Precision Digital PD8-6310 ProtEX-MAX Batch Controller

Quick Overview

• Input: Pulse, open collector, NPN, PNP, TTL, switch contact, sine wave (coil), square wave; Modbus PV (slave)
• Display: Dual-line 6-digit, 0.60″ (15 mm) & 0.46″ (12 mm)
• Enclosure: Smooth die-cast aluminum explosion-proof; NEMA 4X, 7, 9/IP68
• Power: 85-265 VAC or 12-24 VDC option
• Operating Temperature: -40 to 65°C

Features

• Sunbright Display Standard
• Start, batch, & stop with pause front panel buttons
• Display batch total + rate, grand total, batch count or preset
• Single or multi-stage batching with up to 8 relays
• Automatic overflow correction
• Manual control or automatic batching
• SafeTouch® through-glass button programming
• Modbus RS-485 serial communications
• Flanges for wall or pipe mounting
• Isolated 24 VDC @ 25 mA transmitter power supply
• Total can count up or down
• Onboard USB and MeterView® Pro programming software

General

Display: Upper display: 0.60″ (15 mm) high. Lower display: 0.46″ (12 mm) high. Both are 6 digits (-99999 to 999999), red LEDs.
Default Display Assignment: 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.
Custom Display Assignment: 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.
Alternating Display: Displays alternate every 10 seconds when display is selected or the batch is paused.
Display Intensity: Eight user selectable intensity levels
Display Update Rate: 5/second (200 ms)
Overrange: Display flashes 999999
Underrange: Display flashes -99999
Programming Methods: Four through-glass SafeTouch buttons, four mechanical buttons behind glass, digital inputs, PC and MeterView Pro software, or Modbus registers.
F4 Digital Input Contacts: 3.3 VDC on contact. Connect normally open contacts across F4 to COM.
F4 Digital Input Logic Levels: Logic High: 3 to 5 VDC; Logic Low: 0 to 1.25 VDC
Noise Filter: Programmable from 2 to 199 (0 will disable filter)
Filter Bypass: Programmable from 0.1 to 99.9% of calibrated span.
Recalibration: Recommended at least every 12 months.
Max/Min Display: Max (Peak) / min (Valley) readings reached by the process are stored until reset by the user or until power is cycled.
Password: Three programmable passwords restrict modification of programmed settings and two prevent resetting the totals.
Non-Volatile Memory: All programmed settings are stored in non-volatile memory for a minimum of ten years if power is lost.
Power Options: 85-265 VAC 50/60 Hz, 90-265 VDC, 20 W max, or optional sku with 12-24 VDC ±10%, 15 W max.
Fuse: Required external fuse: UL Recognized, 5 A max, slow blow; up to 6 controllers may share one 5 A fuse.
Isolated Transmitter Power Supply: Terminals P+ & P-: 24 VDC ± 10%. Isolated from the input at >500 V. Jumper selectable for 24, 10, or 5 VDC supply (internal jumper J4). All skus transmitter supply rated @ 25mA max.
Normal Rejection Mode: Greater than 60 dB at 50/60 Hz
Isolation: 4 kV input/output-to-power line. 500 V input-to-output or output-to-P+ supply.
Overvoltage Category: Installation Overvoltage Category II: Local level with smaller transient overvoltages than Installation Overvoltage Category III.
Environmental:
T6 Class operating temperature range Ta = -40 to 60°C
T5 Class operating temperature range Ta = -40 to 65°C
Max Power Dissipation: Maximum power dissipation limited to 15.1 W. See PD8 instruction manual for additional details.
Connections: Removable screw terminal blocks accept 12 to 22 AWG wire, RJ45 for external relays, digital I/O, and serial communication adapters.
Enclosure: Explosion-proof die cast aluminum with glass window, corrosion resistant epoxy coating, color: blue. NEMA 4X, 7, & 9, IP68. Default conduit connections: Four ¾” NPT threaded conduit openings and two ¾” NPT metal conduit plugs with 12 mm hex key fitting installed. Additional conduit opening configurations may be available; verify quantity and sizes on specific device labeling during installation.
Mounting: Four slotted flanges for wall mounting or NPS 1½” to 2½” or DN 40 to 65 mm pipe mounting
Dimensions: 6.42″ x 7.97″ x 8.47″ (W x H x D) (163 mm x 202 mm x 215 mm)
Weight: 16.0 lbs (7.26 kg)
Warranty: 3 years parts & labor
USB Connection: Compatibility: USB 2.0 Standard, Compliant
   Connector Type: Micro-B receptacle
   Cable: USB A Male to Micro-B Cable
   Driver: Windows 98/SE, ME, 2000, Server 2003/2008, XP 32/64-Bit,
   Vista 32/64-Bit, Windows 7 32/64-Bit, Windows 10 32/64-Bit
   Power: USB Port

