Page 1
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
Page 2
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
2
Page 3
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
3
Page 4
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
4
Page 5
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
5
Page 6
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
6
Page 7
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
7
Page 8
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
8
Page 9
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
9
Page 10
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.
10
Page 11
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)
11
Page 12
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
12
Page 13
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
13
Page 14
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
14
Page 15
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
15
Page 16
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)
16
Page 17
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)
17
Page 18
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.
18
Page 19
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
19
Page 20
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
20
Page 21
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
21
Page 22
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.
22
Page 23
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
23
Page 24
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
24
Page 25
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.
25
Page 26
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
26
Page 27
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
27
Page 28
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
28
Page 29
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:
29
Page 30
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.
30
Page 31
Model PD6210 & PD6310 Batch Controllers Instruction Manual
External Relay & Digital I/O Connections
The relay and the digital I/O expansion modules PDA1004 & PDA1044
are connected to the controller using a CAT5 cable provided with each
module. The two RJ45 connectors on the expansion modules are
identical and interchangeable; they are used to connect additional
modules to the system.
Note: The jumper located be tween the RJ45 connectors o f the PDA1044
must be removed on the second digital I/O module in order for the
system to recognize it as module #2.
Do not connect or disconnect the expansion modules
with the power on!
Warning!
More detailed instructions are provided with each
optional expansion module.
Figure 23: Expansion Modules & DIN Rail Mounting Kit
RLY5 RLY6 RLY7 RLY8
12
NO C NO C NO C NO C
345678
Figure 24: External Relays Module Connections
31
Page 32
Model PD6210 & PD6310 Batch Controllers Instruction Manual
123456
+5 I1 I2 I3 I4 O1
5 VDC GND
DI 1-4 DO 1-4
78
O2 O3
910
O4 G
Figure 25: Digital I/O Module Connections
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
61). 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 26: Interlock Connection
32
Page 33
Model PD6210 & PD6310 Batch Controllers Instruction Manual
BASIC OPERATION AND PROGRAMMING
The PD6210 is factory calibrated prior to shipment to read in
milliamps and volts depending on the input selection. The
calibration equipment is certified to NIST standards.
The PD6310 has been factory calibrated to read input frequency
in Hz (pulses/sec). The calibration equipment is certified to NIST
standards.
Overview
Most setup and programming is done through the front panel buttons.
The PD6310 has one 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.
After power and input signal connections have been completed and
verified, apply power to the controller.
*Default Setting
33
Page 34
Model PD6210 & PD6310 Batch Controllers Instruction Manual
y
Front Panel Buttons and Status LED Indicators
Button
S
mbol
Note:
F4 is a digital input. Alarms 5-8
enabled when relay expansion
module is installed.
Description LED Status
Menu 1-8 Relay 1 – 8 indicator
START
(Right arrow/F1)
BATCH
(Up arrow/F2)
STOP
(Enter/F3)
R Rate indicator
T Batch Total indicator
G T Grand Total indicator
▲
M
Total overflow
indicator
Manual control relays
&/or analog output
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 press or hold 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 controller.
34
Page 35
Model PD6210 & PD6310 Batch Controllers Instruction Manual
Controller Operati on
The PD6210 controller is capable of accepting current (0-20 mA,
4-20 mA) and voltage signals (0-5 V, 1-5 V, 0-10 V,
PD6310 accepts pulses (e.g. ±40mV to
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 K-factor
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 (and 4 available with an
external expansion module) 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 or pulse
signal.
± 8V), square wave (0-5, 0-12V,
Default Batch Control Operation
The following describes the operation of the three front panel operating
keys 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.
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.
± 10 V) and the
35
Page 36
Model PD6210 & PD6310 Batch Controllers Instruction Manual
Batch Control Operation Example
The following example shows how two stage batch control functions with
a PD6210 or PD6310. 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.
Parameter Setting Function
Relay Assign
Asign1 total
Asign2 total
Precls
Total
Precls Yes
Yes 00005..0
…
Rly 1
relay
Act 1
rly 1
Act 1 Auto
Rly 1 Preset
Preset 00055.0
…
The operation of relay 2 has already been assigned for multi-stage
control preclose, and will not appear as a selection in the
If only one stage batch control was desired, with one relay for control,
then one would set the assignment of relay 2,
grand total.
The following pages show an illustration of how the above settings
control the batch operation. The display assignment is the default.
Press Enter to enter the relay
assignment parameters.
Assign relay 1 to batch total control.
Assign relay 2 to batch total control.
Press Enter to access preclose
selection for multi-stage control.
Yes to enable a preclose value for
relay 2.
Set the preclose value to 5 for closing
the valve controlling relay 2 five
gallons before reaching the preset.
Assignment for optional relays 3-8.
Select relay 1 setup.
Configure activation of relay 1.
Always set to Auto for batch control
function.
Set the preset value for batch control.
Set 55 gallons as the preset.
Setup for optional relays 3-8.
relay menu.
assign2, to off, rate, or
36
Page 37
Model PD6210 & PD6310 Batch Controllers Instruction Manual
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.
37
Page 38
Model PD6210 & PD6310 Batch Controllers Instruction Manual
38
Page 39
Model PD6210 & PD6310 Batch Controllers Instruction Manual
Display Functions and Messages
The controller displays various functions and messages during setup,
programming, and operation. The following table shows the main menu
functions and messages in the order they appear in the menu.
Display Parameter Action/Setting Description
setup
Input
volt
mA
Total
unitS
rate
total
Gtotal
Dec pt
prog
InCAL
factor
sCalE
Cal
Inp 1
Dis 1
Inp 2
Dis 2
Error
T tb
T Cf
Setup
Input
0-10 VDC
4-20 mA
Total
Units
Rate
Total
Grand Total
Decimal point
Program
Input Calibration
K-factor
Scaling
Scale
Calibrate
Input 1
Display 1
Input 2
Display 2
Error
Total time base
Total conversion
factor
Enter Setup menu
Enter Input selection menu
PD6210 Only: Set input for ±10 VDC input
PD6210 Only: Set input for 4-20 mA input
Enable or disable totalizer features
Select the display units/tags
Select the display units for rate
Select the display units for total
Select the display units for grand total
Set decimal point for rate, total, grand total
Enter the Program menu
Enter the Input Calibrat ion menu
PD6310 Only: Programs unit to convert
input pulse to rate in engineering units
Enter the Scale menu
Enter the Calibrate menu
Calibrate input 1 signal or program input 1
value
Program display 1 value
Calibrate input 2 signal or program input 2
value (up to 32 points)
Program display 2 value (up to 32 points)
Error, calibration not successful, check
signal or programmed value
Enter totalizer time base for seconds,
minutes, hours or day.
Enter the conversion factor decimal point
and the conversion factor.
39
Page 40
Model PD6210 & PD6310 Batch Controllers Instruction Manual
Display Parameter Action/Setting Description
mode
T dly
GT tb
GT CF
GT rst
dsplay
big
Little
d-Inty
RELaY
Assign
Asign1
TotaL
Gtotal
mbus
rate
precls
RLY 1
Act 1
Auto
A-man
LatcH
Lt-CLr
Batch mode
Time delay
Grand total time
base
Grand total
conversion factor
Grand total reset
Display
Upper display
Lower display
Display
intensity
Relay
Assignment
Assign 1
Total
Grand total
Modbus
Rate
Batch total relay
preclose
Relay 1
Action 1
Automatic
Auto-manual1
Latching1
Latching-cleared
Automatic or manual batch control
Set time delay for automatic batch restart
Program grand total time base
Program grand total conversion factor
Program grand total reset mode: auto or
manual
Enter the Display menu
Press Enter to assign the Upper display
parameter (default: PV or rate)
Press Enter to assign the Lower display
parameter (default: total)
Set display intensity level from 1 to 8
Enter the Relay menu
Assign relays to rate, total (batch control),
grand total, or Modbus controlled.
Relay 1-2 assignment
Assign relay to batch control
Assign relay to grand total
Assign relay to Modbus input
Assign relay to rate
For relays beyond the first assigned to
total, a preclose amount may be entered.
