PROVU Batch Controllers
PD6210 Analog Input &
PD6310 Pulse Input
• PD6210: 0-20 mA, 4-20 mA, 0-5 V, 1-5 V, ±10 V Inputs
• PD6310: Pulse, Open Collector, NPN, PNP, TTL, Switch
Contact, Sine Wave (Coil), Square Wave Inputs
• NEMA 4X, IP65 Front
• Start/Pause/Stop, Change Batch with Front Panel Buttons
• Single or Multi-Stage Batch Control (Up to 8 Relays)
• Automatic Overrun Correction
• Rate in Units per Second, Minute, Hour, or Day
• Automatic or Manual Batch Control
• Low or High Flow Alarms
• 9 Digit Grand Total with Overflow Feature
• Count Up or Down with Each Batch
• Configure, Monitor, and Datalog from a PC with
Free MeterView
®
Pro Software
PRECISION DIGITAL CORPORATION
89 October Hill Road • Holliston MA 01746 USA
Tel (800) 343-1001 • Fax (508) 655-8990
www.predig.com
Model PD6210 & PD6310 Batch Controllers Instruction Manual
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.
!
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 his/her own risk. Precision Digital
Corporation shall not be held liable for damages resulting from
such improper use.
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
PROVU® and MeterView® Pro are registered trademarks of Precision
Digital Corporation. All other trademarks mentioned in this document
are the property of their respective owners.
© 2012 Precision Digital Corporation. All rights reserved.
www.predig.com
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Model PD6210 & PD6310 Batch Controllers Instruction Manual
Table of Contents
INTRODUCTION ------------------------------------------------------------- 7
ORDERING INFORMATION ---------------------------------------------- 7
SPECIFICATIONS ------------------------------------ ----------------------- 9
General ------------------------------------------------------------------------------- 9
PD6210 Process Input -------------------------------------------------------- 11
PD6310 Pulse Input ------------------------------------------------------------ 12
Batch Controller Rate/Totalizer Display -------------------------------- 14
Relays -------------------------------------------------------------- ---------------- 15
Isolated 4-20 mA Transmitter Output ------------------------------------ 16
Modbus® RTU Serial Communications ---------------------------------- 16
PDA1044 Digital Input & Output Expansion Module ---------------- 17
COMPLIANCE INFORMATION ---------------------------------------- 17
Safety --------------------------------------------------- ---------------------------- 17
Electromagnetic Compatibility --------------------------------------------- 17
SAFETY INFORMATION ------------------------------------------------ 18
INSTALLATION ------------------------------------------------------------ 19
Unpacking ------------------------------------------------------------------------- 19
Panel Mounting Instructions ------------------------------------------------ 19
Mounting Dimensions ------------------------------------------------------- 20
Configuration for 12 or 24 VDC Power Option ------------------------ 21
Transmitter Supply Voltage Selection (P+, P-) ----------------------- 22
Connections ---------------------------------------------------------------------- 22
Connectors Labeling --------------------------------------------------------- 23
Power Connections ---------------------------------------------------------- 24
PD6210 Signal Connections ----------------------------------------------- 24
PD6310 Signal Connections ----------------------------------------------- 26
Modbus RTU Serial Communications ----------------------------------- 28
Relay Connections ----------------------------------------------------------- 28
Switching Inductive Loads -------------------------------------------------- 29
F4 Digital Input Connections ----------------------------------------------- 30
4-20 mA Output Connections ---------------------------------------------- 30
Analog Output Transmitter Power Supply ------------------------------ 30
External Relay & Digital I/O Connections ------------------------------ 31
Interlock Relay Feature ----------------------------------------------------- 32
BASIC OPERATION AND PROGRAMMING ---------------------- 33
Front Panel Buttons and Status LED Indicators --------------------- 34
Controller Operation ------------------------------------- ---------------------- 35
Batch Control Operation Example ---------------------------------------- 36
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Model PD6210 & PD6310 Batch Controllers Instruction Manual
Display Functions and Messages ----------------------------------------- 39
Setting Numeric Values ------------------------------------------------------ 44
Setting Up the Batch Controller (setup) -------------------------------- 44
Scaling and Calibration ----------------------------------------------------- 46
Setting the Input Signal (Input) ------------------------------------------ 46
Setting the Totalizer and Batching Features (total) ---------------- 46
Setting the Input Units or Custom Tags (units) ---------------------- 47
Setting the Decimal Point (dEc pt) -------------------------------------- 48
Programming the Batch Controller (prog)------------------------------ 48
Input Calibration Method (InCAL) ------------------------------------- 49
PD6310 Only: K-Factor Calibration (Factor) ---------------------- 49
Scaling the Controller (SCALE) ----------------------------------------- 50
Time Base, Total Conversion Factor & Total Reset -------------- 51
Batch Start Mode (mode) ------------------------------------------------- 51
Calibrating the Controller with External Source (Cal) ----------- 52
Setting the Display Parameter & Intensity (dsplay) ----------------- 53
Display Setup Menu --------------------------------------------------------- 54
Setting the Relay Operation (relay) ------------------------------------- 55
Relay Assignment (Assign) ----------------------------------------------- 56
Setting the Relay Action ---------------------------------------------------- 57
Setting Batch Control Relays ---------------------------------------------- 57
Programming Alarm Set and Reset Points ----------------------------- 58
Setting Fail-Safe Operation ------------------------------------------------ 58
Programming Time Delay -------------------------------------------------- 58
Relay Action for Loss of 4-20 mA Input (Loop Break) --------------- 58
