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Precision Digital Corporation ProtEX-MAX PD8-6000, Instruction Manual

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ProtEX-MAX PD8-6000 Explosion-Proof Process Meter 

Instruction Manual 

 

 

 

15 

 

Exp-Proof Dual-Pump Alternation 

The ProtEX-MAX can be used as an explosion-proof 
pump controller when combined with a continuous 
level transmitter. The most common pump control 
application is shown below: controlling and alternating 
two pumps and providing high and low-level alarms. 
In addition, the ProtEX-MAX provides the 24 V to 
power the transmitter. 

 

 

Relay #4 turns the main pump on at 6000 gallons and 
turns it off at 1000 gallons. 

 

 

With the Pump Alternation feature activated, the next 
time the level reaches 6000 gallons, relay #3 transfers 
and starts the backup pump.

 

If the backup pump is not able to keep up, and the 
level reaches 7000 gallons, relay #4 transfers and 
starts the main pump as well. 

 

 

Relay #2 trips the High Level Alarm at 7500 gallons 
and resets at 6900 gallons. 

 

 

Relay #1 trips the Low Level Alarm at 495 gallons and 
resets at 750 gallons. 

 

Learn how to use the ProVu (ProtEX-MAX) 
meter as an explosion-proof pump 
controller. See how the four relays can be 
used to alternate two pumps and provide 
high and low alarms. 

predig.com/videos/PumpControl 

 

 

 

Summary of Contents for ProtEX-MAX PD8-6000

Page 1: ...ations Operating Temperature Range 40 to 60 C 40 to 140 F FM Approved as Explosion Proof Dust Ignition Proof Flame Proof CSA Certified as Explosion Proof Dust Ignition Proof Flame Proof ATEX and IECEx Certified as Flame Proof Input Power Options 85 265 VAC 90 265 VDC or 12 24 VDC 12 24 VAC Display Input in Two Different Scales Simultaneously Great for Level Applications Multi Pump Alternation Cont...

Page 2: ...2 ...

Page 3: ...pair or replacement of the defective unit See Warranty Information and Terms Conditions on www predig com for complete details Registered Trademarks All trademarks mentioned in this document are the property of their respective owners 2022 Precision Digital Corporation All rights reserved FREE MeterView Pro Programming Software The meter can be powered from the USB connection When using the USB co...

Page 4: ...Selection P P 25 Connections 25 Required Factory Wired Connection 25 PROVU Electronics Module Layout 26 USB Connection 26 Power Connections 27 Signal Connections 27 Relay Connections 27 Switching Inductive Loads 28 RS 485 Connections 28 RS 485 Multi Drop Connection 28 Digital I O Connections 29 F4 Digital Input Connections 29 4 20 mA Output Connections 29 Analog Output Power Supply 29 Remote Progr...

Page 5: ... 46 Pump Alternation Control Applications Altern 46 Setting Up the Interlock Relay Force On Feature 47 Scaling the 4 20 mA Analog Output Aout 48 Reset Menu reset 48 Manual Control Menu Contrl 48 Setting Up the Password pass 49 Protecting or Locking the Meter 49 Making Changes to a Password Protected Meter 49 Disabling Password Protection 49 Advanced Features Menu 50 Advanced Features Menu Display ...

Page 6: ...ctions 27 Figure 8 Transmitter Powered by Internal Supply 27 Figure 9 Transmitter Powered by External Supply or Self Powered 27 Figure 10 Voltage Input Connections 27 Figure 11 Relay Connections 27 Figure 12 AC and DC Loads Protection 28 Figure 13 Low Voltage DC Loads Protection 28 Figure 14 RS 485 Connections 28 Figure 15 Three Wire RS 485 Connections 28 Figure 16 Digital Input and Output Connect...

Page 7: ...outputs and RS 485 serial communications The four relays can be used for alarm indication or process control applications such as pump alternation control The 4 20 mA isolated output Modbus RTU serial communications and digital I O features make the ProtEX MAX an excellent addition to any system SafeTouch Buttons To make it possible to program and operate the ProtEX MAX in a hazardous area the pro...

