
Function Key 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.
Digital Input Operation
Five (5) digital inputs, F4-F8, come standard on
the meter. These digital inputs are
programmed identically to function keys
F1, F2, and F3. The inputs are triggered
with a contact closure to +5 (COM in the
case of F4, see Digital I/O Connections on
page 19 for details), or with an active low
signal. During operation, digital inputs
operate according to the way they are programmed in the Advanced Features – User menu.
Advanced Setup and Calibration
Multi-Point Calibration & Scaling
The controller is set up at the factory for 2-point linear calibration. The number of points for multi-point
calibration/scaling is set up in the Advanced Features menu. Up to 32 linearization points may be
selected. See page 53 for details.
Maximum/Minimum Readings
The max & min readings (peak & valley) reached by the process can be displayed either continuously or
momentary:
1. Display briefly by assigning to the digital inputs in the User menu.
2. Display continuously by assigning either display to max/min through the Display menu.
Any of the digital inputs can be programmed to reset the max & min readings.
To display max/min readings continuously:
Assign either display to Max (d Hi), Min (d Lo), or toggle between Max and Min (d HL) every 10
seconds.
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Helios Large Display Pulse Input Batch Controller Instruction Manual PD2-6310
Display
Parameter
Action/Setting
Gate
Gate
Gate settings
Lo G
Low gate
Program Low gate value
Hi G
High gate
Program High gate value
filtEr
Filter
Set noise filter value
Hi spd
High Speed Filter
Program High Speed Filter
Lo spd
Low Speed Filter
Program Low Speed Filter
Round
Round
Set the rounding value for display variables
seriAl
Serial
Set serial communication parameters
SlaveId
Slave ID
Set slave ID or meter address
baud
Baud rate
Select baud rate
Tr dLY
Transmit delay
Set transmit delay for serial communication
Parity
Parity
Select parity: Even, Odd, or None with 1 or 2 stop bits
t-byt
Time byte
Set byte-to-byte timeout
SelEct
Select
Enter the Select menu (function, cutoff, out)
Functn
Signal input
conditioning
Select linear, square root, programmable exponent, or round
horizontal tank function
Linear
Linear
Set for linear function, select number of linearization points
No PtS
Number of points
Set PV1 for 2 to 32-point linearization
Set PV2 for 2 to 8-point linearization
CutofF
Cutoff
Set low-flow cutoff
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.
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.
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Helios Large Display Pulse Input Batch Controller Instruction Manual PD2-6310
Display
Parameter
Action/Setting
Count
Count
Set total and grand total count direction
Tot C
Total Count
Set total to count up or down
Gtot C
Grand Total Count
Set grand total to count up or down
C Strt
Count Start
Set start for total or grand total countdown
AoutPr
Analog output
programming
Program analog output parameters
Source
Source
Select source for the 4-20 mA output
O-rang
Overrange
Program mA output for display overrange
u-rang
Underrange
Program mA output for display underrange
break
Break
Set input break condition operation
Force
Force
Force analog output value for loop break
Ignore
Ignore
Ignore loop break condition
mAx
Maximum
Program maximum mA output allowed
min
Minimum
Program minimum mA output allowed
Calib
Calibrate
Calibrate 4-20 mA output (internal reference source used for
scaling the output)
4 mA
4 mA output
Enter mA output value read by milliamp meter with at least
0.001 mA resolution
20 mA
20 mA output
Enter mA output value read by milliamp meter with at least
0.001 mA resolution
user
User I/O
Assign function keys and digital I/O
F1
F1 function key
Assign F1 function key
F2
F2 function key
Assign F2 function key
F3
F3 function key
Assign F3 function key
F4
F4 function
Assign F4 function (digital input)
dI I
Digital input 1
Assign digital input 1 – 4, if expansion modules are connected
dO 1
Digital output 1
Assign digital output 1 – 4, if expansion modules are connected
ICal
Internal source
calibration
Enter internal source calibration (used for scaling the meter
without a signal source)
C CAL
Current calibration
Calibrate 4-20 mA current input (internal reference source used
for scaling the input)
C lo
Current low
Calibrate low current input (e.g. 4 mA)
C Hi
Current high
Calibrate high current input (e.g. 20 mA)
v CAL
Voltage calibration
Calibrate voltage input
v Lo
Voltage low
Calibrate low voltage input (e.g. 0 V)
v Hi
Voltage high
Calibrate high voltage input (e.g. 10 V)
Diag
Diagnostics
Display parameter settings
LED t
LED test
Test all LEDs
Info
Information
Display software and S/N information
Erase
Erase
Delete the MeterView Pro installation files from the meter
Gate Function (Gate)
The gate function is used for displaying slow pulse rates. Using the programmable gate, the meter is able
to display pulse rates as slow as 1 pulse every 999.9 seconds (0.001 Hz). The gate function can also be
used to obtain a steady display reading with a fluctuating input signal.