Relay Operation Details ------------------------------------------------------ 59
Overview ------------------------------------------------------------------------ 59
Relays Initialization ----------------------------------------------------------- 59
Fail-Safe Operation ---------------------------------------------------------- 59
Front Panel LEDs ------------------------------------------------------------- 60
Automatic Reset (Auto) ----------------------------------------------------- 60
Pump Alternation Control --------------------------------------------------- 60
Setting Up the Interlock Relay (Force On) Feature ------------------ 61
Sample Relay Operation ---------------------------------------------------- 62
Relay and Alarm Operation Diagrams ----------------------------------- 62
High Alarm Operation (Set > Reset) ------------------------------------- 62
Low Alarm Operation (Set < Reset) -------------------------------------- 63
High Alarm with Fail-Safe Operation (Set > Reset) ------------------ 63
Low Alarm with Fail-Safe Operation (Set < Reset) ------------------- 63
Rate Relay Sampling Operation ------------------------------------------ 64
Total Relay Sampling Operation ------------------------------------------ 64
Signal Loss or Loop Break Relay Operation --------------------------- 65
Time Delay Operation ------------------------------------------------------- 66
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Model PD6210 & PD6310 Batch Controllers Instruction Manual
Scaling the 4-20 mA Analog Output (Aout) ---------------------------- 67
Reset Menu (reset) -------------------------- ---------------------------------- 68
Control Menu (Contrl) -------------------------------------------------------- 68
Setting Up the Password (pass) ------------------------------------------- 69
Protecting or Locking the Controller ------------------------------------- 69
Grand Total Reset Password & Non-Resettable Total -------------- 70
Making Changes to a Password Protected Controller -------------- 70
Disabling Password Protection -------------------------------------------- 70
ADVANCED OPERATION AND PROGRAMMING --------------- 71
Advanced Features Menu & Display Messages ---------------------- 72
F4 Operation ------------------------------------------------------------------- 75
Multi-Point Calibration & Scaling -------------------------------------- 75
MeterView® Pro Software ----------------------------------------------- 76
Noise Filter Bypass (bypass) ---------------------------------------------- 77
Rounding Feature (round) ------------------------------------------------- 77
Modbus RTU Serial Communications (serial) ---------------------- 77
Select Menu (SElEct) ------------------------------------------------------- 78
Signal Conditioning Selection (Functn) ----------------------------- 79
Low-Flow Cutoff (CutofF) ---------------------------------------------- 79
Total and Grand Total Count Direction (Count) ------------------- 80
Analog Output Programming (AoutPr) ------------------------------ 80
Programmable Function Keys User Menu (user) -------------------- 81
PD6210 Only: Internal Source Calibration (ICAL) -------------------- 82
Controller Copy Function (Copy) ------------------------------------------ 84
TROUBLESHOOTING ---------------------------------------------------- 85
Diagnostics Menu (diag) --------------------------------------------------- 85
Determining Software Version -------------------------------------------- 85
Reset Controller to Factory Defaults ------------------------------------- 86
Factory Defaults & User Settings ----------------------------------------- 87
Troubleshooting Tips --------------------------------------------------------- 91
Alphabetical List of Display Functions & Messages --------------- 92
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Model PD6210 & PD6310 Batch Controllers Instruction Manual
Table of Figures
Figure 1: 1/8 DIN Panel Mounting ...................................................... 19
Figure 2: Controller Dimensions - Side View .................................... 20
Figure 3: Controller Dimensions - Top View ..................................... 20
Figure 4: Jumper Configuration for 12/24 VDC Power ..................... 21
Figure 5: Transmitter Supply Voltage Selection ............................... 22
Figure 6: Connector Labeling for Fully Loaded PD6210 .................. 23
Figure 7: Connector Labeling for Fully Loaded PD6310 .................. 23
Figure 8: Power Connections ............................................................. 24
Figure 9: Transmitters Powered by Internal Supply ......................... 24
Figure 10: Transmitter Powered by Ext. Supply or Self-Powered ... 25
Figure 11: Voltage Input Connections ............................................... 25
Figure 12: Flowmeter Powered by Internal Power Supply ............... 26
Figure 13: Flowmeter Powered by External Supply ......................... 26
Figure 14: Self-Powered Magnetic Pickup Coil Flowmeter .............. 26
Figure 15: NPN open Collector Input ................................................. 27
Figure 16: PNP Sensor Powered by Internal Supply ........................ 27
Figure 17: Switch Input Connections ................................................ 27
Figure 18: Relay Connections ............................................................ 28
Figure 19: AC and DC Loads Protection ........................................... 29
Figure 20: Low Voltage DC Loads Protection ................................... 29
Figure 21: F4 Digital Input Connections ............................................ 30
Figure 22: 4-20 mA Output Connections ........................................... 30
Figure 23: Expansion Modules & DIN Rail Mounting Kit .................. 31
Figure 24: External Relays Module Connections ............................. 31
Figure 25: Digital I/O Module Connections ....................................... 32
Figure 26: Interlock Connection ......................................................... 32
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Model PD6210 & PD6310 Batch Controllers Instruction Manual
INTRODUCTION
The PROVU® PD6210 and PD6310 are easy to use batch controllers ideal for
simplifying independent batch control operations where local control is preferred
to expensive and expansive plant operation systems.