Pulse Input

Inputs: Field selectable: Pulse or square wave 0-5 V, 0-12 V, or 0-24 V @ 30 kHz; TTL; open collector 4.7 k Ω pull-up to 5 V @ 30 kHz; NPN or PNP transistor, switch contact 4.7 k Ω pull-up to 5 V @ 40 Hz; coil (sine wave) 40 mVp-p min @ 10 kHz; Modbus PV (Slave)
Low Voltage Mag Pickup (Isolated): Sensitivity: 40 mVp-p to 8 Vp-p
Minimum Input Frequency: 0.001 Hz – Minimum frequency is dependent on high gate setting.
Maximum Input Frequency: 30,000 Hz (10,000 for Low Voltage Mag Pickup)
Input Impedance: Pulse input: Greater than 300 kΩ @ 1 kHz. Open collector/switch input: 4.7 k Ω pull-up to 5 V.
Accuracy: 0.03% of calibrated span 1 count
Display Update Rate: Total: 10/sec, Rate: 10/sec to 1/1000 sec
Temperature Drift: Rate display is not affected by changes in temperature.
Multi-Point Linearization: 2 to 32 points
Low-Flow Cutoff: 0-999999 (0 disables cutoff function)
Decimal Point: Up to five decimal places or none: d.ddddd, dd.dddd, ddd.ddd, dddd.dd, ddddd.d, or dddddd.
Calibration: May be calibrated using K-factor, scale using internal calibration, or calibrate by applying an external calibration signal.
K-Factor: Field programmable K-factor converts input pulses to rate in engineering units. May be programmed from 0.00001 to 999,999 pulses/unit.
Calibration Range: Input 1 signal may be set anywhere in the range of the controller; input 2 signal may be set anywhere above setting.
Filter: Programmable contact de-bounce filter, 40 to 999 Hz maximum input frequency allowed with low speed filter.
Time Base: Second, minute, hour, or day
Low Gate: 0.1-99.9 seconds; this function determines how often the incoming pulses are calculated and the rate display is updated.
High Gate: 2.0-999.9 seconds; this function determines how long to wait for pulses before the display goes to zero. This function is used to display slow pulse rates.
Note: The combination of the low and high gate functions makes it possible to have a fast display update for fast pulse rates while displaying slow pulse rates, if needed. For example: If the low gate is set to 1.0 second and the high gate to 999.9 second, with a fast pulse rate the display is updated every second; with a slow pulse rate the controller is capable of waiting up to 999.9 seconds before calculating the rate, making it possible to display a very slow rate down to 1 pulse/999.9 second (0.001 pulse/second).

Batch Controller

Rate Display Indication: 0 to 999999, lead zero blanking. “R” LED illuminates while displaying rate.
Total Displays & Grand Total Overflow: 0 to 999,999; automatic lead zero blanking. “T” LED is illuminated while displaying batch total and “GT” for grand total. Up to 999,999,999 with total-overflow feature. “” is displayed to the left of grand total overflow and  LED is illuminated.
Batch Total Decimal Point: Up to five decimal places or none: d.ddddd, dd.dddd, ddd.ddd, dddd.dd, ddddd.d, or dddddd. Total decimal point is independent of rate decimal point.
Totalizer: Calculates total based on rate and field programmable multiplier to display total in engineering units. Time base must be selected according to the time units in which the rate is displayed.
Total Conversion Factor: 0.00001 to 999,999
Batch Preset: 0.00001 to 999,999 based on batch total decimal point.
Automatic Batch Restart Delay: 00000.1 to 999.9 seconds. The batch will automatically restart after completion of the last batch.
Grand Total Rollover: Totalizer rolls over when display exceeds 999,999,999. Relay status reflects the display value.
Grand Total Alarms: Up to seven, user selectable under Setup menu. Any set point can be assigned to grand total and may be programmed anywhere in the range of the controller for grand total alarm indication. 
Note that Relay 1 should always be assigned to batch control (total).
Grand Total Reset: Via front panel button, external contact closure on digital inputs, automatically via user selectable preset value and time delay, or through serial communications.
Grand Total Reset Password: A grand total password may be entered to prevent resetting the grand total from the front panel.
Non-Resettable Grand Total: The grand total can be programmed as a non-resettable total by entering the password “050873”.
Caution: Once the Grand Total has been programmed as “non-resettable” the feature cannot be disabled.