The gate function (Gate) is the first option in the Advanced Features menu. There are two settings for the
Gate, low gate (Lo G) and high gate (Hi G).
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Helios Large Display Pulse Input Batch Controller Instruction Manual PD2-6310
Slow Pulse Rate
Low Gate* (sec)
High Gate (sec)
Min Freq** (Hz)
1.0
2.0
0.5000
1.0
10.0
0.1000
1.0
20.0
0.0500
1.0
100.0
0.0100
1.0
200.0
0.0050
1.0
400.0
0.0025
1.0
800.0
0.0012
1.0
999.9
0.0010
*The low gate setting corresponds to the display update rate
and is used to stabilize the display reading with a fluctuating
signal.
**The minimum frequency is dependent on high gate
setting.
Contact De-Bounce Filter
Filter Setting
Speed Setting
Max Freq (Hz)
2
Lo SPd
999
4
Lo SPd
499
8
Lo SPd
249
16
Lo SPd
124
32
Lo SPd
62
40
Lo SPd
50
50
Lo SPd
40
N/A
Hi SPd
30,000
Low Gate (
For most applications, low gate setting should be left at 1.0 second. Increase low gate setting to obtain a
steadier rate display. The rate display will update in accordance with the low gate setting, for example if
low gate is set at 10.0, the display will update every 10 seconds; changes in rate between updates will not
be reflected until next display update.
High Gate (
Set the high gate value to correspond to the highest expected pulse period (lowest pulse rate). For
instance, if the meter must display a rate when there is 1 pulse coming into the meter every 10 seconds,
set the high gate to 11.0 seconds. When the signal is removed from the meter, the display will show the
last reading for 11 seconds; then it will read zero.
Lo G
Hi G
)
)
Gate Settings
Contact De-Bounce Filter (FiLter)
The filter function (FiLter) can be used for applications where the meter is set up to count pulses
generated by switch contacts. The filter value can be set anywhere between 2 and 50, the higher the
value, the greater the filtering.
The filter function (Filter) is the second option in the Advanced Features menu. There are two settings,
Hi SPd (high speed) and Lo SPd (low speed), press ENTER when Lo SPd is displayed to enable the filter
function. Program the filter value, so that there are no extra counts when a contact closure is completed.
Filter Settings
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Helios Large Display Pulse Input Batch Controller Instruction Manual PD2-6310
Rounding
Selection
Actual
Value
Display
Value
Actual
Value
Display
Value
1
12.022
12.022
12.023
12.023
5
12.022
12.020
12.023
12.025
10
12.024
12.020
12.025
12.030
Warning!
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.
Do not disconnect the RJ45 connector located to the left of the power terminal
block. Doing so will disable the onboard digital I/O, RS-485 serial
communications, and M-Link functionality.
Rounding Feature (round)
The rounding feature is used to give the user a
steadier display with fluctuating signals. Rounding
is used in addition to the filter function.
Rounding causes the display to round to the
nearest value according the rounding selected. See
examples below:
Modbus RTU Serial Communications (serial)
The meter is equipped with serial communications capability as a standard feature using Modbus RTU
Serial Communication Protocol.