The controller comes programmed for easy front panel start, pause, stop, and
batch size (preset) changes. The bottom display can be programmed to display
rate, grand total, batch count, or preset by cycling the Stop (F3) button. A digital
input is standard.
Single and multi-stage batching is possible with up to 4 on-board relays and 4 with
the external relay module. 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.
At least two SPDT relays are included for use in batch control or rate alarms.
The batch controllers also share all common P
isolated 24 VDC transmitter power supply and Modbus RTU Serial
communications.
ROVU Series features, including an
ORDERING INFORMATION
Analog Input Standard Models
85-265 VAC
Model
PD6210-6R2 PD6210-7R2 2 relays (PD1102*)
PD6210-6R4 PD6210-7R4 4 relays (PD1104*)
PD6210-6R5 PD6210-7R5 2 relays & 4-20 mA output (PD1105*)
PD6210-6R7 PD6210-7R7 4 relays & 4-20 mA output (PD1107*)
*Model number for replacement option card.
12/24 VDC
Model
Options Installed
Analog Input SunBright Display Models
85-265 VAC
Model
PD6210-6H2 PD6210-7H2 2 relays (PD1102*)
PD6210-6H4 PD6210-7H4 4 relays (PD1104*)
PD6210-6H5 PD6210-7H5 2 relays & 4-20 mA output (PD1105*)
PD6210-6H7 PD6210-7H7 4 relays & 4-20 mA output (PD1107*)
*Model number for replacement option card.
12/24 VDC
Model
Options Installed
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Model PD6210 & PD6310 Batch Controllers Instruction Manual
Pulse Input Standard Models
85-265 VAC
Model
PD6310-6R2 PD6310-7R2 2 relays (PD1102*)
PD6310-6R4 PD6310-7R4 4 relays (PD1104*)
PD6310-6R5 PD6310-7R5 2 relays & 4-20 mA output (PD1105*)
PD6310-6R7 PD6310-7R7 4 relays & 4-20 mA output (PD1107*)
*Model number for replacement option card.
12/24 VDC
Model
Options Installed
Pulse Input SunBright Display Models
85-265 VAC
Model
PD6310-6H2 PD6310-7H2 2 relays (PD1102*)
PD6310-6H4 PD6310-7H4 4 relays (PD1104*)
PD6310-6H5 PD6310-7H5 2 relays & 4-20 mA output (PD1105*)
PD6310-6H7 PD6310-7H7 4 relays & 4-20 mA output (PD1107*)
*Model number for replacement option card.
12/24 VDC
Model
Options Installed
Accessories
Model Description
PDA1002 DIN rail mounting kit for two expansion modules
PDA1004 4 SPST (Form A) relays
PDA1044 4 digital inputs & 4 digital outputs (2 may be connected)
PDA1200 Meter copy cable
PDA1232 RS-232 serial adapter
PDA1485 RS-485 serial adapter
PDA7485-I RS-232 to RS-422/485 isolated converter
PDA8232-N USB to RS-232 non-isolated converter
PDA8485-I USB to RS-422/485 isolated converter
PDA8008 USB serial adapter
PDA2811 1 Meter Plastic NEMA 4X Enclosure
PDA2812 2 Meter Plastic NEMA 4X Enclosure
PDX6901
Suppressor (snubber): 0.01 µF/470 Ω, 250 VAC
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Model PD6210 & PD6310 Batch Controllers Instruction Manual
SPECIFICATIONS
Except where noted all specifications apply to operation at +25°C.