Relay 1 setup
Set relay 1 action
Set relay for automatic reset
Set relay for automatic & manual reset
any time
Set relay for latching operation (relays
assigned to rate)
1
Set relay for latching operation with
manual reset only after alarm condition
40
1
1
(relays assigned to rate)
1
Page 41
Model PD6210 & PD6310 Batch Controllers Instruction Manual
Display Parameter Action/Setting Description
has cleared (relays assigned to rate)1
Altern
Sampl
OFF
Preset
Set 1
RSt 1
RLY 2
FaiLSF
FLS 1
on
off
DeLAY
DLY 1
On 1
OFF 1
break
iGnorE
On
OFF
Aout
Dis 1
Out 1
Dis 2
Out 2
Alternate2
Sampling
Off
Preset
Set 1
Reset 1
Relay 2
Fail-safe
Fail-safe 1
On
Fail-safe off
Delay
Delay 1
On Set relay 1 On time delay
Off
Loop break
Ignore
On
Off
Analog output
Display 1
Output 1
Display 2
Output 2
Set relay for pump alternation control
(relays assigned to rate)
Set relay for sampling operation (rate or
GT)
Disable relay and front panel status LED
(Select Off to enable Interlock feature)
Set batch preset
Program set point 1
Program reset point 1
Relays 2-8 setup. Relays 5-8 are shown,
only if expansion relay module is installed.
Enter Fail-safe menu
Set relay 1 fail-safe operation
Enable fail-safe operation
Disable fail-safe operation
Enter relay Time Delay menu
Enter relay 1 time delay setup
Set relay 1 Off time delay
Set relay condition if loop break detected
(For mA input only)
Ignore loop break condition
(Processed as a low signal condition)
Relay goes to alarm condition when loop
break is detected
Relay goes to non-alarm condition when
loop break is detected
Enter the Analog output scaling menu
Program display 1 value
Program output 1 value (e.g. 4.000 mA)
Program display 2 value
Program output 2 value (e.g. 20.000 mA)
41
2
Page 42
Model PD6210 & PD6310 Batch Controllers Instruction Manual
Display Parameter Action/Setting Description
reset
Rst Hi
Rst Lo
Rst HL
Rst t
Rst Gt
Rst bc
Contrl
Auto
mAn
pass
Pass 1
Pass 2
Pass 3
Total
Gtotal
nonrst
unloc
locd
999999
-99999
Reset
Reset high
Reset low
Reset
high & low
Reset total
Reset
grand total
Reset
batch count
Control
Automatic
Manual
Password
Password 1
Password 2
Password 3
Total
password
Grand total
password
Non-resettable
Unlocked
Locked
Flashing
display
Press Enter to access the Reset menu
Press Enter to reset max display
Press Enter to reset min display
Press Enter to reset max & min displays
Press Enter to reset total
Press Enter to reset grand total
Press Enter to reset batch count
Enter Control menu
Press Enter to set controller for automatic
operation
Press Enter to manually control relays or
analog output operation
Enter the Password menu
Set or enter Password 1
Set or enter Password 2
Set or enter Password 3
Set or enter password for manual reset
Set or enter password for manual reset
Non-resettable grand total set after
entering “050873” for Gtotal password
Program password to lock controller
Enter password to unlock controller
Overrange condition
Underrange condition
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.
42
Page 43
Model PD6210 & PD6310 Batch Controllers Instruction Manual
Main Menu Map
The main menu consists of the most commonly used functions: Setup,
Reset, Control, and Password.
• Press Menu button when a batch is not running to enter
Programming Mode then press the Up arrow button to scroll main
menu.
• 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.
• The display moves to the next menu every time a setting is
accepted by pressing Enter.
43
Page 44
Model PD6210 & PD6310 Batch Controllers Instruction Manual
.
g
g
g
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.
Select
Next
Digit
004.000
004.000
dis 1 dis 1 dis 1
Increment
ital
Di
Value
005
000
Accept
Settin
Next
Settin
Setting Up the Batch Controller (setup)
The Setup menu is used to select:
1. Input signal the controller will accept
2. Enable or disable totalizer and batching features
3. Select the display units/tags
4. 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.
Please reference the “Setup” flow chart on the following page in
order to view the Setup Menu hierarchy for both the PD6210 and
PD6310.
44
Page 45
Model PD6210 & PD6310 Batch Controllers Instruction Manual
45
Page 46
Model PD6210 & PD6310 Batch Controllers Instruction Manual
Scaling and Calibration
It is very important to read the following information, before proceeding
to program the controller:
• There is no need to recalibrate the controller when first received
from the factory.
• All inputs are factory calibrated. The calibration equipment used is
certified to NIST standards.
• Use the Scale menu to enter the scaling without a signal source.
• Use the Calibrate menu to apply a signal from a calibrator or a
flowmeter for the scaling.
Setting the Input Signal (Input)
PD6210: Enter the Input menu to set up the controller to display current
(
mA) or voltage (volt) inputs.
The current input is capable of accepting any signal from 0 to 20 mA.
Select current input to accept 0-20 mA or 4-20 mA signals.
The voltage input is capable of accepting any signal from -10 to +10 VDC.
Select voltage input to accept 0-5, 1-5, 0-10, or
PD6310: 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
flowmeter manufacturers provide this information with the device. Enter
K-Factor (Factor) menu and select the decimal point with highest
the
resolution possible and program the K-factor value (
controller will automatically calculate the flow rate using the K-factor and
the time base selected.
*
Default setting
±10 VDC signals.
K-Factor function. Most
i.e. pulses/gal). The
Setting the Totalizer and Batching Features (total)
After the input type is entered, set the total parameter to “Yes” to
enable batch control (this is set by default). If the
disabled, most batching features and functions are hidden from the
menus.
46
total features are
Page 47
Model PD6210 & PD6310 Batch Controllers Instruction Manual
Setting the Input Units or Custom Tags (units)
Enter the input unit or custom tag that will be displayed if alternating rate,
total, or grand total and units is selected in the
is selected as the Lower display parameter. See the flow chart on page
54 to access the display menu to show the unit or tag on the Lower
display. The engineering units or custom legends can be set using the
following 7-segment character set:
Display Character
0
1
2
3
4
5
6
7
8
9
A
b
C
c
d
e
f
g
9
H
h
I
I
j
Notes:
Degree symbol represented by (<) if programming with MeterView
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.
0
1
2
3
4
5
6
7
8
9
A
b
C
c
d
E
F
G
g
H
h
I
i
J
47
units menu, or d unit
Display Character
k
l
m
n
O
o
p
q
r
s
t
u
v
uw
x
y
z
/
[
]
=
!
K
L
m
n
O
o
P
q
r
S
t
u
V
w
X
Y
Z
-
/
]
[
=
Degree(<)
Space
®
Pro.
Page 48
Model PD6210 & PD6310 Batch Controllers Instruction Manual
Setting the Decimal Point (dEc pt)
The decimal point may be set with up to five decimal places or with no
decimal point at all. The rate, total, and grand total decimal points are
independent.
Press the Up arrow to move the decimal point one place to the left.
Press the Right arrow to move the decimal point one place to the right.
Programming the Batch Controller (prog)
It is very important to read the following information, before proceeding
to program the controller:
• The PD6210 is factory calibrated prior to shipment to read in
milliamps and volts depending on the input selection. The calibration
equipment is certified to NIST standards.
• The PD6310 has been factory calibrated to read input frequency in
Hz (pulses/sec). The calibration equipment is certified to NIST
standards.
• Use the K-Factor in the PD6310 menu to match the rate/totalizer
with a flowmeter’s k-factor (pulse/unit of measure).
• Use the Scale menu to scale process inputs without a signal source.
A calibrated signal source is not needed to scale the controller.
Program menu contains the following menus:
The
1. Enter K-Factor (PD6310 only)
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
The process inputs may be calibrated or scaled to any display value
within the range of the controller.
Additional parameters, not needed for most applications, are
programmed in the
OPERATION AND PROGRAMMING, page 71.
Advanced Features menu; see ADVANCED
48
Page 49
Model PD6210 & PD6310 Batch Controllers Instruction Manual
Input Calibration Method (InCAL)
There are three methods of calibrating (or scaling) the display to show
the correct engineering units.
• Use the Factor menu to enter a K-Factor. (Pulse input models only.)