The meter may be connected to a PC for initial configuration via the onboard micro USB connection. For
ongoing digital communications with a computer or other data terminal equipment, an RS-232, or RS-485
option is required; see Ordering Information on page 5 for details.
Note: More detailed instructions are provided with each optional serial communications adapter.
Note: Refer to the Modbus Register Tables for details.
When using more than one meter in a multi-drop mode, each meter must be provided with its own unique
address. The meter address (Slave ID) may be programmed between 1 and 247. The transmit delay may
be set between 0 and 199 ms. The parity can be set to even, odd, or none with 1 or 2 stop bits.
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Helios Large Display Pulse Input Batch Controller Instruction Manual PD2-6310
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), lowflow cutoff, and analog output
programming. The multi-point
linearization is part of the
linear function selection.
Signal Input Conditioning (Functn)
The Function menu is used to select the signal input conditioner applied to the input: linear, square root,
programmable exponent, or round horizontal tank volume calculation. The multi-point linearization is part
of the linear function selection.
Meters are set up at the factory for linear function with 2-point linearization. The linear function provides a
display that is linear with respect to the input signal.
Multi-Point Linearization (
Meters are set up at the factory for linear function with 2-point linearization. Up to 32 linearization points
can be selected for PV1 under the linear function. The multi-point linearization can be used to linearize
the display for non-linear signals such as those from level transmitters used to measure volume in oddshaped tanks or to convert level to flow using weirs and flumes with complex exponent.
If the dual-scale level feature has been selected, the menus for PV1 & PV2 are enabled. PV2 can be
programmed with up to 8 linearization points.
Linear
)
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.
The cutoff value may be programmed from 0 to 999999. The meter will display zero below the cutoff
value. Programming the cutoff value to zero disables the cutoff feature.
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.
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Helios Large Display Pulse Input Batch Controller Instruction Manual PD2-6310
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.
!
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. Overrange: Analog output value with display in overrange condition
3. Underrange: Analog output value with display in underrange condition
4. Break: Analog output value when loop break is detected
5. Max: Maximum analog output value allowed regardless of input
6. Min: Minimum analog output value allowed regardless of input
7. Calibrate: Calibrate the internal 4-20 mA source reference used to scale the 4-20 mA output
Analog Output Source
The source for generating the 4-20 mA output may be assigned to the rate/process variable, total, grand
total, maximum or minimum value reached by the rate/process, or one of the set points, or the Modbus
PV input.
Analog Output Calibration
To perform the analog output calibration, it is recommended to use a milliamp meter with a resolution of
at least 0.1 µA to measure the output current. The values saved internally during this procedure are used
for scaling the 4-20 mA output in the Setup menu.
Programmable Function Keys User Menu (user)
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. reset max & min, hold relay states,
etc.). This allows the meter to be greatly customized for use in specialized applications.
Up to eight digital outputs can be assigned to a number of actions and functions executed by the meter
(i.e. alarms, relay acknowledgement, reset max, min, or max & min, tare, and reset tare). The digital
outputs can be used to trigger external alarms or lights to indicate these specific events.
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Helios Large Display Pulse Input Batch Controller Instruction Manual PD2-6310
Display
Description
Start
Starts the batch process
Stop
Stops the batch process
srtstp
Allows the same function key to
both start and stop the batch
process
Rly d
Disable all relays until a button
assigned to enable relays (Rly E)
is pressed
Rly E
Enable all relays to function as they
have been programmed
O Hold
Hold current relay states and
analog output as they are until a
button assigned to enable relays
(Rly E) is pressed
d Hold
Hold the current display value, relay
states, and analog output
momentarily while the function key
or digital input is active. The
process value will continue to be
calculated in the background.