General
DISPLAY
DEFAULT
DISPLAY
ASSIGNMENT
CUSTOM
DISPLAY
ASSIGNMENT
ALTERNATING
DISPLAY
DISPLAY
INTENSITY
DISPLAY
UPDATE RATE
OVERRANGE
UNDERRANGE
FRONT PANEL
PROGRAMMING
METHODS
NOISE FILTER
FILTER BYPASS
RECALIBRATION
MAX/MIN
DISPLAY
Upper display: 0.6" (15 mm) high, red LEDs
Lower display: 0.46" (12 mm) high, red LEDs
6 digits: each (-99999 to 999999), with lead zero blanking.
The Upper display shows batch total. The Lower display
shows rate with alternating units, and can be switched to
show grand total, batch count, or preset with the STOP key.
The Upper and Lower displays 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.
Displays alternate every 10 seconds when display is
selected or the batch is paused.
Eight user selectable intensity levels
5/second (200 ms)
Display flashes
Display flashes
NEMA 4X, IP65
Four front panel buttons, digital inputs, PC and MeterView
Pro software, or cloning using Copy function.
Programmable from 2 to 199 (0 will disable filter)
(PD6210 only)
Programmable from 0.1 to 99.9% of calibrated span
(PD6210 only)
All ranges are calibrated at the factory. Recalibration is
recommended at least every 12 months.
Max/min readings reached by the process are stored until
reset by the user or until power to the controller is cycled.
999999
-99999
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Model PD6210 & PD6310 Batch Controllers Instruction Manual
PASSWORD
NON-VOLATILE
MEMORY
POWER
OPTIONS
FUSE
ISOLATED
TRANSMITTER
POWER SUPPLY
NORMAL MODE
REJECTION
ISOLATION
OVERVOLTAGE
CATEGORY
ENVIRONMENTAL
MAX POWER
DISSIPATION
CONNECTIONS
Three programmable passwords restrict modification of
programmed settings and two prevent resetting the totals.
Pass 1: Allows use of function keys and digital inputs
Pass 2: Allows use of function keys, digital inp uts and editing set/reset points
Pass 3: Restricts all programming, function keys, and digital inputs.
Total Password: Prevents resetting the total manually
Gtotal Password: Prevents resetting the grand total manually
All programmed settings are stored in non-volatile memory
for a minimum of ten years if power is lost.
85-265 VAC 50/60 Hz, 90-265 VDC, 20 W max
or jumper selectable 12/24 VDC ± 10%, 15 W max
Required external fuse: UL Recognized, 5 A max, slow
blow; up to 6 controllers may share one 5 A fuse
Terminals P+ & P-: 24 VDC ± 10%. 12/24 VDC powered models
selectable for 24, 10, or 5VDC supply (internal jumper J4).
ProVu Series (PD6210):
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.
ProtEX-MAX (PD8 Series):
All models transmitter supply rated @ 25mA max.
Greater than 60 dB at 50/60 Hz
4 kV input/output-to-power line
500 V input-to-output or output-to-P+ supply
Installation Overvoltage Category II:
Local level with smaller transient overvoltages than
Installation Overvoltage Category III.
ProVu Series (PD6210):
Operating temperature range: -40 to 65°C
Storage temperature range: -40 to 85°C
Relative humidity: 0 to 90% non-condensing
ProtEX-MAX (PD8 series):
T6 Class operating temperature range Ta = -40 to 60°C
T5 Class operating temperature range Ta = -40 to 65°C
See LIM8 ProtEX-MAX instruction manual for additional
details.
ProtEX-MAX (PD8 Series): Maximum power dissipation
limited to 15.1 W. See LIM8 ProtEX-MAX instruction
manual for additional details.
Removable screw terminal blocks accept 12 to 22 AWG
wire, RJ45 for external relays, digital I/O, and serial
communication adapters.
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Model PD6210 & PD6310 Batch Controllers Instruction Manual
ENCLOSURE
MOUNTING
TIGHTENING
TORQUE
OVERALL
DIMENSIONS
WEIGHT
WARRANTY
1/8 DIN, high impact plastic, UL 94V-0, color: black
1/8 DIN panel cutout required:
3.622" x 1.772" (92 mm x 45 mm)
Two panel mounting bracket assemblies are provided.
Screw terminal connectors: 5 lb-in (0.56 Nm)
4.68" x 2.45" x 5.64" (119 mm x 62 mm x 143 mm)
(W x H x D)
9.5 oz (269 g)
3 years parts & labor
PD6210 Process Input
INPUTS
ACCURACY
TEMPERATURE
DRIFT
SIGNAL INPUT
CONDITIONING
MULTI-POINT
LINEARIZATION
PROGRAMMABL
E EXPONENT
LOW-FLOW
CUTOFF
DECIMAL POINT
CALIBRATION
RANGE
INPUT
IMPEDANCE
INPUT
OVERLOAD
F4 DIGITAL INPUT
CONTACTS
Field selectable:
0-20, 4-20 mA, ±10 V (0-5, 1-5, 0-10 V), Modbus PV (Slave)
±0.03% of calibrated span ±1 count,
square root & programmable exponent accuracy range:
10-100% of calibrated span
0.005% of calibrated span/°C max from 0 to 65°C ambient,
0.01% of calibrated span/°C max from -40 to 0°C ambient
Linear, square root, or programmable exponent
2 to 32 points
1.0001 to 2.9999
0-999999 (0 disables cutoff function)
Up to five decimal places or none:
d.ddddd, d.dddd, d.ddd, d.dd, d.d, or dddddd
Input
Range
4-20 mA 0.15 mA
±10 V
An error message will appear if the input 1 and input 2
signals are too close together.