Relays

Rating: 2 or 4 SPDT (Form C) internal and/or 4 SPST (Form A) external; rated 3 A @ 30 VDC and 125/250 VAC resistive load; 1/14 HP (≈ 50 W) @ 125/250 VAC for inductive loads
Noise Suppression: Noise suppression is recommended for each relay contact switching inductive loads.
Relay Assignment: Relays may be assigned to batch control, sampling, rate, or grand total alarms.
Preclose: 0-100% of batch size, individually user programmable for each additional batch control relay beyond the first.
Alarm Deadband: 0-100% of span, user programmable
High or Low Alarm: User may program any alarm for high or low trip point. Unused alarm LEDs and relays may be disabled (turned off).
Batching Relay Operation: Single or (2 to 8) multi-relay batching with optional preclose for multi-stage operation. Each additional relay may be programmed with an individual preclose value.
Alarm Relay Operation: Automatic (non-latching), latching (requires manual acknowledge), sampling (based on rate or grand total), pump alternation control (2 to 8 relays), off (disable unused relays), and manual on/off control mode. Alarms are active only when the batch is running.
Alarm Relay Reset: User selectable via front buttons, digital inputs, or PC
   1. Automatic reset only (non-latching), when input passes the reset point or total is reset to zero.
   2. Manual reset only, when batch is stopped (latching).
   3. Manual reset only after alarm condition has cleared (latching)
Note: Front panel button or digital input may be assigned to acknowledge relays programmed for manual reset. This replaces one of the standard batch control function keys. Only the PAUSE/STOP key function is possible during a batch process, so manual reset may only be done when thecontroller is in STOP mode.
Deadband: 0-100% of span, user programmable
Time Delay: 0 to 999.9 seconds, on & off relay time delays. Programmable and independent for each relay.
Fail-Safe Operation: Programmable and independent for each relay.
Note: Relay coil is energized in non-alarm condition. In case of power failure, relay will go to alarm state.
Auto Initialization: When power is applied, relays will reflect the state of the input. Alarms are active only when the batch is running.

Isolated 4-20 mA Transmitter Output

Output Source: Rate/process, total, grand total, max, min, set points 1-8, manual control setting, or Modbus input
Scaling Range: 1.000 to 23.000 mA for any display range
Calibration: Factory calibrated: 4.000 to 20.000 = 4-20 mA output
Analog Output Programming: 23.000 mA maximum for all parameters: Overrange, underrange, max, min, and break
Accuracy: ±0.1% FS ±0.004 mA
Temperature Drift: 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.
Isolated Transmitter Power Supply: Terminals I+ & R: 24 VDC ± 10%. Isolated from the input at >500 V. May be used to power the 4-20 mA output or other devices. All skus @ 25 mA max.
External Loop Power Supply: 35 VDC maximum
Output Loop Resistance:

Power supplyMinimumMaximum24 VDC10 Ω700 Ω35 VDC (external)100 Ω1200Ω

Serial Communications

Compatability: EIA-485
Connectors: Removable screw terminal connector
Max Distance: 3,937′ (1,200 m) max
Status Indication: Separate LEDs for Power (P), Transmit (TX), and Receive (RX)
Protocol: Modbus® RTU
Controller Address/Slave ID: 1 – 247
Baud Rate: 300 – 19,200 bps
Transmit Time Delay: Programmable between 0 and 199 ms or transmitter always on for RS-422 communication
Data: 8 bit (1 start bit, 1 or 2 stop bits)
Parity: Even, odd, or none with 1 or 2 stop bits
Byte-to-Byte Timeout: 0.01 – 2.54 seconds
Turn Around Delay: Less than 2 ms (fixed)
Note: Refer to the PD6000/PD7000 Modbus Register Tables located in the documentation section of this page.

Digital Inputs and Outputs

Channels: 4 digital inputs & 4 digital outputs per module
System: One expansion module may be added for a total of 8 inputs & 8 outputs
Note: The jumper located between the RJ45 connectors must be removed on the expansion module. 
Digital Input Logic: High: 3 to 5 VDC; Low: 0 to 1.25 VDC
Digital Output Logic: High: 3.1 to 3.3 VDC; Low: 0 to 0.4 VD
Source Current: 10 mA maximum output current
Sink Current: 1.5 mA minimum input current
+5 V Terminal: To be used as pull-up for digital inputs only. Connect normally open pushbuttons across +5 V & DI 1-4. Warning: DO NOT use +5 V terminal (pin 1) to power external devices.
Function Assignment: The on-board digital inputs (1-4) are designed to mimic the behavior of the front panel buttons (Menu, F1, F2, & F3). If you wish to change their behavior, re-assign F1-F3 to the desired function, then change the corresponding digital input to match.