Ln1 Hi
Display maximum display value on
line 1
Ln1 Lo
Display minimum display value on
line 1
Ln1 HL
Display maximum & minimum
display values on line 1
Ln2 Hi
Display maximum display value on
line 2
Ln2 Lo
Display minimum display value on
line 2
Ln2 HL
Display maximum & minimum
display values on line 2
Ln2 gt
Display the grand total on line 2
Ln2 bc
Display the batch count on line 2
Contrl
Directly access the control menu
Display
Description
disabl
Disable the selected function key or
digital I/O
AcH
Acknowledge all active relays that
are in a manual operation mode
such as auto-manual or latching
Reset
Directly access the reset menu
Rst t
Reset the total
Rst gt
Reset the grand total
Rst bc
Reset the batch count
Rst Hi
Reset the maximum display value
Rst Lo
Reset the minimum display value
Rst HL
Reset the maximum & minimum
display values
relay
Directly access the relay menu
preset
Change the preset value
Set 2*
Directly access the set point menu
for relay 2 (*through 8)
nmenu
Mimic the menu button functionality
(digital inputs only)
rigHt
Mimic the right arrow/F1 button
functionality (digital inputs only)
up
Mimic the up arrow/F2 button
functionality (digital inputs only)
Enter
Mimic the enter/F3 button
functionality (digital inputs only)
F On 1*
Force relay 1 (*through 4) into the
on state. This function is used in
conjunction with a digital input
expansion module to achieve
interlock functionality. See page 44
for details about interlock relays.
Alnm 1*
Provide indication when alarm 1
(*through 8) has been triggered
(digital outputs only)
Function Keys & Digital I/O Available Settings
Refer to the following table for descriptions of each available function key or digital I/O setting.
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Helios Large Display Pulse Input Batch Controller Instruction Manual PD2-6310
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.
Diagnostics Menu (diag)
The Diagnostics menu is located in the Advanced Features menu, to access Diagnostics menu see
Advanced Features Menu, page 49.
This menu allows the user to test the functionality of all the meter LEDs, check the meter’s software and
version information, and erase the MeterView Pro software installation files from the meter. Press the
Enter button to view the settings and the Menu button to exit at any time.
For a description of the diagnostic messages, see Advanced Features Menu, page 49.
Determining Software Version
To determine the software version of a meter:
1. Go to the Diagnostics menu (diAG) and press Enter button.
2. Press Up arrow button and scroll to Information menu (Info).
3. Press Enter to access the software number (SFT) and version (UER) information. Write down the
information as it is displayed. Continue pressing Enter until all the information is displayed.
4. The meter returns to Run Mode after displaying all the settings.
Reset Controller to Factory Defaults
When the parameters have been changed in a
way that is difficult to determine what’s
happening, it might be better to start the setup
process from the factory defaults.
Instructions to load factory defaults:
1. Enter the Advanced Features menu.
See Advanced Features Menu, page 49.
2. Press Up arrow to go to Diagnostics menu
3. Press and hold Right arrow for three
seconds, press
Enter when display flashes reset.
Note: If Enter is not pressed within
three seconds, the display returns to
the Diagnostics menu.
4. The meter goes through an initialization
sequence (similar as on power-up), and loads the
factory default settings.
Note: The dual-scale selection for some level applications (d-SCAL) is not reset to the single scale
factory default. This can be changed using the Setup – Input menu.