Voltage ranges: greater than 500 kΩ
Current ranges: 50 - 100 Ω
Current input protected by resettable fuse, 30 VDC max.
Fuse resets automatically after fault is removed.
3.3 VDC on contact. Connect normally open contacts
across F4 to COM.
Minimum Span
Input 1 & Input 2
0.10 V
(depending on resettable fuse impedance)
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Model PD6210 & PD6310 Batch Controllers Instruction Manual
F4 DIGITAL INPUT
LOGIC LEVELS
Logic High: 3 to 5 VDC
Logic Low: 0 to 1.25 VDC
PD6310 Pulse Input
INPUTS
LOW VOLTAGE
MAG PICKUP
(Isolated)
MINIMUM INPUT
FREQUENCY
MAXIMUM INPUT
FREQUENCY
INPUT
IMPEDANCE
ACCURACY
TEMPERATURE
DRIFT
MULTI-POINT
LINEARIZATION
LOW-FLOW
CUTOFF
DECIMAL POINT
CALIBRATION
K-FACTOR
CALIBRATION
RANGE
FILTER
TIME BASE
Field selectable: Pulse or square wave 0-5 V, 0-12 V, or
0-24 V @ 30 kHz; TTL; open collector 4.7 kΩ pull-up to 5 V
@ 30 kHz; NPN or PNP transistor, switch contact 4.7 kΩ
pull-up to 5 V @ 40 Hz; Modbus PV (Slave)
Sensitivity: 40 mVp-p to 8Vp-p
0.001 Hz
Minimum frequency is dependent on high gate setting.
30,000 Hz (10,000 for low voltage mag pickup)
Pulse input: Greater than 300 kΩ @ 1 kHz.
Open collector/switch input: 4.7 kΩ pull-up to 5 V.
±0.03% of calibrated span ±1 count
Rate display is not affected by changes in temperature.
2 to 32 points
0-999999 (0 disables cutoff function)
Up to five decimal places or none:
d.ddddd, d.dddd, d.ddd, d.dd, d.d, or dddddd
May be calibrated using K-factor, internal calibration, or by
applying an external calibration signal.
Field programmable K-factor converts input pulses to rate in
engineering units. May be programmed from 0.00001 to
999,999 pulses/unit.
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.
Programmable contact de-bounce filter: 40 to 999 Hz
maximum input frequency allowed with low speed filter.
Second, minute, hour, or day
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Model PD6210 & PD6310 Batch Controllers Instruction Manual
GATE
F4 DIGITAL INPUT
CONTACTS
F4 DIGITAL INPUT
LOGIC LEVELS
Low gate: 0.1-99.9 seconds
High gate: 2.0-999.9 seconds
3.3 VDC on contact. Connect normally open contacts
across F4 to COM.
Logic High: 3 to 5 VDC
Logic Low: 0 to 1.25 VDC
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Model PD6210 & PD6310 Batch Controllers Instruction Manual
Batch Controller Rate/Totalizer Display
RATE DISPLAY
INDICATION
BATCH TOTAL &
GRAND TOTAL
DISPLAY
BATCH TOTAL
DECIMAL POINT
TOTALIZER
GRAND
TOTALIZER
ROLLOVER
GRAND TOTAL
ALARMS
PROGRAMMABL
E DELAY
ON RELEASE
GRAND TOTAL
RESET
GRAND TOTAL
RESET
PASSWORD
NONRESETTABLE
GRAND TOTAL
-99999 to 999999, lead zero blanking. “R” LED illuminates
while displaying rate.
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 totaloverflow feature. “
overflow and ▲ LED is illuminated.
Up to five decimal places or none:
oF” is displayed to the left of grand total
d.ddddd, d.dddd, d.ddd, d.dd, d.d, or dddddd
Total decimal point is independent of rate decimal point.
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 rolls over when display exceeds
999,999,999. Relay status reflects display.
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.
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.
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 passwords may be entered to prevent resetting
the grand total from the front panel.
The grand total can be programmed as a non-resettable
total by entering the password “050873”.
Once the Grand Total has been programmed
!
Caution!
as “non-resettable” the feature cannot
disabled.
be
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Model PD6210 & PD6310 Batch Controllers Instruction Manual
Relays
RATING
NOISE
SUPPRESSION
RELAY
ASSIGNMENT
PRECLOSE
ALARM
DEADBAND
HIGH OR LOW
ALARM
RELAY
OPERATION
RELAY RESET
ALARM TIME
DELAY
FAIL-SAFE
OPERATION
ALARM AUT O
INITIALIZATION
1. Alarms are active only when the batch is running.
2. These functions are not functional when the unit is being used as a batch
controller with total set to yes.