• 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 K-Factor, Scale, and Cal ibrate functions are exclusive of
each other. The meter uses the last function pr ogr ammed. Only one
of these methods can be employed at a time. The Scale and
Calibrate functions can use up to 32 po int s ( d efa ult is 2). The
number of points should be set for Scale an d Cal ibrate accordingly
under the Number of Points
and calibration of the meter, see page 79 for detail s .
(nopts) menu selection prior to scaling
PD6310 Only: K-Factor Calibration (Factor)
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 (
meter will automatically calculate the flow rate using the k-factor and the
time base selected.
49
i.e. pulses/gal). The
Page 50
Model PD6210 & PD6310 Batch Controllers Instruction Manual
Scaling the Controller (SCALE)
The process inputs (4-20 mA and ±10 VDC) and frequency inputs can be
scaled to display the process variable in engineering units.
A signal source is not needed to scale the controller; simply program the
inputs and corresponding display values.
For instructions on how to program numeric
values see
Setting Numeric Values, page 44.
Error Message (Error)
An error message indicates that the calibration or scaling process was not
successful.
After the error message is displayed, the controller reverts to input 2
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 2
signals required to complete the calibration or scaling of the controller.
Input range Input 1 & input 2 span
4-20 mA 0.15 mA
±10 VDC
0.10 VDC
50
Page 51
Model PD6210 & PD6310 Batch Controllers Instruction Manual
Time Base, Total Conversion Factor & Total Reset
The time base, total conversion factor, and total reset menus are located
in the
Program menu.
The total and grand total have their own independent settings. This
means that one can be displaying the value in gallons while the other
displays in million gallons, liters, m
3
, 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 35. 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 (
only occur after a successful batch. A manually stopped batch will
require a manual start to begin a new batch process.
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 grand total after the assigned preset is reached.
t dly). Automatic batch start will
Non-Resettable Totalizer
The total and grand total can be password-protected to prevent
unauthorized resets. The grand total can be programmed as a nonresettable total, see page 70 for details.
51
Page 52
Model PD6210 & PD6310 Batch Controllers Instruction Manual
Calibrating the Controller with External Source (Cal)
To scale the controller without a signal source refer to Scaling the
Controller (
SCALE) page 49.
The controller can be calibrated to display the process variable in
engineering units by applying the appropriate input signal and the
corresponding display value.
The use of a calibrated signal source is strongly recommended to
calibrate the controller.
Warm up the controller for at least 15 minutes before performing
calibration to ensure specif ied accuracy.
52
Page 53
Model PD6210 & PD6310 Batch Controllers Instruction Manual
Setting the Display Parameter & Intensity (dsplay)
The Upper display (Big) 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 Lower 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.
For direct sunlight readability, Sunbright display models are highly
recommended. See Ordering Information on page 7 for details.
Little) can be programmed to display:
53
Page 54
Model PD6210 & PD6310 Batch Controllers Instruction Manual
Display Setup Menu
After setting up the input and the 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.
54
Page 55
Model PD6210 & PD6310 Batch Controllers Instruction Manual
Setting the Relay Operation (relay)
This menu is used to set up the operation of the relays.
During setup, the relays do not follow the
!
Caution!
1. Relay assignment
2. Relay action
3. Set and reset points; batch preset
4. Fail-safe operation
5. Time delay
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.
!
a. Rate for low and high alarm
b. Total for batch control relays
c. Grand total for grand total alarms
a. Automatic reset only (non-latching)
b. Automatic + manual reset when not in a batch process
(non-latching)
c. Latching (manual reset when not in a batch process only)
d. Latching with Clear (manual reset when not in a batch
process only after alarm condition has cleared)
e. Pump alternation control (automatic reset only, for level
applications unrelated to batch control)
f. Sampling (the relay is activated for a user-specified time
and may be assigned to rate or grand total)
g. Off (relay state controlled by Interlock feature)
a. On (enabled)
b. Off (disabled)
a. On delay (0-999.9 seconds)
b. Off delay (0-999.9 seconds)
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.
input and they will remain in the state f ound
prior to entering the Relay menu.
55
Page 56
Model PD6210 & PD6310 Batch Controllers Instruction Manual
A
Relay Assignment (Assign)
The relays can be assigned to any of the following parameters:
1. Rate for low or high alarm indication
2. Total for batch control relays
3. Grand total for alarm indication
ssign preclose
if multiple relays
are assigned.
Note: Relay 1 should always be assigned to “total” for batch control
applications.
56
Page 57
Model PD6210 & PD6310 Batch Controllers Instruction Manual
Setting the Relay Action
Operation of the relays is programmed in the Action menu. The relays
are commonly 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 (nonlatching)
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.)
Setting Batch Control Relays
Operation of batch control relays are programmed in the Assign menu by
selecting
will include a preclose parameter (
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
the relay perform identically to the first batch control relay set to
total as the assignment. Relays set to total beyond the first
precls) option. Selecting yes for
no for precls will have
total.
57
Page 58
Model PD6210 & PD6310 Batch Controllers Instruction Manual
Programming Alarm Set and Reset Points
High alarm indication: program set point above reset point.
Low alarm indication: program set point below reset point.
The deadband is determined by the difference between set and reset
points. Minimum deadband is one display count. 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
Failsafe mode should not be used on batch relays assigned to total.
on to enable or select off to disable fail-safe operation.
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.
Off time delay is associated with the reset point.
The
Relay Action for Loss of 4-20 mA Input (Loop Break)
The loop break feature is associated with the 4-20 mA input. Rate alarm
relays may be programmed to go to one of the following conditions when
the controller detects the loss of the input signal (i.e. < 0.005 mA):
1. Turn
2. Turn
3. Ignore (Process as a low signal condition)
Note: This is not a true loop break condition; if the signal drops below
0.005 mA, it is interpreted as a “loop break” con di tio n.
On (Go to alarm condition)
Off (Go to non-alarm condition)
58
Page 59
Model PD6210 & PD6310 Batch Controllers Instruction Manual
Relay Operation Detai ls
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 and/or 4 external relays expansion module.
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 36.
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 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)
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 alarm relays behave based on the failsafe selection for each relay:
Fail-Safe
Selection
Off Open Closed Closed Open
On Closed Open Open Closed
Note: NO = Normally Open, NC = Normally Closed. This refers to the
condition of the relay contacts when the power to the controller is off.
De-Energized State Energized State
NO NC NO NC
Power Failure
Relays in deenergized state
Relays in
energized state
59
Page 60
Model PD6210 & PD6310 Batch Controllers Instruction Manual
Front Panel LEDs
The LEDs on the front panel provide status indication for the following:
LED Status LED Status
1 Alarm 1 5 Alarm 5
2 Alarm 2 6 Alarm 6
3 Alarm 3 7 Alarm 7
4 Alarm 4 8 Alarm 8
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 PD6200
and PD6300 instruction manuals available at www.predig.com.
Automatic Reset (Auto)
Automatic reset only
Condition LED Relay
Normal Off Off
Alarm On On
Ack (No effect) On On
Normal Off Off
In this application, the controller is set up for automatic reset (nonlatching 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.
Pump Alternation Control
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 PD6200 and PD6300 instruction manuals
available at www.predig.com.
60
Page 61
Model PD6210 & PD6310 Batch Controllers Instruction Manual
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
2. In the Advanced features –
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 (dI-1 to dI-4) terminal.
Setup – Relay – Action menu and set the action to off.
User menu program any of the digital
SW2
SW1
123456
+5 I1 I2 I3 I4 O1
5 VDC GND
DI 1-4 DO 1-4
78
O2 O3
910
O4 G
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
61
Page 62
Model PD6210 & PD6310 Batch Controllers Instruction Manual
relay will stop, and will re-start only after the interlock relay is reactivated 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 (
600.0 seconds, every time the set point rate is reached.
A total sampling relay will activate for the sample time (
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.
sam t), up to
sam t), up to
Relay and Alarm Operation Diagrams
The following graphs illustrate the common operation of the relays,
status LEDs, and ACK button.
