Precision Digital Corporation Helios PD2-6310 Instruction Manual Download Page 1

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Helios Large Display Pulse Input Batch Controller

Instruction Manual

PD2-6310

Precision Digital Corporation

Batch Controller

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Large 1.80" Digits

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Dual-Line 6-Digit Display

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Readable from up to 100 Feet (30 Meters) Away

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Superluminous Sunlight Readable Display

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NEMA 4X, IP65 Rated Field Mountable Enclosure

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Operating Temperature Range of -40 to 65°C (-40 to 150°F)

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Single or Multi-Stage Batch Control (up to 4 Relays)

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Pulse, Open Collector, NPN, PNP, TTL, Switch Contact,

Sine Wave (Coil), Square Wave Inputs

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Start/Pause/Stop, Change Batch with Front Panel Buttons

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Automatic Overrun Correction

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Input Power Options Include 85-265 VAC or 12-24 VDC

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Isolated 24 VDC Transmitter Power Supply

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Count Up or Down with Each Batch

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2 or 4 Isolated 4-20 mA Output Options

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Onboard USB & RS-485 Serial Communications

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Modbus

RTU Communication Protocol Standard

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Program the Meter from a PC with onboard USB and MeterView Pro

USB Install

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.com

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Summary of Contents for Helios PD2-6310

Page 1: ...to 4 Relays Pulse Open Collector NPN PNP TTL Switch Contact Sine Wave Coil Square Wave Inputs Start Pause Stop Change Batch with Front Panel Buttons Automatic Overrun Correction Input Power Options Include 85 265 VAC or 12 24 VDC Isolated 24 VDC Transmitter Power Supply Count Up or Down with Each Batch 2 or 4 Relays Isolated 4 20 mA Output Options Onboard USB RS 485 Serial Communications Modbus RT...

Page 2: ...roperty loss Anyone using this product for such applications does so at their own risk Precision Digital Corporation shall not be held liable for damages resulting from such improper use 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 Di...

Page 3: ...lay Action 39 Setting Batch Control Relays 39 Programming Set and Reset Points 40 Setting Fail Safe Operation 40 Programming Time Delay 40 Relay and Alarm Operation Diagrams 40 High Alarm Operation Set Reset 40 Low Alarm Operation Set Reset 40 High Alarm with Fail Safe Operation Set Reset 41 Low Alarm with Fail Safe Operation Set Reset 41 Relay Sampling Operation 41 Total Relay Sampling Operation ...

Page 4: ...peration systems It features large 1 8 inch superluminous LED digits which can be read in sunlight from up to 100 feet away It is housed in a water resistant field mountable NEMA 4X IP65 rated enclosure for convenient indoor and outdoor installation The controller comes programmed for easy start pause stop and batch size preset changes Display line two 2 can be programmed to display rate grand tot...

Page 5: ...d Programming Methods Four programming buttons digital inputs PC and MeterView Pro software or Modbus registers Noise Filter Programmable from 2 to 199 0 will disable filter Filter Bypass Programmable from 0 1 to 99 9 of calibrated span Recalibration All ranges are calibrated at the factory Recalibration is recommended at least every 12 months Max Min Display Max min readings reached by the proces...

Page 6: ...r switch contact 4 7 k pull up to 5 V 40 Hz Modbus PV Slave Low Voltage Mag Pickup Isolated Sensitivity 40 mVp p to 8Vp p Minimum Input Frequency 0 001 Hz Minimum frequency is dependent on high gate setting Maximum Input Frequency 30 000 Hz 10 000 for low voltage mag pickup Input Impedance Pulse input Greater than 300 k 1 kHz Open collector switch input 4 7 k pull up to 5 V Accuracy 0 03 of calibr...

Page 7: ...50873 Caution Once the Grand Total has been programmed as non resettable the feature cannot be disabled 1 Alarms are active only when the batch is running 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 switch...

Page 8: ...terminal connector Max Distance 3 937 1 200 m max Status Indication Separate LEDs for Power P Transmit TX and Receive RX Modbus RTU Serial Communications Slave Id 1 247 Controller address Baud Rate 300 19 200 bps Transmit Time Delay Programmable between 0 and 199 ms 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 second Turn Arou...