4-Relay Expansion Module

Relays: Four Form A (SPST) rated 3 A @ 30 VDC and 125/250 VAC resistive load; 1/14 HP (. 50 watts) @ 125/250 VAC for inductive loads.

Product Ratings and Approvals

FM Enclosure: Type 4X; IP66 
   Class I, Division 1, Groups B, C, D 
   Class II, Division 1, Groups E, F, G 
   Class III, Division 1, T5/T6 
   Class I, Zone 1, AEx d, IIC Gb T5/T6 
   Zone 21, AEx tb IIIC T90°C; Ta -40°C to +65°C 
   T6 Ta = -40°C to +60°C; T5 Ta = -40°C to +65°C 
   Certificate Number: 3047283 
CSA: Class I, Division 1, Groups B, C, D 
   Class II, Division 1, Groups E, F, G 
   Class III, Division 1 
   Class I Zone 1 Ex d IIC 
   Zone 21 Ex tb IIIC T90°C 
   -40°C < Tamb. < +60° C; Temperature Code T6 
   -40°C < Tamb. < +65° C; Temperature Code T5 
   Enclosure Type 4X & IP66 
   Certificate Number: 2531731 
ATEX: II 2 G D    Ex d IIC T* Gb
   Ex tb IIIC T90°C Db IP68
   Ta = -40°C to +*°C
   *T6 = -40°C to +60°C
   *T5 = -40°C to +65°C
   Certificate number: Sira 12ATEX1182
IECEx: Ex d IIC T* Gb
   Ex tb IIIC T90°C Db IP68
   Ta = -40°C to +*°C
   *T6 = -40°C to +60°C
   *T5 = -40°C to +65°C
   Certificate Number: IECEx SIR 12.0073

Applications

Single and Multi-Stage Batching

The ProtEX-MAX can be used as a single or multi-stage batch controller. Relays assigned to the total act as batch control relays, with additional relays beyond the first including a preclose value. The preclose deactivates the relay before the batch is finished, to allow slower fill rates and a more accurate batch finish. With expansion module relays, up to eight-stage batching is possible. Each additional stage batching relay has an individually programmable preclose amount.

Single Stage Batch Control

Multi-Stage Batch Control

Manual Multi-Stage Batch Control Operation

System Setup
1. Both valves are closed with an empty barrel in place. The batched total is displayed in the upper display, the preset is selected for the lower display.

Batch Start
2. The START button is pressed, with both valves open. The barrel begins to fill.

Preclose Valve
3. When the batch total reaches a value of 50.00 (Preset [55.00] Preclose [5.00]) the full-flow valve closes. The fill rate of the tank slows as a result.

Completed Batch
4. When the batch total equals the preset amount, the restricted-flow valve closes. The barrel is now full. If some overrun occurs, the next batch will adjust for this offset amount to maintain accuracy.

Change Preset
5. After placing a new, empty barrel, a new preset fill amount may be selected with the Batch key, while the process is stopped.

Begin New Batch
6. Press the START key and a new batch will begin. With both valves open, the process continues.

Pause/Stop
7. At any time, the STOP button may be pressed, once to Pause the process, or twice to cancel the batch, which stops the process.

MeterView^® Pro Software

MeterView® Pro software is designed for use with ProVu, ProtEX-MAX, or Helios Series meters and allows users to remotely program, monitor, and datalog using a PC. Remote programming allows for all available meter settings to be programmed through an easy, user-friendly interface. The data acquisition feature allows the user to gather readings from a meter at user-selected intervals and generate charts using common tools like Microsoft® Excel. A linearization setup function is also included. With this utility the user can configure up to 32 linearization points and upload them to the meter. All configuration data can be saved to a file for future use.
This software is accessible via the onboard USB connection on all Helios large display meters, ProVu panel meters, and ProVu-based ProtEX-MAX explosion-proof meters produced since 6 September 2016 (firmware version 4.0 or higher). In order for meters produced prior to 6 September 2016 (firmware version 3.1 or lower) to establish digital communications with a PC, a serial communications adapter is required. For an RS-232 connection, use a PDA1232 adapter.
To determine the software version of a meter:

1. Go to the Diagnostics menu () and press Enter button.
2. Press Up arrow button and scroll to Information menu (Info).
3. Press Enter to access the software number (), version (), and serial number () information. Write down the information as it is displayed. Continue pressing Enter until all the information is displayed.
4. The meter returns to Run Mode after displaying all the settings.

Monitor and Datalog

Setup

Programming

Relays

Data Sheet: PD8-6310 Data sheet
Instruction Manual: PD8-6310 Instrument Manual