High Alarm Operation (Set > Reset)
62
Page 63
Model PD6210 & PD6310 Batch Controllers Instruction Manual
S
Low Alarm Operation (Set < Reset)
Input
Reset
et
Relay
LED
energized
on
de-energized
off
Automatic (non-latching)
High Alarm with Fail-Safe Operation (Set > Reset)
Note: Relay coil is energized in non-alarm conditio n.
In case of power failure, relay w ill go to alarm state.
Low Alarm with Fail-Safe Operation (Set < Reset)
Input
Reset
Set
Relay
LED
de-energized
on
energized
off
Automatic (non-latching)
Note: Relay coil is energized in non-alarm conditio n.
In case of power failure, relay w ill go to alarm state.
63
Page 64
Model PD6210 & PD6310 Batch Controllers Instruction Manual
Rate Relay Sampling Operation
When the signal crosses the set point, the relay trips and the sample
time starts. After the sample time has elapsed, the relay resets. The
cycle repeats every time the set point is crossed, going up for high
alarms and going down for low alarms.
The sample time can be programmed between 0.1 and 600.0 seconds.
Total Relay Sampling Operation
When the batch total reaches the set point, the relay trips and the
sample time starts. After the sample time has elapsed, the relay resets.
The cycle repeats every time the set point value is added to the batch
total.
64
Page 65
Model PD6210 & PD6310 Batch Controllers Instruction Manual
Signal Loss or Loop Break Relay Operation
The following graph shows the loop break operation for a high alarm
relay.
When the controller 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 (Process as a low signal condition)
65
Page 66
Model PD6210 & PD6310 Batch Controllers Instruction Manual
Time Delay Operation
The following graphs show the operation of the time delay function.
When the signal crosses the set point, the
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
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.
On time delay timer starts and
On time
66
Page 67
Model PD6210 & PD6310 Batch Controllers Instruction Manual
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 rate 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 rate display values.
For instructions on how to program numeric values see
Numeric Values
, page 44.
67
Setting
Page 68
Model PD6210 & PD6310 Batch Controllers Instruction Manual
Reset Menu (reset)
The Reset menu is used to reset the total, grand totals, batch count,
maximum, or minimum reading (peak or valley) reached by the process;
both maximum and minimum may be reset at the same time by selecting
“reset high & low” (
rst HL).
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.
68
Page 69
Model PD6210 & PD6310 Batch Controllers Instruction Manual
Setting Up the Password (pass)
The Password menu is used for programming three levels of security to
prevent unauthorized changes to the programmed parameter settings
and to program the non-resettable totalizer.
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 Password: Prevents resetting the total
Gtotal Password: Prevents resetting the grand total manually
Protecting or Locking the Controller
Enter the Password menu and program a six-digit password.
For instructions on how to program numeric values see
, page 44.
Values
manually
Setting Numeric
Record the password for future reference. If appropriate, it may be
recorded in the space provided.
Model:
Serial Number:
Password 1: __ __ __ __ __ __
Password 2: __ __ __ __ __ __
Password 3: __ __ __ __ __ __
Total __ __ __ __ __ __
GTotal __ __ __ __ __ __
69
Page 70
Model PD6210 & PD6310 Batch Controllers Instruction Manual
Grand Total Reset Password & Non-Resettable Total
The grand total can be password-protected to prevent unauthorized total
resets.
The grand total can be programmed as a non-resettable total by entering
the password “050873”.
!
Caution!
Once the Grand Total has been programmed as “nonresettable” the feature cannot
be disabled.
Making Changes to a Password Protected Contr oller
If the controller is password protected, the controller will display the
message
Enter button while the message is being displayed and enter the correct
password to gain access the menu. After exiting the programming mode,
the controller returns to its password protected condition.
Locd (Locked) when the Menu button is pressed. Press the
Disabling Password Protection
To disable the password protection, access the Password menu and
enter the correct password twice, as shown below. The controller is now
unprotected until a new password is entered.
If the correct six-digit password is entered, the controller displays the
message
password is programmed.
If the password entered is incorrect, the controller displays the message
Locd (Locked) for about two seconds, and then it returns to Run Mode.
To try again, press Enter while the
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
controller.
unLoc (unlocked) and the protection is disabled until a new
Locked message is displayed.
Did you forget the password?
70
Page 71
Model PD6210 & PD6310 Batch Controllers Instruction Manual
ADVANCED OPERATION AND PROGRAMMING
In addition to the functions described in Controller Operation on page 35,
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.
Advanced Features Menu
To simplify the setup process, functions not needed for most applications
are located in the
Press and hold the Menu button for three seconds to access the
advanced features of the controller. This cannot be done during a back
process as all functions other than STOP are disabled during a batch
process, including the Menu button.
Advanced Features menu.
PD6210 Advanced Features Menu
PD6310 Advanced Features Menu
71
Page 72
Model PD6210 & PD6310 Batch Controllers Instruction Manual
Advanced Features Menu & Display Messages
The following table shows the functions and messages of the Advanced
Features
menu in the order they appear in the menu.
Display Parameter Action/Setting
Gate
Lo G
Hi G
filter
Hi spd
Lo spd
bypASs
Round
seriAl
SlaveId
baud
Tr dLY
Parity
t-byt
SelEct
Functn
Linear
No PtS
Square
Prog E
CutofF
Count
Tot C
Gate
Low gate
High gate
Filter
High Speed
Filter
Low Speed Filter
Bypass
Round
Serial
Slave ID
Baud rate
Transmit
delay
Parity
Time byte
Select
Signal Input
Conditioning
Linear
Number of points
Square root
Programmable
exponent
Cutoff
Count
Total count
Gate settings (PD6310)
Program Low gate value
Program High gate value
Set noise filter value
Program High Speed Filter
Program Low Speed Filter
Set filter bypass value
Set the rounding value for display variables
Set serial communication parameters
Set slave ID or controller address
Select baud rate
Set transmit delay for serial communication
Select parity
Even, Odd, or None with 1 or 2 stop bits
Set byte-to-byte timeout
Enter the Select menu (function, cutoff, out)
Select linear, square root, or programmable
exponent
Set controller for linear function and select
number of linearization points
Set controller for 2 to 32-point linearization
Set controller for square root extraction
Set controller for programmable exponent and
enter exponent value
Set low-flow cutoff
Set the totals to count up or down from a set
value
Set the batch to count up to or down from the
preset
72
Page 73
Model PD6210 & PD6310 Batch Controllers Instruction Manual
Display Parameter Action/Setting
up
Douwn
Gtot C
C strt
AoutPr
Source
O-rang
u-rang
Break
Force
Ignore
mAx
min
Calib
4 mA
20 mA
user
F1
F2
F3
F4
dI I
dO 1
ICal
C CAL
Up
Down
Grand total
count
Count start
Analog output
programming
Source
Overrange
Underrange
Loop Break
Force output
Ignore
Maximum
Minimum
Calibrate
4 mA output
20 mA output
User I/O
F1 function key
F2 function key
F3 function key
F4 function
Digital input 1
Digital output 1
Internal source
calibration
Current
calibration
Set the total to count up
Set the total to count down
Set the grand total to count up or down from a
defined value
Set the starting grand total value when counting
down
Program analog output parameters
Select source for the 4-20 mA output
Program mA output for display overrange
Program mA output for display underrange
Set relay condition if loop break detected
Force analog output value for loop break
Ignore loop break condition
Program maximum mA output allowed
Program minimum mA output allowed
Calibrate 4-20 mA output (internal reference
source used for scaling the output)
Enter mA output value read by milliamp meter
with at least 0.001 mA resolution
Enter mA output value read by milliamp meter
with at least 0.001 mA resolution
Assign function keys and digital I/O
Assign F1 function key
Assign F2 function key
Assign F3 function key
Assign F4 function (digital input)
Assign digital input 1 – 8, if expansion modules
are connected
Assign digital output 1 – 8, if expansion
modules are connected
Enter internal source calibration (used for
scaling the controller without a signal source
Calibrating 4-20 mA current input (internal
reference source used for scaling the input)
73
Page 74
Model PD6210 & PD6310 Batch Controllers Instruction Manual
Display Parameter Action/Setting
C lo
C Hi
v CAL
v Lo
v Hi
Copy
send
done
Diag
Input
units
Filter
bypass
Round
Functn
SCALE
Factor
Gate
Cutoff
T tb
T CF
mode
T delay
Gt tb
Gt Cf
Gt rst
Dsplay
RELAY
Aout
Current low
Current high
Voltage
calibration
Voltage low
Voltage high
Copy
Send
Done
Diagnostics
Input
Units
Filter
Bypass
Round
Function Function selected
Scale
K-factor
Gate Gate settings
Cutoff
Total time base
Total correction
factor
Batch mode
Time delay
Grand total time
base
GT correction
factor
Grand total reset
Display
Relays Relay settings
Analog output
Calibrate low current input (e.g. 4 mA)
Calibrate high current input (e.g. 20 mA)
Calibrating voltage input
Calibrate low voltage input (e.g. 0 V)
Calibrate high voltage input (e.g. 10 V)
Enter copy function
Send controller settings to another controller
Copy function completed
Display parameter settings
Input selection
Select the display units/tags
Set noise filter level
Set filter bypass level
Round the display values to the nearest entered
multiple
Scaling parameter
K-factor value
Cutoff value
Set time period
Set correction factor
Automatic or manual batch start
Set time delay for automatic batch restart
Set grand total time period
Set grand total correction factor
Set grand total reset method
Display assignments
Analog output scaling
74
Page 75
Model PD6210 & PD6310 Batch Controllers Instruction Manual
Display Parameter Action/Setting
Aoutpr
seriAl
LED t
Info
Analog output
programming
Serial
LED test
Information
Analog output programming
Set serial communication parameters
Test all LEDs
Display software information
Function Keys Operation
During operation, the programmable function keys operate according to
the way they have been programmed in the
Advanced Features – User
menu. The following table shows the default setting for each of the
function keys.