Page 9: ...a UL 508 Industrial Control Equipment United States C22 2 No 142 Canadian National Standard UL File Number E160849 Front Panel UL Type 4X NEMA 4X IP65 Low Voltage Directive EN 61010 1 2010 Safety requirements for measurement control and laboratory use www GlobalTestSupply com Find Quality Products Online at sales GlobalTestSupply com ...

Page 10: ... holes located on the bottom of the controller There are a total of four pre drilled conduit entry holes located at the bottom of the controller If the need to drill additional holes arises make sure you will have the clearance necessary for conduit mounting hardware Do not disconnect the RJ45 connector found on the right side of the controller wiring board Doing so will disable the onboard digita...

Page 11: ...l 2 Using a drill bit slightly smaller than the girth of the mounting screws pre drill holes at the mounting locations previously marked 3 Insert mounting screws into the four mounting holes and screw them into the pre drilled holes Do not overtighten the mounting screws as it is possible that the enclosure could crack and become damaged Figure 1 Meter Mounting Holes Mounting Dimensions Figure 2 C...

Page 12: ...1 Secure the mounting plates to the top and bottom for vertical pipes or left and right for horizontal pipes of the reverse side of the meter enclosure using the provided fasteners Do not overtighten the fasteners as it could cause damage to the enclosure 2 Using the provided nuts and U bolts secure the mounting plates to the pipe enough torque such that the meter cannot be moved up or down or sid...

Page 13: ...the connections board see diagram below 4 Flip this switch into the appropriate position for the required transmitter excitation Figure 6 Transmitter Supply Voltage Selection Connections All connections are made to screw terminal connectors located under the front door panel Remove the single securing screw in order to access the wiring terminals Caution Use copper wire with 60 C or 60 75 C insula...

Page 14: ... left of the power terminal block Doing so will disable the onboard digital I O RS 485 serial communications and M Link functionality Figure 7 Connector Labeling for Fully Loaded PD2 6310 Power Connections Power connections are made to a two terminal connector labeled POWER on Figure 7 on page 14 The meter will operate regardless of DC polarity connection The and symbols are only a suggested wirin...

Page 15: ...re 14 Switch Input Connections Modbus RTU Serial Communications Serial communications connection can be made to the onboard RS485 terminal block or USB connector shown in Figure 7 If RS232 is required an RS485 to RS232 adapter PDA7485 may be used See Ordering Information on page 5 for additional information Relay Connections Relay connections are made to two six terminal connectors labeled RELAY1 ...

Page 16: ...amp through closed contacts Notes 1 Use capacitors rated for 250 VAC 2 RC networks may affect load release time of solenoid loads Check to confirm proper operation 3 Install the RC network at the meter s relay screw terminals An RC network may also be installed across the load Experiment for best results Figure 17 Low Voltage DC Loads Protection RC Networks Available from Precision Digital RC netw...

Page 17: ... 19 shows the connection of several meters to a PC using a PDA7485 RS 232 to RS 422 485 converter in an RS 485 network When using more than one meter in a multi drop mode each meter must be provided with its own unique address The meter address Slave ID may be programmed between 1 and 247 The transmit delay may be set between 0 and 199 ms The parity can be set to even odd or none with 1 or 2 stop ...

Page 18: ... Figure 20 details the wiring connections from the RS 485 connector to an RS 422 485 serial converter such as the PDA7485 or PDA8485 for a four wire network Three Wire Connection In order to wire the 5 pins for use as a 3 wire half duplex RS 485 connection it is necessary to create a jumper connection between DI DO and DI DO as shown below Figure 21 Three Wire RS485 Connection RS485 Connector to R...

Page 19: ...and the 5 VDC block Digital output connections are made by wiring from the appropriate digital output block to the grounding terminal block Figure 22 Digital Input and Output Connections F4 Digital Input Connections Digital input F4 is also available on the meter This digital input is connected with a normally open contact across F4 and COM or with an active low signal applied to F4 Figure 23 F4 D...

Page 20: ...lay Feature As the name implies the interlock relay feature reassigns one or more alarm control relays for use as interlock relay s Interlock contact s are wired to digital input s and trigger the interlock relay This feature is enabled by configuring the relay and relative digital input s see page 44 In one example dry interlock contacts are connected in series to one digital input which will be ...