Page 8: ...videos MVPro_SW MeterView Pro Software Demonstration Learn how easy it is to program Precision Digital s ProVu ProtEX MAX process meter for a level application using MeterView Pro PC based programming software predig com videos MVPro_Demo Connect to PC for Programming Learn how to connect a ProVu ProtEX MAX process meter to your PC and install free MeterView Pro programming software predig com vid...

Page 9: ...strated by the above diagram This feature not only saves the cost of an external power supply but also greatly simplifies wiring In addition there is a second 25 mA power supply provided with the 4 20 mA output option evident also in the above diagram The first thing you notice about the PD8 6000 is its modern looking rugged die cast aluminum housing with convenient mounting flanges Housed inside ...

Page 10: ...to monitor and datalog a ProtEX MAX using your PC You can also generate and save programming files for later use Advanced Display Features Dual Line Makes All the Difference The main display can be programmed to indicate PV maximum peak minimum valley alternating maximum minimum one of four alarm set points or Modbus input The second display can be configured to display the input in a different sc...

Page 11: ...for pressure force current power feet meters GPM CFM and more Gallons mA Gallons Height Gallons Percent Gallons Head PSI Rounding for Even Steadier Display The rounding feature is used to give the user a steadier display with fluctuating signals It causes the display to round to the nearest value according to the rounding value selected 1 2 5 10 20 50 or 100 For example with a rounding value of 10...

Page 12: ...rammed and operated without removing the cover and exposing the electronics in a hazardous area These buttons can be disabled for security by selecting the DISABLE setting on the NO CONTACT BUTTONS switch located on the back of the electronics module inside the enclosure Rugged Heavy Duty Enclosure The ProtEX MAX is housed in a rugged NEMA 4X 7 9 IP68 die cast aluminum enclosure designed to withst...

Page 13: ...text for equipment identification instruction or whatever else is needed in your facility Each tag comes with a stainless steel wire and lead seal for easy mounting wherever you need it Removable Screw Terminals Industrial applications require screw terminal connections for easy field wiring and the ProtEX MAX goes one step further in convenience by making them removable also USB Port MeterView Pr...

Page 14: ...on to power the 4 20 mA output Fuse Prevents Current Overload Another very useful aspect of the ProtEX MAX is that the current input is protected against current overload by a resettable fuse 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 Input Signal Conditioning Non linear input signals i e weirs f...

Page 15: ...00 gallons and turns it off at 1000 gallons With the Pump Alternation feature activated the next time the level reaches 6000 gallons relay 3 transfers and starts the backup pump If the backup pump is not able to keep up and the level reaches 7000 gallons relay 4 transfers and starts the main pump as well Relay 2 trips the High Level Alarm at 7500 gallons and resets at 6900 gallons Relay 1 trips th...

Page 16: ...nt and output functions including voltage current thermocouple and RTD PD9502 Low Cost Signal Generator The PD9502 is a low cost compact simple to use 4 20 mA or 0 10 VDC signal generator It can easily be set for 0 20 mA 4 20 mA 0 10 V or 2 10 V ranges Signal adjustment is made with a one turn knob A 15 27 VDC wall plug is provided with the instrument Optional USB power bank is available ...

Page 17: ...n non volatile memory for a minimum of ten years if power is lost Power Options 85 265VAC50 60Hz 90 265VDC 20Wmax 12 24 VDC 12 24 VAC 15 W max Powered over USB for configuration only Fuse Required external fuse UL Recognized 5 A max slow blow up to 6 meters may share one 5 A fuse Normal Mode Rejection Greater than 60 dB at 50 60 Hz Isolation 4 kV input output to power line 500 V input to output or...

Page 18: ...xisting HART communications it displays the 4 20 mA primary variable and it allows the HART communications to pass through without interruption The meter is not affected if a HART communicator is connected to the loop The meter does not display secondary HART variables Relays Rating 4 SPDT Form C internal and rated 3 A 30 VDC and 125 250 VAC resistive load 1 14 HP 50 W 125 250 VAC for inductive lo...

Page 19: ... ProtEX MAX Modbus Register Tables located at www predig com for details Digital Input F4 Function Remote operation of front panel buttons acknowledge reset relays reset max min values See Function Keys Digital I O Available Settings on page 54 for a complete list of capabilities Contacts 3 3 VDC on contact Connect normally open contacts across F4 to COM Logic Levels Logic High 3 to 5 VDC Logic Lo...