Function Key/Button Default Setting Action
F1/START
F2/BATCH
F3/STOP
F4/Digital Input
Start
preset
stop
Srtstp
Start batch
Change preset
Pause/stop batch
Start/stop batch
F4 Operation
A digital input, F4, is standard on the meter. This digital input is
programmed identically to function keys F1, F2, and F3. The input is
triggered with a contact closure to COM, or with an active low signal.
During operation, F4 operates according to the way is has been
programmed in the
Advanced Features – User menu.
Only STOP Operation Enabled if a Batch is Running.
During a batch process, the only function that can be
performed is the pause/st op 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 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 79 for details.
75
Page 76
Model PD6210 & PD6310 Batch Controllers Instruction Manual
MeterView® Pro Software
The controller can be programmed and operated using the PC-based
MeterView Pro software available for free download at www.predig.com.
Batches may be started, paused, and stopped, through the monitoring
window of the MeterView Pro software. Preset and preclose values may
be changed, and the total and grand total reset.
Data logging for one controller at the time is available with MeterView
Pro software. More advanced data acquisition may be accomplished by
using any Modbus RTU compliant software.
In order to operate or program the batch controller using a computer, the
controller must be connected using a USB, RS-232, or RS-485 serial
adapter, see Accessories on page 8 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
2. Display continuously by assigning either display to max/min through
the
Display menu.
Changing the programming of the F1-F3 function keys will
!
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 (
disable the default batch operation of these keys, and is
not recommended for batch control appli c ations.
d HL) every 10 seconds.
User menu.
Note that changing default the programming of the upper
!
or lower displays will interfere with seeing the batch total
(upper display) or rate (lower display) of the batch
process.
76
Page 77
Model PD6210 & PD6310 Batch Controllers Instruction Manual
Noise Filter (filter)
The noise filter is available for unusually noisy signals that cause an
unstable process variable display. The noise filter averages the input
signal over a certain period. The filter level determines the length of time
over which the signal is averaged. The filter level can be set between 2
and 199. The higher the filter level, the longer the averaging time and so
the longer it takes the display to settle to its final value. Setting the filter
level to zero disables the filter function.
Note: The filter for a PD6310 works differently. There are two available
settings: Hi Speed and Lo Speed (programmable from 2 to 50).
Noise Filter Bypass (bypass)
The noise filter bypass changes the behavior of the controller so that
small variations in the signal are filtered out but large abrupt changes in
the input signal are displayed immediately. The bypass value determines
the minimum amount of signal change to be displayed immediately. All
signal changes smaller than the bypass value are filtered or averaged by
the controller. The noise filter bypass may be set between 0.1 and 99.9%
of full scale.
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 to
the rounding selected. This setting affects the last two digits, regardless
of decimal point position.
Modbus RTU Serial Communications (serial)
The controller is equipped with serial communications capability as a
standard feature using Modbus RTU Serial Communication Protocol.
To communicate with a computer or other data terminal equipment, an
RS-232, RS-485, or USB adapter option is required; see
Information
on page 7 for details.
Ordering
Do not connect any equipment other than Precision
Digital’s expansion modules, cables, or controllers to
Warning!
Note: More detailed instructions are provided with each optional serial
the RJ45 M-LINK connector. Otherwise dama ge will
occur to the equipment and the controller.
®
ProVu
communications adapter. Note: Refer to the
Register Tables located at www.predig.com for details.
77
Modbus
Page 78
Model PD6210 & PD6310 Batch Controllers Instruction Manual
When using more than one controller in a multi-drop mode, each
controller must be provided with its own unique address. The controller
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.
The PD6210 can also be connected to another PD6210 with a special
PDA1200 cable, allowing the user to copy all the settings from one
controller to another, using the
Copy function.
A PD6310 may be similarly connected to another PD6310.
A PD6210 may not be connected to a PD6310.
Select Menu (SElEct)
The Select menu is used to select the signal input conditioning applied to
the input (linear, square root, or programmable exponent, low-flow cutoff,
and analog output programming. The multi-point linearization is part of
the linear function selection.
78
Page 79
Model PD6210 & PD6310 Batch Controllers Instruction Manual
Signal Conditioning Selection (Functn)
The Function menu is used to select the signal conditioning function
applied to the input: linear, square root, or programmable exponent. The
multi-point linearization is part of the linear function selection.
Controllers 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.
Square Root Linearization (Square)
The square root function can be used to linearize the signal from a
differential pressure transmitter and display flow rate in engineering
units.
Programmable Exponent Linearization (Prog E)
The programmable exponent can be used to linearize the signal from
level transmitters in open-channel flow applications using weirs and
flumes.
Multi-Point Linearization (Linear)
Controllers are set up at the factory for linear function with 2-point
linearization. Up to 32 linearization points can be selected 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 odd-shaped tanks or to convert level to flow using
weirs and flumes with complex exponent.
Low-Flow Cutoff (CutofF)
The low-flow cutoff feature allows the controller to be programmed so
that the often-unsteady output from a differential pressure transmitter, at
low flow rates, always displays zero on the controller.
The cutoff value may be programmed from 0 to 999999. The controller
will display zero below the cutoff value. Programming the cutoff value to
zero disables the cutoff feature.
79
Page 80
Model PD6210 & PD6310 Batch Controllers Instruction Manual
Total and Grand Total Count Direction (Count)
By default, the batch total and grand total count up during batch
processes.
Count parameter allows this to change. When set to count
down, the batch total will count down from the preset to 0. When set to
count down, the grand total will count down from a set value to zero.
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, one of the set points, or the Modbus PV
input.
Analog Output Calibration
To perform the analog output calibration it’s 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.
80
Page 81
Model PD6210 & PD6310 Batch Controllers Instruction Manual
Programmable Function Keys User Menu (user)
Changing the programming of the F1-F3 function keys will
disable the default batch operation of these keys, and is
!
not recommended for batch control applications.
The User menu allows the user to assign the front panel function keys
F1, F2, F3, F4 (digital input) and up to eight digital inputs (DI 1 to DI 8) to
access most of the menus or to activate functions immediately (e.g.
Reset max & min). Up to eight digital outputs (DO 1 to DO 8) can be
assigned to a number of actions and functions executed by the controller
(e.g. Alarms, relay acknowledgement, etc.).