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 is recommended for each relay contact
switching inductive loads; see page 29 for details.
Relays may be assigned to batch control total, sampling,
rate, or grand total alarms.
0-100% of batch size, individually user programmable for
each additional batch control relay beyond the first.
0-100% of span, user programmable
User may program any alarm for high or low trip point.
Unused alarm LEDs and relays may be disabled (turn off).
Batch control
Automatic (non-latching)
1
Sampling
Off (disable unused relays and enable Interlock feature)
Manual on/off control mode
Secondary Functions
2
Pump alternation control (2 to 8 relays)
Latching (requires manual acknowledge)
User selectable via front panel buttons, digital inputs, or PC
1. Automatic reset only (non-latching), when the input
passes the reset point or total is reset to zero.
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 (L)
Note: Digital inputs may be assigned to acknowledge relays
programmed for manual res et. It is not recommended to
change the functions of front panel buttons to manual reset.
0 to 999.9 seconds, on & off relay time delays
Programmable and independent for each relay.
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.
When power is applied to the controller, relays will reflect
the state of the input to the controller.
1
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Model PD6210 & PD6310 Batch Controllers Instruction Manual
Isolated 4-20 mA Transmitter Output
OUTPUT
SOURCE
SCALING RANGE
CALIBRATION
ANALOG OUT
PROGRAMMING
ACCURACY
TEMPERATURE
DRIFT
ISOLATED
TRANSMITTER
POWER SUPPLY
EXTERNAL LOOP
POWER SUPPLY
OUTPUT LOOP
RESISTANCE
Rate/process, total, grand total, max, min, set points 1-8,
Modbus register, or manual control mode
1.000 to 23.000 mA for any display range.
Factory calibrated: 4.000 to 20.000 = 4-20 mA output
23.000 mA maximum for all parameters:
Overrange, underrange, max, min, and break
± 0.1% FS ± 0.004 mA
0.4 µA/°C max from 0 to 65°C ambient,
0.8 µA/°C max from -40 to 0°C ambient
Note: Analog output drift is separate from input drift.
Terminals I+ & R: 24 VDC ± 10% . May be used to power
the 4-20 mA output or other devices.Refer to
Figure 6 on page 23 and Figure 22 on page 30.
ProVu Series (PD6210):
All models rated @ 40 mA max.
ProtEX-MAX (PD8 Series):
All models @ 25mA max.
35 VDC maximum
Power supply Minimum Maximum
24 VDC
35 VDC (external)
10 Ω 700 Ω
100 Ω 1200 Ω
Modbus® RTU Serial Communications
SLAVE ID
BAUD RATE
TRANSMIT
TIME DELAY
DATA
PARITY
BYTE-TO-BYTE
TIMEOUT
TURN AROUND
DELAY
Note: Refer to the PROVU® Modbus Register Tables located at www.predig.com
for details.
1 – 247 (Controller address)
300 - 19,200 bps
Programmable between 0 and 199 ms
8 bit (1 start bit, 1 or 2 stop bits)
Even, Odd, or None with 1 or 2 stop bits
0.01 – 2.54 second
Less than 2 ms (fixed)
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Model PD6210 & PD6310 Batch Controllers Instruction Manual
PDA1044 Digital Input & Output Expansion Module
CHANNELS
SYSTEM
DIGITAL INPUT
LOGIC HIGH
DIGITAL INPUT
LOGIC LOW
DIGITAL OUTPUT
LOGIC HIGH
DIGITAL OUTPUT
LOGIC LOW
SOURCE
CURRENT
SINK CURRENT
+5 V
TERMINAL
4 digital inputs & 4 digital outputs per module
Up to 2 modules for a total of 8 inputs & 8 outputs
3 to 5 VDC
0 to 1.25 VDC
3.1 to 3.3 VDC
0 to 0.4 VDC
10 mA maximum output current
1.5 mA minimum input current
To be used as pull-up for digital inputs only
Connect normally open pushbuttons across +5 V & DI 1-4.