Page 21: ...re no jumpers to set for the meter input selection The controller has one switch located to the right of the input connector which must be configured according to the input level and type Setup and programming is done through the programming buttons located under the front door panel After power and input signal connections have been completed and verified apply power to the meter www GlobalTestSu...

Page 22: ...r Note F4 F8 are digital inputs Total overflow indicator M Flashing Manual control of flashing relays M flashing alone indicates manual analog output Indicators flash every 10 seconds 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 thr...

Page 23: ...e labeled MAINSTAL 3 Double click on the file named MAStart The program will open a few windows and install two programs on your computer Simply follow the onscreen instructions until you see one of the dialogs below If you receive a User Account Control warning click Yes 4 If there is an update available click the Update button to install the new version Otherwise click Configure to begin program...

Page 24: ...stage batch control or as alarms that will be active when the batch process is running A 4 20 mA output option is also available for retransmitting the process variable analog signal Default Batch Control Operation The following describes the operation of the three operating buttons as programmed with default settings START Button Press the START button to begin a new batch process BATCH Button Pr...

Page 25: ...e relay for control then one would set the assignment of relay 2 assign2 to off rate or grand total The following pages show an illustration of how the above settings control the batch operation The display assignment is the default Batch Control Operation 1 A new container is prepared for the batch Both valves are closed Note that the upper display may show the batch total from the last batch 2 T...

Page 26: ...Helios Large Display Pulse Input Batch Controller Instruction Manual PD2 6310 26 www GlobalTestSupply com Find Quality Products Online at sales GlobalTestSupply com ...

Page 27: ...alue up to 32 points Dis 2 Display 2 Program display 2 value up to 32 points Error Error Error calibration not successful check signal or programmed value T tb Total time base Program total time base T CF Total conversion factor Program total conversion factor mode Batch mode Automatic or manual batch control T dly Time delay Set time delay for automatic batch restart GT tb Grand total time base P...

Page 28: ...Enter Fail safe menu FLS 1 Fail safe 1 Set relay 1 fail safe operation on On Enable fail safe operation off Off Disable fail safe operation FLS 2 Fail safe 2 Set relays 2 8 fail safe operation DeLAY Delay Enter relay Time Delay menu DLY 1 Delay 1 Enter relay 1 time delay setup On 1 On 1 Set relay 1 On time delay OFF 1 Off 1 Set relay 1 Off time delay DLY 2 Delay 2 Enter relays 2 8 time delay setup...

Page 29: ...omatic Press Enter to set meter for automatic operation mAn Manual Press Enter to manually control relays or analog output operation pass Password Enter the Password menu Pass 1 Password 1 Set or enter Password 1 Pass 2 Password 2 Set or enter Password 2 Pass 3 Password 3 Set or enter Password 3 Total Total password Set or enter password for manual reset Gtotal Grand total password Set or enter pa...

Page 30: ...The display moves to the next menu every time a setting is accepted by pressing Enter F3 Setting Numeric Values The numeric values are set using the Right and Up arrow buttons Press Right arrow to select next digit and Up arrow to increment digit value The digit being changed is displayed brighter than the rest Press and hold up arrow to auto increment the display value Press the Enter button at a...

Page 31: ...or is used to select the excitation voltage 24 V 10 V or 5 V which is supplied to the P and P wiring terminals The controller may be calibrated using the K Factor function Most flowmeter manufacturers provide this information with the device Enter the K Factor Factor menu and select the decimal point with highest resolution possible and program the K factor value i e pulses gal The controller will...

Page 32: ...P 7 7 H H q q 8 8 h h r r 9 9 I I s S A A I i t t Degree b b j J u u Space Notes Degree symbol represented by if programming with MeterView Pro The letters m and w use two 7 segment LEDs each when selected the characters to the right are shifted one position Press and hold up arrow to auto scroll the characters in the display Setting the Decimal Point dEc pt The decimal point may be set with up to...

Page 33: ...base conversion factor 6 Total reset mode for total grand total Note The Scale Calibrate and K Factor functions are exclusive of each other The meter uses the last function programmed Only one of these methods can be employed at a time The Scale and Calibrate functions can use up to 32 points default is 2 The number of points should be set in the Advanced Features menu under the Multi Point Linear...