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Helios Large Display Pulse Input Batch Controller Instruction Manual PD2-6310
Parameter
Display
Default Setting
Input type
Input
Pulse
Total
total
Yes
Units
units
Rate
Pulse
Total
Pulse
Gr. Total
Pulse
Filter
filter
Hi Spd
Function
Functn
Linear
Number of points
No Pts
2
Programming
prog
Scale
Input 1
InP 1
00000.0
Display 1
Dis 1
00000.0
Input 2
InP 2
10000.0
Display 2
Dis 2
10000.0
Rate decimal point
Ddddd.d
1 place
Total decimal point
Ddddd.d
1 place
Gr. total decimal point
Dddddd
0 places
K-factor
Factor
1.000
Cutoff value
CutofF
0.000 (disabled)
Display line 1
Line 1
Rate/Process
Display line 2
Line 2
Total value
Display intensity
d-Inty
8
Total time base
T tb
Second
Total conversion factor
T CF
1.000
Batch mode
mode
Manual
Grand total time base
GT tb
Second
GTotal conversion factor
gT CF
1.000
Grand total reset
gT rst
Manual
Total count up/down
Tot C
Up
Grand tot count
Gtot C
Up
Relay 1 assignment
Asign1
Total
Relay 2 assignment
Asign2
Total
Relay 2 preclose
preCls
No
Relay 3 assignment
Asign3
Rate
Relay 4 assignment
Asign4
Rate
Relay 1 action
Act 1
Automatic
Batch preset
Preset
100.0
Factory Defaults & User Settings
The following table shows the factory setting for most of the programmable parameters on the meter.
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Helios Large Display Pulse Input Batch Controller Instruction Manual PD2-6310
Parameter
Display
Default Setting
Relay 2 action
Act 2
Automatic
Relay 2 set point
Set 2
200.0
Relay 3 action
Act 3
Automatic
Relay 3 set point
Set 3
3.000
Relay 3 reset point
RSt 3
2.500
Relay 4 action
Act 4
Automatic
Relay 4 set point
Set 4
4.000
Relay 4 reset point
RSt 4
3.500
Fail-safe relay 1
Fls 1
Off
Fail-safe relay 2
Fls 2
Off
Fail-safe relay 3
Fls 3
Off
Fail-safe relay 4
Fls 4
Off
Display 1 analog out
Dis 1
4.000
Output 1 value
Out 1
4.000 mA
Display 2 analog out
Dis 2
20.000
Output 2 value
Out 2
20.000 mA
Source analog output
Source
Rate/process
Overrange output
O-rang
21.000 mA
Underrange output
u-rang
3.000 mA
Loop break output
break
1.000 mA
Maximum output
mAx
23.000 mA
Minimum output
min
1.000 mA
F1 function key
F1
Reset max & min
Password 1
Pass 1
000000 (unlocked)
Password 2
Pass 2
000000 (unlocked)
Password 3
Pass 3
000000 (unlocked)
Total password
Total
000000 (unlocked)
Grand total password
Gtotal
000000 (unlocked)
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Helios Large Display Pulse Input Batch Controller Instruction Manual PD2-6310
Symptom
Check/Action
No display at all
Check power at power connector
Not able to change setup or
programming, Locd is displayed
Meter is password-protected, enter correct six-digit password to
unlock
Controller displays error
message during calibration
(Error)
Check:
Signal connections
Input selected in Setup menu
Minimum input span requirements
Controller displays
999999
-99999
Check:
Input selected in Setup menu
Corresponding signal at Signal connector
Display is unstable
Check:
Input signal stability and value
Display scaling vs. input signal
Filter and bypass values (increase)
Display response is too slow
Check filter and bypass values
Display reading is not accurate
Check:
Signal input conditioner selected: Linear, square root, etc.
Scaling or calibration
Display does not respond to
input changes, reading a fixed
number
Check:
Display assignment, it might be displaying max, min, or set point.
Display alternates between
Hi and a number
Lo and a number
Press Menu to exit max/min display readings.
Relay operation is reversed
Check:
Fail-safe in Setup menu
Wiring of relay contacts
Relay and status LED do not
respond to signal
Check:
Relay action in Setup menu
Set and reset points
Flashing relay status LEDs
Relays in manual control mode or relay interlock switches opened.
Controller not communicating
with application programs
Check:
Serial adapter and cable
Serial settings
Controller address and baud rate
If the display locks up or the
controller does not respond at all
Cycle the power to reboot the
microprocessor.
Other symptoms not described
above
Call Technical Support for
assistance.
Troubleshooting Tips
Note: Certain sequences of events can cause unexpected results. To solve these issues, it is best to start
fresh from factory defaults and map changes ahead of time, rather than at random.
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