Function Keys & Digital I/O Available Setting s
Display Description Display Description
Start
stop
srtstp
Rly d
Rly e
O Hold
D Hold
big Hi
big Lo
big Hl
Lit Hi
Lit Lo
Lit HL
Lit gt
Lit bc
Contrl
disabl
AcH
Start batch
Pause/stop batch
Start/stop combo
Disable all relays
Enable all relays
Output level hold
Display hold
Max on Upper display
Min on Upper display
Max/min on Upper
display
Max on Lower display
Min on Lower display
Max/min Lower display
GT on Lower display
Batch count display
Control Menu
Disable input/button
Acknowledge relays
reset
Rst t
Rst Gt
Rst bc
Rst Hi
Rst Lo
Rst HL
relay
Preset
Set 2
menu
Right
up
enter
F On 1
F On 2
F On 3
F On 4
Reset Menu
Reset total
Reset grand total
Reset batch count
Reset max
Reset min
Reset max & min
Relay menu
Change preset
Set point 2 – 8
Enter menu (DI only)
Right/F1(DI only)
Up/F2 (DI only)
Enter/F3 (DI only)
Force relay 1 on (DI only)
Force relay 2 on (DI only)
Force relay 3 on (DI only)
Force relay 4 on (DI only)
81
Page 82
Model PD6210 & PD6310 Batch Controllers Instruction Manual
PD6210 Only: Internal Source Calibration (ICAL)
Note: The PD6210 is factory calibrated prior to shipment to read in
milliamps and volts depending on the input selection. The calibration
equipment is certified to NIST standar d s.
The use of a calibrated signal source is necessary to calibrate the
internal source of the meter. The meter’s internal source is what allows
the user to scale the meter without applying a signal.
Check calibration of the controller at least every 12 months. Each input
type must be recalibrated separately.
Notes:
1. If controller is in operation and it is intended to accept only
one input type (e.g. 4-20 mA),
recalibration of other input is not ne c essary.
2. Allow the controller to warm up for at least 15 minutes
before performing the internal source calibration procedure.
Internal calibration menu is part of the Advanced Features menu.
The
1. Press and hold the Menu button for three seconds to access the
advanced features of the controller.
2. Press the Up
(
ICAL) and press Enter.
3. The controller displays either current calibration (
calibration (
the calibration process.
Example of Internal Calibration for current input:
4. The controller displays low input current message (C lo). Apply the
low input signal and press Enter. The display flashes for a moment
while the controller is accepting the low input signal.
5. After the display stops flashing, a number is displayed with the
leftmost digit brighter than the rest. The bright digit is the active digit
that can be changed by pressing the Up
arrow button to move to the next digit.
Right
6. Set the display value to correspond to the input signal being
calibrated, typically 4.000 mA.
7. The display moves to the
high input signal and press Enter.
8. Set the display for the high input calibration, in the same way as it
was set for the low input calibration, typically 20.000 mA.
arrow button to scroll to the Internal calibration menu
C CAL) or voltage
v CAL), according to the input setup. Press Enter to start
arrow button. Press the
high input calibration (C Hi). Apply the
82
Page 83
Model PD6210 & PD6310 Batch Controllers Instruction Manual
T
he display
while sensing
the inputs
The graphic above shows the calibration of the current input. The voltage
input is calibrated in a similar way.
Tips:
•
Low and high input signals can be any valid value within the
range of the controller.
• Observe minimum input span requirements between input 1
and input 2.
• Low input should be less than high input signal.
Error Message (Error)
An error message indicates that the calibration or scaling process was not
successful.
After the error message is displayed, the controller reverts to input 2
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.
83
Page 84
Model PD6210 & PD6310 Batch Controllers Instruction Manual
Minimum Input Span
The minimum input span is the minimum difference between input 1 and 2
signals required to complete the calibration or scaling of the controller.
Input range Input 1 & input 2 span
4-20 mA 0.15 mA
±10 VDC
0.10 VDC
Controller Copy Function (Copy)
The Copy function is used to copy (or clone) all the settings from one
controller to other controllers requiring exactly the same setup and
programming (
etc.).
Warning!
Copy Function Requirements
To successfully copy setting s from one co ntroller to another, both
controllers must have the same soft ware version and baud rate setting.
See Determining Software Version, page 85 for instructions.
Controller Copy or Cloning Instructions
i.e. type of input, scaling, decimal point, filter, bypass,
Only the PDA1200 meter copy cable must be used for
meter-to-meter interfacing. Using standard CAT5 or
other cable will cause damage to both controllers.
!
Caution!
1. Connect two controllers using a PDA1200 controller copy cable.
2. Do not connect the two controllers to the same signal source.
3. Power up both controllers. Leave clone controller in Run Mode.
4. Enter the
ADVANCED OPERATION AND PROGRAMMING page 71.
5. Scroll to the
Enter.
6. The controller displays the message
flashes while sending data. The message
copying is completed.
Do not connect the two controlle rs to the same signal
source while cloning. Internal calibration may be affected.
Advanced Features menu of the Master controller see
Copy function using the Up arrow button then press
Send. Press Enter, the display
done is displayed when
84
Page 85
Model PD6210 & PD6310 Batch Controllers Instruction Manual
7. The Clone controller displays the message CPY rC while being
programmed then the message
The controller initializes and returns to Run Mode using the same
settings as the Master.
8. If controller to be cloned does not respond to the data being sent,
refer to the
Copy Function Requirements on page 84.
done when copying is completed.
TROUBLESHOOTING
The rugged design and the user-friendly interface of the controller should
make it unusual for the installer or operator to refer to this section of the
manual. However, due to the many features and functions of the
controller, it’s possible that the setup of the controller does not agree
with what an operator expects to see.
If the controller is not working as expected, refer to the
and recommendations below.
Diagnostics Menu (diag)
The Diagnostics menu is located in the Advanced Features menu, to
Diagnostics menu see ADVANCED OPERATION AND
access
PROGRAMMING, page 71.
It provides an easy way to view the programmed parameter settings for
troubleshooting purposes. Press the Enter
and the Menu button to exit at any time.
For a description of the diagnostic messages,
Display Messages, page 72.
Menu &
button to view the settings
see Advanced Features
Determining Software Version
To determine the software version of a controller:
1. Go to the
2. Press Up arrow button and scroll to Information menu (
3. Press Enter to access the software number (
version (
displayed. Continue pressing Enter until all the information is
displayed.
4. The controller returns to Run Mode after displaying all the
settings.
Diagnostics menu (diAG) and press Enter button.
UER) information. Write down the information as it is
Diagnostics menu
Info).
SFT) and
85
Page 86
Model PD6210 & PD6310 Batch Controllers Instruction Manual
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 defaul ts:
1. Enter the Advanced Features menu. See ADVANCED OPERATION
AND PROGRAMMING, page 71.
2. Press Up arrow to go to
3. Press and hold Right arrow for three seconds, press
Enter when display flashes
Note: If Enter is not pressed within three seconds, the display
returns to the
4. The controller goes through an initialization sequence (similar as on
power-up), and loads the factory default settings.
Diagnostics menu.
Diagnostics menu
reset.
86
Page 87
Model PD6210 & PD6310 Batch Controllers Instruction Manual
Factory Defaults & User Settings
The following table shows the factory setting for the major programmable
parameters on the controller. Next to the factory setting, the user may
record the new setting for the particular application.