Page 34: ... selection prior to scaling and calibration of the meter see page 53 for details 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 i e pulses gal The meter will automatical...

Page 35: ...put 1 signal inadvertently applied to calibrate input 2 Minimum Input Span The minimum input span is the minimum difference between input 1 and input 2 signals required to complete the calibration or scaling of the meter Input Range Input 1 Input 2 Span 4 20 mA 0 15 mA 10 VDC 0 01 VDC Calibrating the Meter with External Source Cal Note To scale the meter without a signal source refer to K Factor C...

Page 36: ...se The time base is the amount of time over which the rate parameter should accrue For example if the rate was ten and the time base was in minutes then the total would increase by ten every one minute Total Grand Total Conversion Factor The total grand total conversion factor is the amount by which the rate is multiplied before it is added to the total or grand total For Example if the rate was t...

Page 37: ...otal 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 c...

Page 38: ... a user specified time g Off relay state controlled by Interlock feature 3 Set and reset points 4 Fail safe operation a On enabled b Off disabled 5 Time delay a On delay 0 999 9 seconds b Off delay 0 999 9 seconds 6 Relay action for loss break of 4 20 mA input ignore on off Note Fail safe should not be used for relays assigned to batch control Rate Alarms Only Active During a Batch Process The rat...

Page 39: ...other applications 4 Automatic manual reset when not in a batch process non latching 5 Latching manual reset only when not in a batch process 6 Latching with Clear manual reset only when not in a batch process after alarm condition has cleared 7 Pump alternation control automatic reset only for level applications unrelated to batch control The following graphic shows relay 1 action setup relay 2 4...

Page 40: ...eration Failsafe mode should not be used on batch relays assigned to total Programming Time Delay The On and Off time delays may be programmed for each relay between 0 and 999 9 seconds The relays will transfer only after the condition has been maintained for the corresponding time delay The On time delay is associated with the set point The Off time delay is associated with the reset point Relay ...

Page 41: ...fter the sample time has elapsed the relay resets The cycle repeats every time the set point is crossed going up for high alarms and going down for low alarms The sample time can be programmed between 0 1 and 5999 9 seconds Total Relay Sampling Operation 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 cycl...

Page 42: ...ays for single or multi stage batching as rate or grand total alarm or as a sampling relay based on grand total or rate alarm These capabilities include front panel alarm status LEDs and 2 or 4 internal relays The relays used for batch control total are activated when the batching process starts and deactivate when the batch total is reached minus any preclose amount programmed for batch total rel...

Page 43: ...only enabled during a batching process and deactivate when the processes is stopped Latching relays or relays with manual reset are not recommended when using this controller for batch control as the manual reset will not be acknowledged during a batch process when the rate alarms are active For information on latching and manual reset alarms see the PD2 6200 instruction manuals available Automati...

Page 44: ... will stop and will re start only after the interlock relay is re activated by the digital inputs switches Sample Relay Operation The sampling function allows the operator to set a set point for a sampling relay This can be done for the rate total or grand total Each time the relay reaches the set point it will close that relay s contacts for a programmed period of time A rate sampling relay will ...

Page 45: ...set The Reset menu is used to reset the maximum or minimum reading peak or valley reached by the process both may be reset at the same time by selecting reset high low rst HL The tare value used to zero the display may be reset by selecting reset tare rst tr Control Menu Contrl The Control menu is used to control the 4 20 mA analog output and the relays manually ignoring the input Each relay and a...

Page 46: ...resetting the total manually Gtotal Prevents resetting the grand total manually Protecting or Locking the Meter Enter the Password menu and program a six digit password For instructions on how to program numeric values see Setting Numeric Values page 30 Total Reset Password Non Resettable Total The total and the grand total can be password protected to prevent unauthorized total resets The grand t...

Page 47: ...nu and enter the correct password twice as shown below The meter is now unprotected until a new password is entered If the correct six digit password is entered the meter displays the message unLoc unlocked and the protection is disabled until a new password is programmed If the password entered is incorrect the meter displays the message Locd Locked for about two seconds and then it returns to Ru...

Page 48: ...e factory for 2 point linear calibration The number of points for multi point calibration scaling is set up in the Advanced Features menu Up to 32 linearization points may be selected See page 53 for details Maximum Minimum Readings The max min readings peak valley reached by the process can be displayed either continuously or momentary 1 Display briefly by assigning to the digital inputs in the U...