COMPLIANCE INFORMATION
Safety
UL & c-UL LISTED
UL FILE NUMBER
FRONT PANEL
LOW VOLTAGE
DIRECTIVE
Electromagnetic Compatibility
EMISSIONS
Radiated
Emissions
AC Mains
Conducted
Emissions
IMMUNITY
RFI - Amplitude
USA & Canada
UL 508 Industrial Control Equipment
E160849
UL Type 4X, NEMA 4X, IP65; panel gasket provided
EN 61010-1:2001
Safety requirements for measurement, control, and
laboratory use
EN 55022:2006/A1:2007
Class A ITE emissions requirements
Class A
Class A
EN 61326-1:2006
Measurement, control, and laboratory equipment
EN 61000-6-2:2005
EMC heavy industrial generic immunity standard
80 -1000 MHz 10 V/m 80% AM (1 kHz)
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Model PD6210 & PD6310 Batch Controllers Instruction Manual
Modulated
Electrical Fast
Transients
Electrostatic
Discharge
RFI - Conducted
AC Surge
Surge
Power-Frequency
Magnetic Field
Voltage Dips
Voltage
Interruptions
Note:
Testing was conducted on PD6200 and PD6300 series meters
installed through the covers of grounded metal enclosures with
cable shields grounded at the poin t of entry representing
installations designed to optimize EMC performance. All
hardware is identical to the PD6210 and PD6310 controllers.
Declaration of Conformity avai l able at www.predig.com
1.4 - 2.0 GHz 3 V/m 80% AM (1 kHz)
2.0 - 2.7 GHz 1 V/m 80% AM (1 kHz)
±2kV AC mains, ±1kV other
±4kV contact, ±8kV air
10V, 0.15-80 MHz, 1kHz 80% AM
±2kV Common, ±1kV Differential
1KV (CM)
3 A/m 70%V for 0.5 period
40%V for 5 & 50 periods
70%V for 25 periods
<5%V for 250 periods
SAFETY INFORMATION
!
CAUTION: Read complete
instructions prior to installation
and operation of the controller.
Warning!
Hazardous voltages exist within enclosure.
Installation and service should be performed only by
trained service personnel.
WARNING: Ri sk of electric
shock or personal injury.
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Model PD6210 & PD6310 Batch Controllers Instruction Manual
A
A
INSTALLATION
There is no need to remove the controller from its case to
complete the installation, wiring, and setup of the controller for
most applications. Instructions are provided for setting up a
12/24 VDC powered controller to operate from 12 VDC and for
changing the transmitter power supply to output 5 or 10 VDC
instead of 24 VDC, see page 21.
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.
Panel Mounting Instructions
• Prepare a standard 1/8 DIN panel cutout – 3.622" x 1.772" (92 mm x
45 mm). Refer to Figure 1 for more details.
• Clearance: allow at least 6.0" (152 mm) behind the panel for wiring.
• Panel thickness: 0.04" - 0.25" (1.0 mm - 6.4 mm).
Recommended minimum panel thickness to maintain Type 4X
rating: 0.06" (1.5 mm) steel panel, 0.16" (4.1 mm) plastic panel.
• Remove the two mounting brackets provided with the controller (back-off the
two screws so that there is ¼" (6.4 mm) or less through the bracket. Slide the
bracket toward the front of the case and remove).
• Insert controller into the panel cutout.
• Install mounting brackets and tighten the screws against the panel. To
achieve a proper seal, tighten the mounting bracket screws evenly until
controller is snug to the panel along its short side. DO NOT OVER
TIGHTEN, as the rear of the panel may be damaged.
Gasket
Mountin g
Bracket
Panel
B
1.772"
(45mm)
3.622" (92 mm)
Square Corners to 0.060"
(1.5mm) Max Radius
Panel Cutout
to DIN 43700
Tolerances:
: +0.032 (+0.8mm)
-0.000 (-0.0mm)
B: +0.024 (+0.6mm)
-0.000 (-0.0mm)
Figure 1: 1/8 DIN Panel Mounting
Mounting
Screw
Removable
Connectors
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Model PD6210 & PD6310 Batch Controllers Instruction Manual
Mounting Dimensions
Figure 2: Controller Dimensions - Side View
R
-
O
N
+
N
C
N
C
N
O
C
C
O
N
N
N
C
O
N
C
C
C
Figure 3: Controller Dimensions - Top View
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Model PD6210 & PD6310 Batch Controllers Instruction Manual
Configuration for 12 or 24 VDC Power Option
Do not exceed voltage rating of the selected
Warning!
Controllers equipped with the 12/24 VDC power option are shipped
from the factory ready to operate from 24 VDC.
To configure the controller for 12 VDC power:
1. Remove all the connectors.
2. Unscrew the back cover.
3. Slide the back cover about 1 inch.
4. Configure the J9 jumper, located behind the power connector, for 12
V as shown below.
configuration.
J9 CONFIGURATION
+
_
MAIN BOARD
J9
12 V
24 V
Factory
Default
M-LINK
24 VDC
12 VDC
POWER
Figure 4: Jumper Configuration for 12/24 VDC Power
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Model PD6210 & PD6310 Batch Controllers Instruction Manual
Transmitter Supply Voltage Select ion (P+, P-)
All controllers, including models equipped with the 12/24 VDC power
option, are shipped from the factory configured to provide 24 VDC
power for the transmitter or sensor.
If the transmitter requires 5 or 10 VDC excitation, the internal jumper
J4 must be configured accordingly.