Model: ______________ S/N: _______________ Date: _________
Parameter Display Default Setting User Setting
Input type
Total
Units (PD6210)
Units (PD6310)
Rate decimal point
Total decimal point
G. Total decimal
point
K-factor
Input
yes
units
units
ddd.ddd
ddddd.d
dddddd
Factor
PD6210: 4-20 mA
PD6310: Pulse
Total enabled
Rate / total / gr. total
mA / mA / mA
Rate / total / gr. total
Pulse / Pulse / Pulse
PD6210: 3 Places
PD6310: 1 Place
1 Place
0 Places
1.000; PD6310 Only
Function
Number of points
Programming
Input 1
Display 1
Input 2
Display 2
Upper display
Lower display
Display intensity
Total time base
Functn
No Pts
prog
InP 1
Dis 1
InP 2
Dis 2
big
Little
d-Inty
T tb
Linear
2
Scale
PD6210: 4.000 mA
PD6310: 00000.0
PD6210: 4.000
PD6310: 00000.0
PD6210: 20.000 mA
PD6310: 10000.0
PD6210: 20.000
PD6310: 10000.0
Display total
Display rate and
units
8
Second
87
Page 88
Model PD6210 & PD6310 Batch Controllers Instruction Manual
Parameter Display Default Setting User Setting
Total conversion
factor
Batch mode
Grand total time
base
Grand total
conversion factor
Grand total reset
T CF
mode
GT tb
T CF
T rst
1.000
Manual
Second
1.000
Manual
Relay 1 assignment
Relay 2 assignment
Relay 2 preclose
Relay 3 assignment
Relay 4 assignment
Relay 1 action
Batch preset
Relay 2 action
Relay 2 set point
Relay 3 action
Relay 3 set point
Relay 3 reset point
Relay 4 action
Relay 4 set point
Relay 4 reset point
Fail-safe relay 1
Fail-safe relay 2
Asign1
Asign2
preCls
Asign3
Asign4
Act 1
Preset
Act 2
Set 2
Act 3
Set 3
RSt 3
Act 4
Set 4
RSt 4
Fls 1
Fls 2
Total
Total
No
Rate
Rate
Automatic
100.0
Automatic
200.0
Automatic
3.000
2.500
Automatic
4.000
3.500
Off
Off
Fail-safe relay 3
Fls 3
Off
88
Page 89
Model PD6210 & PD6310 Batch Controllers Instruction Manual
Parameter Display Default Setting User Setting
Fail-safe relay 4
On delay relay 1
Off delay relay 1
On delay relay 2
Off delay relay 2
On delay relay 3
Off delay relay 3
On delay relay 4
Off delay relay 4
Loop break relay 1
Loop break relay 2
Loop break relay 3
Loop break relay 4
Display 1 analog out
Output 1 value
Display 2 analog out
Output 2 value
Source analog
output
Overrange output
Fls 4
On 1
Off 1
On 2
Off 2
On 3
Off 3
On 4
Off 4
ignore
ignore
ignore
ignore
Dis 1
Out 1
Dis 2
Out 2
Source
O-rang
Off
0.0 sec
0.0 sec
0.0 sec
0.0 sec
0.0 sec
0.0 sec
0.0 sec
0.0 sec
Ignore,
PD6210 Only
Ignore,
PD6210 Only
Ignore,
PD6210 Only
Ignore,
PD6210 Only
PD6210: 4.000
PD6310: 0
4.000 mA
PD6210: 20.000
PD6310: 1000.0
20.000 mA
Rate/process
21.000 mA
Underrange output
Loop break output
Filter
Bypass
u-rang
break
filter
Bypass
3.000 mA
1.000 mA
PD6210: 70
PD6310: Hi Spd
0.2, PD6210 Only
89
Page 90
Model PD6210 & PD6310 Batch Controllers Instruction Manual
Parameter Display Default Setting User Setting
Cutoff value
Maximum output
Minimum output
Slave ID (Address)
Baud rate
Transmit delay
Parity
Byte-to-byte timeout
F1 function key
F2 function key
F3 function key
F4 function
Digital input 1
Digital input 2
Digital input 3
Digital input 4
Digital output 1-4
CutofF
mAx
min
Slave Id
baud
Tr dly
Parity
t-byt
F1
F2
F3
F4
dI 1
dI 2
dI 3
dI 4
dO 1
0.000 (disabled)
23.000 mA
1.000 mA
247
9600
50 ms
Even
010 (0.1 sec)
Start
Preset
Stop
Start/Stop
Menu
Right arrow
Up arrow
Enter
Alarm 1-4
Password 1
Password 2
Password 3
Total password
Grand total
password
Pass 1
Pass 2
Pass 3
Total
Gtotal
000000 (unlocked)
000000 (unlocked)
000000 (unlocked)
000000 (unlocked)
000000 (unlocked)
90
Page 91
Model PD6210 & PD6310 Batch Controllers Instruction Manual
r
r
Troubleshooting Tips
Symptom Check/Action
No display at all
Not able to change setup or
programming, Locd is displayed
Controller displays error message
during calibration (Error)
Controller displays
Display is unstable
Display response is too slow
Display reading is not accurate
Display does not respond to input
changes, reading a fixed number
Display alternates between
1. Hi and a number
2. Lo and a numbe
Relay operation is reversed
Relay and status LED do not
respond to signal
Flashing relay status LEDs
Controller not communicating with
application programs
If the display locks up or the
controller does not respond at all
Other symptoms not described
above
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.
999999
-99999
Check power at power connector
Controller is password-protected, enter
correct six-digit password to unlock
Check:
1. Signal connections
2. Input selected in Setup menu
3. Minimum input span requirements
Check:
1. Input selected in Setup menu
2. Corresponding signal at Signal
connecto
Check:
1. Input signal stability and value
2. Display scaling vs. input signal
3. Filter and bypass values (increase)
Check filter and bypass values
1. Signal input conditioning selected:
Linear, square root, etc.
2. Scaling or calibration
Check:
Display assignment, it might be
displaying max, min, or set point.
Press Menu to exit max/min display
readings.
Check:
1. Fail-safe in Setup menu
2. Wiring of relay contacts
Check:
1. Relay action in Setup menu
2. Set and reset points
Relays in manual control mode or relay
interlock switches opened.
Check:
1. Serial adapter and cable
2. Serial settings
3. Controller address and baud rate
Cycle the power to reboot the
microprocessor.
Call Technical Support for
assistance.
91
Page 92
Model PD6210 & PD6310 Batch Controllers Instruction Manual
Alphabetical List of Display Functions & Messages
Display Parameter Action/Setting Description
20 mA
4 mA
999999
-99999
Ack
Act 1
Alm 1
Altern
A-nman
Aout
Aoutpr
Asign1
Assign
Auto
baud
big
Big Hi
Big HL
Big Lo
break
bypASs
20 mA output
4 mA output
Flashing
display
Acknowledge Acknowledge relays
Action 1
Alarm 1
Alternate
Auto-manual
Analog output
Analog output
programming
Assign 1
Assignment
Automatic
Baud rate
Upper display
Max on Upper
display
Max/min Upper
display
Min on Upper
display
Loop break
Bypass
Enter mA output value read by milliamp
meter with at least 0.001 mA resolution
Enter mA output value read by milliamp
meter with at least 0.001 mA resolution
Overrange condition
Underrange condition
Set relay 1 action
Assign digital output to Alarm 1 – 8
Set relay for pump alternation control
(relays assigned to rate)
Set relay for automatic & manual reset
any time
Analog output scaling
Analog output programming
Relay 1 assignment
Assign relays to rate, total, or grand total
For automatic reset
Select baud rate
Press Enter to assign the Upper display
parameter (default: PV or rate)
Assign digital input to display max on the
Upper display
Assign digital input to toggle max/min on
the Upper display
Assign the digital input to display min on the
Upper display
Set relay condition if loop break detected
(For mA input only)
Set filter bypass value
92
Page 93
Model PD6210 & PD6310 Batch Controllers Instruction Manual
Display Parameter Action/Setting Description
C CAL
C Hi
C lo
Cal
Calib
Contrl
Copy
Count
Cutoff
D Hi
D HL
D Hold
D Lo
D off
D rate
D tot
D gtot
D g-t
D r-t
D r_u
D unit
dCount
Dec pt
DeLAY
Current
calibration
Current high
Current low
Calibrate
Calibrate
Control
Copy
Count
Cutoff
Display high
Display H&L
Display hold
Display low
Display off
Display rate
Display total
Display grand
total
Display g-t
Display r-t
Display r-u
Display units
Display Count
Decimal point
Delay
Calibrating 4-20 mA current input (internal
reference source used for scaling the input)
Calibrate high current input (e.g. 20 mA)
Calibrate low current input (e.g. 4 mA)
Enter the Calibrate menu
Calibrate 4-20 mA output (internal
reference source used for scaling the
output)
Enter Control menu
Enter copy function
Set total and grand total count direction
Cutoff value
Select to display the max
Select to display the max & min toggling
Display hold
Select to display the min
Select to not turn off display
Select to display rate
Select to display batch total
Select to display grand total
Select to display grand total and batch total
Select to display rate and batch total
Select to display rate and units