Page 49: ...lter Set noise filter value Hi spd High Speed Filter Program High Speed Filter Lo spd Low Speed Filter Program Low Speed Filter Round Round Set the rounding value for display variables seriAl Serial Set serial communication parameters SlaveId Slave ID Set slave ID or meter address baud Baud rate Select baud rate Tr dLY Transmit delay Set transmit delay for serial communication Parity Parity Select...

Page 50: ...Assign F3 function key F4 F4 function Assign F4 function digital input dI I Digital input 1 Assign digital input 1 4 if expansion modules are connected dO 1 Digital output 1 Assign digital output 1 4 if expansion modules are connected ICal Internal source calibration Enter internal source calibration used for scaling the meter without a signal source C CAL Current calibration Calibrate 4 20 mA cur...

Page 51: ...0 20 0 0 0500 1 0 100 0 0 0100 1 0 200 0 0 0050 1 0 400 0 0 0025 1 0 800 0 0 0012 1 0 999 9 0 0010 The low gate setting corresponds to the display update rate and is used to stabilize the display reading with a fluctuating signal The minimum frequency is dependent on high gate setting Contact De Bounce Filter FiLter The filter function FiLter can be used for applications where the meter is set up ...

Page 52: ... are provided with each optional serial communications adapter Note Refer to the Modbus Register Tables for details When using more than one meter in a multi drop mode each meter must be provided with its own unique address The meter address Slave ID may be programmed between 1 and 247 The transmit delay may be set between 0 and 199 ms The parity can be set to even odd or none with 1 or 2 stop bit...

Page 53: ...r 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 If the dual scale level feature has been selected the menus for PV1 PV2 are enabled PV2 can be programmed with up to 8 linearization p...

Page 54: ... analog output calibration it is recommended to use a milliamp meter with a resolution of at least 0 1 µA to measure the output current The values saved internally during this procedure are used for scaling the 4 20 mA output in the Setup menu Programmable Function Keys User Menu user Changing the programming of the F1 F3 function keys will disable the default batch operation of these keys and is ...

Page 55: ...values on line 2 Ln2 gt Display the grand total on line 2 Ln2 bc Display the batch count on line 2 Contrl Directly access the control menu Display Description disabl Disable the selected function key or digital I O AcH Acknowledge all active relays that are in a manual operation mode such as auto manual or latching Reset Directly access the reset menu Rst t Reset the total Rst gt Reset the grand t...

Page 56: ...row button and scroll to Information menu Info 3 Press Enter to access the software number SFT and version UER information Write down the information as it is displayed Continue pressing Enter until all the information is displayed 4 The meter returns to Run Mode after displaying all the settings Reset Controller to Factory Defaults When the parameters have been changed in a way that is difficult ...

Page 57: ... decimal point Ddddd d 1 place Gr total decimal point Dddddd 0 places K factor Factor 1 000 Cutoff value CutofF 0 000 disabled Display line 1 Line 1 Rate Process Display line 2 Line 2 Total value Display intensity d Inty 8 Total time base T tb Second Total conversion factor T CF 1 000 Batch mode mode Manual Grand total time base GT tb Second GTotal conversion factor gT CF 1 000 Grand total reset g...

Page 58: ...l safe relay 4 Fls 4 Off Display 1 analog out Dis 1 4 000 Output 1 value Out 1 4 000 mA Display 2 analog out Dis 2 20 000 Output 2 value Out 2 20 000 mA Source analog output Source Rate process Overrange output O rang 21 000 mA Underrange output u rang 3 000 mA Loop break output break 1 000 mA Maximum output mAx 23 000 mA Minimum output min 1 000 mA F1 function key F1 Reset max min Password 1 Pass...

Page 59: ...spond to input changes reading a fixed number Check Display assignment it might be displaying max min or set point Display alternates between Hi and a number Lo and a number Press Menu to exit max min display readings Relay operation is reversed Check Fail safe in Setup menu Wiring of relay contacts Relay and status LED do not respond to signal Check Relay action in Setup menu Set and reset points...

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Precision Digital Corporation Helios PD2-6310, Instruction Manual

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