To access the voltage selection jumper:
1. Remove all the connectors.
2. Unscrew the back cover.
3. Slide the back cover about 1 inch.
4. Configure the J4 jumper, located behind the input signal connector,
for the desired excitation voltage as shown.
Figure 5: Transmitter Supply Voltage Selection
6000SensorExcitation
Connections
All connections are made to removable screw terminal connectors
located at the rear of the controller.
!
Caution!
Use copper wire with 60°C or 60/75°C insulation for
all line voltage connections. Observe all safety
regulations. Electrical wiring sho ul d be performed in
accordance with all applicable national, state, and
local codes to prevent damage to the controller and
ensure personnel safety.
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Model PD6210 & PD6310 Batch Controllers Instruction Manual
Connectors Labeling
The connectors’ label, affixed to the controller, shows the location of all
connectors available with requested configuration.
Do not connect any equipment other than Precision
Digital’s expansion modules, cables, or controllers to
Warning!
the RJ45 M-LINK connector. Otherwise dama ge will
occur to the equipment and the controller.
Figure 6: Connector Labeling for Fully Loaded PD6210
C
C
Figure 7: Connector Labeling for Fully Loaded PD6310
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Model PD6210 & PD6310 Batch Controllers Instruction Manual
Power Connections
Power connections are made to a two-terminal connector labeled POWER
on Figure 6. The controller will operate regardless of DC polarity
connection. The + and - symbols are only a suggested wiring convention.
POWER
-
+
AC or DC
POWER
Required External Fuse:
5 A max, 250 V Slow Blow
Figure 8: Power Connections
PD6210 Signal Connections
Signal connections are made to a six-terminal connector labeled
SIGNAL on Figure 6. The COM (common) terminal is the return for the
4-20 mA and the ±10 V input signals.
Current and Voltage Connections
The following figures show examples of current and voltage connections.
There are no switches or jumpers to set up for current and voltage inputs.
Setup and programming is performed through the front panel buttons.
Figure 9: Transmitters Powered by Internal Supply
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Model PD6210 & PD6310 Batch Controllers Instruction Manual
Figure 10: Transmitter Powered by Ext. Supply or Self-Powered
The current input is protected against current overload by a resettable
fuse. The display may or may not show a fault condition depending on
the nature of the overload.
The fuse limits the current to a safe level when it detects a fault
condition, and automatically resets itself when the fault condition is
removed.
Figure 11: Voltage Input Connections
The controller is capable of accepting any voltage from -10 VDC to
+10 VDC.
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Model PD6210 & PD6310 Batch Controllers Instruction Manual
PD6310 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.
Figure 12: Flowmeter Powered by Internal Power Supply
Figure 13: Flowmeter Powered by External Supply
Figure 14: Self-Powered Magnetic Pickup Coil Flowmeter
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Model PD6210 & PD6310 Batch Controllers Instruction Manual
Figure 15: NPN open Collector Input
Figure 16: PNP Sensor Powered by Internal Supply
Figure 17: Switch Input Connections
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Model PD6210 & PD6310 Batch Controllers Instruction Manual
Modbus RTU Serial Communications
Serial communications connection is made to an RJ45 connector labeled
M-LINK on Figure 7. Use the PDA1232 for RS-232 interfacing, the
PDA1485 for RS-485 interfacing, or the PDA8008 for USB interfacing. The
same port is used for interfacing with all expansion modules (e.g. external
relays, digital I/O).
Use the PDA1200 controller copy cable for meter-to-meter interfacing for
cloning purposes (i.e. copying settings from one controller to other
controllers).
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.
RELAY4 RELAY3
4365 21
CNONO NC NC C
Figure 18: Relay Connections
RELAY2 RELAY1
4365 21
CNONO NC NC C
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Model PD6210 & PD6310 Batch Controllers Instruction Manual
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:
C
C
R
Figure 19: 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 rat ed 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 controller's relay screw terminals. An
RC network may also be installed across the load. Experiment for
best results.
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.
Figure 20: Low Voltage DC Loads Protection
RC Networks Available from Precision Dig ital
RC networks are available from Precision Digital and should be applied
to each relay contact switching an inductive load. Part number:
PDX6901.
Relays are de-rated to 1/14th HP (50 watts) with an inductive load.
Note:
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Model PD6210 & PD6310 Batch Controllers Instruction Manual
F4 Digital Input Connections
A digital input, F4, is standard on the meter. This digital input connected
with a normally open closure across F4 and COM, or with an active low
signal applied to F4.
Figure 21: F4 Digital Input Connections
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.
24 V
MA OUT
-
+
12-35 VDC
Power
Supply
RI- I+
132
RELAY1
321
MA OUT
+
4-20 mA Input
Remote Display,
Chart Recorder, Etc.
24 V
RI- I+
132
-
RELAY1
321
-
+
4-20 mA
Input Meter
Figure 22: 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.
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