Select to display engineering units or label
Select to display number of batches
Set decimal point for rate, total, grand total
Enter relay Time Delay menu
93
Page 94
Model PD6210 & PD6310 Batch Controllers Instruction Manual
Display Parameter Action/Setting Description
dI 1
Diag
d-Inty
Dis 1
Dis 2
disabl
DLY 1
dO 1
done
Douwn
DSet 1
dsplay
Enter
Error
F On 1
F1
F2
F3
F4
factor
FaiLSF
filter
FLS 1
Force
Digital input 1
Diagnostics
Display
intensity
Display 1
Display 2
Disable
Delay 1
Digital
output 1
Done
Down
Display set 1
Display
Enter Button
Error
Force On 1
F1 function key
F2 function key
F3 function key
F4 function
K-factor
Scaling
Fail-safe
Filter
Fail-safe 1
Force
Assign digital input 1-8, if expansion
modules are connected
Display parameter settings
Set display intensity level from 1 to 8
Program display 1 value
Program display 2 value
Disable function key
Enter relay 1 time delay setup
Assign digital output 1 – 8, if expansion
modules are connected
Copy function completed
Set the total to count down
Select to display set point 1 (1-8)
Enter the Display menu
Assign digital input to Enter button
Error, calibration not successful, check signal
or programmed value
Force relay 1 on using digital input (1-8)
Assign F1 function key
Assign F2 function key
Assign F3 function key
Assign F4 function (digital input)
Programs unit to convert input pulse to rate
in engineering units
Enter Fail-safe menu
Set noise filter value
Set relay 1 fail-safe operation
Force analog output value for loop break
94
Page 95
Model PD6210 & PD6310 Batch Controllers Instruction Manual
Display Parameter Action/Setting Description
Functn
G total
GT CF
GT rst
GT tb
Gtot C
Gtotal
Hi spd
Ical
Ignore
InCAL
Info
Inp 1
Inp 2
Input
LatCH
LED t
Linear
Lit Hi
Lit HL
Function
Grand total
Grand total
conversion factor
Grand total reset
Grand total time
base
Grand Total
Count
Grand total
password
High Speed
Filter
Internal source
calibration
Ignore
Input Calibration
Information
Input 1
Input 2
Input
Latching
LED test
Linear
Max on Lower
display
Max/min Lower
display
Select linear, square root, or programmable
exponent signal input conditioning
Assign relay to grand total
Program grand total conversion factor
Program grand total reset mode: auto or
manual
Program grand total time base
Set grand total to count up or down
Set or enter password for manual reset
Program High Speed Filter
Enter internal source calibration (used for
scaling the controller without a signal
source
Ignore loop break condition
Enter the Input Calibration menu
Display software and S/N information
Calibrate input 1 signal or program input 1
value
Calibrate input 2 signal or program input 2
value (up to 32 points)
Input selection
Set relay for latching operation (relays
assigned to rate)
Test all LEDs
Set controller for linear function and select
number of linearization points
Assign digital input to display max on the
Lower display
Assign the digital input to toggle max/min
on the Lower display
95
Page 96
Model PD6210 & PD6310 Batch Controllers Instruction Manual
Display Parameter Action/Setting Description
Lit Lo
Little
locd
Lo spd
Lt-CLr
mA
mAn
mAx
mbus
menu
min
No PtS
nonrst
O Hold
OFF
OFF 1
On
On 1
O-rang
Out 1
Out 2
pass
Pass 1
Min on Lower
display
Lower display
Locked
Low Speed Filter
Latching-cleared
4-20 mA
Manual
Maximum
Modbus
Menu button
Minimum
Number of points
Non-resettable
Relays output
hold
Off
Off
On
On
Overrange
Output 1
Output 2
Password
Password 1
Assign digital input to display min on the
Lower display
To assign the Lower display parameters
Enter password to unlock controller
Program Low Speed Filter
Set relay for latching operation with manual
reset only after alarm condition has cleared
(relays assigned to rate)
Set controller for 4-20 mA input
To manually control
Program maximum mA output allowed
Select to display Modbus input or to assign
Modbus input as the analog output source
Assign digital input to Menu button
Program minimum mA output allowed
Set controller for 2 to 32-point linearization
Non-resettable grand total set after entering
“050873” for Gtotal password
Assign digital input to hold all relays state
Disable relay and front panel status LED,
turn relays off, program off time delay
Set relay 1 Off time delay
Enable fail-safe operation, turn relays on,
program on time delay
Set relay 1 On time delay
Program mA output for display overrange
Program output 1 value (e.g. 4.000 mA)
Program output 2 value (e.g. 20.000 mA)
Enter the Password menu
Set or enter Password 1
96
Page 97
Model PD6210 & PD6310 Batch Controllers Instruction Manual
Display Parameter Action/Setting Description
Pass 2
Pass 3
preCls
Preset
prog
Prog E
rATE
RELaY
reset
Right
RLY 1
RLY 2
Rly d
Rly E
Round
RSt 1
Rst bc
Rst Gt
Rst Hi
Rst HL
Rst Lo
Rst t
Sanmpl
Password 2
Password 3
Preclose
Preset
Program
Programmable
exponent
Rate
Relay
Reset
Right arrow
Relay 1
Relay 2
Disable relay
Enable relay
Round
Reset 1
Reset batch
count
Reset
grand total
Reset high
Reset
high & low
Reset low
Reset Total
Sampling
Set or enter Password 2
Set or enter Password 3
The amount before the preset is reached
that multi-stage relays will deactivate.
Batch control preset
Enter the Program menu
Set controller for programmable exponent
and enter exponent value
Assign relay to rate
Enter the Relay menu
To access the Reset menu
Assign digital input to Right arrow button/F1
Relay 1 setup
Relays 2-8 setup
Note: Relays 5-8 are shown, only if
expansion relay module is installed.
Assign digital input to disable all relays
Assign digital input to enable all relays
Select rounding values for PV display
Program reset point 1
To reset the batch count
To reset grand total
Press Enter to reset max display
Press Enter to reset max & min displays
Press Enter to reset min display
Reset total
Set relay for sampling operation
97
Page 98
Model PD6210 & PD6310 Batch Controllers Instruction Manual
Display Parameter Action/Setting Description
sCalE
SelEct
send
seriAl
Set 1
setup
SlavId
Source
Square
Start
Stop
Rst tr
tare
T CF
T dly
T rst
T tb
Tot C
Total
Tr dLY
units
unloc
up
up
u-rang
user
Scale
Select
Send
Serial
Set 1
Setup
Slave ID
Source
Square root
Start
Stop
Reset tare
Capture Tare
Total conversion
factor
Time delay
Total reset
Total time base
Total Count
Total
Transmit delay
Units
Unlocked
Up arrow button
Up
Underrange
User I/O
Enter the Scale menu
Enter the Select menu (function, cutoff, out)
Send controller settings to another
controller
Set serial communication parameters
Program set point 1
Enter Setup menu
Set Slave ID or controller address
Select source for the 4-20 mA output
Set controller for square root extraction
Begin batch
Pause/Stop batch
Reset tare
Capture Tare
Program total conversion factor
Program time delay for total auto reset
Program total reset mode: auto or manual
Program total time base
Set total to count up or down
Enable or disable totalizer features
Set transmit delay for serial communication
Select the display units/tags
Program password to lock controller
To assign digital input to up arrow button
Set the total to count up
Program mA output for display underrange
Assign function keys and digital I/O
98
Page 99
Model PD6210 & PD6310 Batch Controllers Instruction Manual
Display Parameter Action/Setting Description
v CAL
v Hi
v Lo
volt
Voltage
calibration
Voltage high
Voltage low
0-10 VDC
Calibrating voltage input
Calibrate high voltage input (e.g. 10 V)
Calibrate low voltage input (e.g. 0 V)
Set controller for ±10 VDC input
99
Page 100
Model PD6210 & PD6310 Batch Controllers Instruction Manual
How to Contact Precision Digital
• For Technical Support please
Call: (800) 610-5239 or (508) 655-7300
Fax: (508) 655-8990
Email: [email protected]
• For Sales Support or to place an order please
contact your local distributor or
Call: (800) 343-1001 or (508) 655-7300
Fax: (508) 655-8990
Email: [email protected]
• For the latest version of this manual please visit
www.predig.com
LIM6210_B.doc
SFT039 Ver 3.10 & up
08/12
Loading...