Page 20: ...5 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 E...

Page 21: ...sed by opening the enclosure To access electrical connectors remove the 2 captive screws and then remove the electronics module Connectors are on the rear of the electronics module Unpacking Remove the meter from box Inspect the packaging and contents for damage Report damages if any to the carrier If any part is missing or the meter malfunctions please contact your supplier or the factory for ass...

Page 22: ...les located in the cast in flanges In addition the internal electronic assembly can be rotated to allow the enclosure to be mounted in any position To mount the meter to a wall follow these instructions Prepare a section of wall approximately 7 x 8 5 178 mm x 216 mm for meter mounting by marking with a pencil the mounting holes shown in Figure 1 on the wall Select the appropriate mounting screws f...

Page 23: ...s kit includes two U bolts the necessary hardware and is available in zinc plated steel PDA6848 and 316 stainless steel PDA6848 SS To mount the meter using a U Bolt kit follow these instructions Orient the groove on the back of the instrument with the pipe and secure it to the pipe with the two U bolts and hardware provided Vertical Pipe Mounting Horizontal Pipe Mounting ...

Page 24: ...viewpro MeterView Pro Installation 1 Connect one end of the provided USB cable to the meter and the other end to the computer The computer will automatically install the driver software it needs to talk to the meter Follow the on screen instructions and allow sufficient time for the process to complete This can take a few minutes If the process is interrupted then it could leave the system in an u...

Page 25: ...ate and local codes to prevent damage to the meter and ensure personnel safety Static electricity can damage sensitive components Observe safe handling precautions for static sensitive components Use proper grounding procedures codes If the instrument is installed in a high voltage environment and a fault or installation error occurs high voltage may be present on any lead or terminal Follow all f...

Page 26: ...D8 6000 6H0 and PD8 6000 7H0 the upper set of connectors RELAYs MA OUT are not present Figure 5 PROVU Electronics Module Layout USB Connection Figure 6 USB Connection DO NOT disconnect the RJ45 M LINK connector cable Otherwise the instrument will not function properly The meter should only be connected to a computer while it is located in a safe area ...

Page 27: ...t is protected against current overload by an internal 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 Voltage V Connections The following figures show examples of voltage connections There are no...

Page 28: ...Part number PDX6901 Note Relays are de rated to 1 14th HP 50 watts with an inductive load RS 485 Connections The RS 485 connections are made to a five terminal connector used for Modbus RTU serial communications The RS 485 terminals include Transmit Data DO and DO Receive Data DI and DI and Signal Ground See Modbus RTU Serial Communications serial on page 51 for more information There are three di...

Page 29: ... to F4 It can be used for remote operation of front panel buttons to acknowledge reset relays or to reset max min values See Function Keys Digital I O Available Settings on page 54 for a complete list of capabilities Figure 17 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 ...

Page 30: ...y configuring the relay and the corresponding digital input s see Setting Up the Interlock Relay Force On Feature on page 47 In the example below an Interlock Contact switch is connected to a digital input which will be used to force on energize the Interlock Relay The Interlock Relay and the Control Relay are connected in series with the load When the Interlock Contact is closed safe the Interloc...

Page 31: ...Setup and programming is done using MeterView Pro or through the programming buttons After power and input signal connections have been completed and verified apply power to the meter LED Status Indicators LED State Indication 1 4 Steady Alarm condition based on set and reset points independent of relay status in certain configurations Available on all meter configurations including those without ...

Page 32: ...ea These buttons can be disabled for security by selecting DISABLE on the switch labeled NO CONTACT BUTTONS located on the connector board To actuate a button press one finger to the glass directly over the marked button area Then retract finger more than three inches from the glass before pressing the next button When the cover is removed the four mechanical buttons located next to the sensors ar...

Page 33: ...gn the small display parameter default engineering units d Inty Display intensity Set display intensity level from 1 to 8 RELaY Relay Enter the Relay menu RLY 1 Relay 1 Relay 1 setup Display Functions Messages Display Parameter Action Setting Description Act 1 Action 1 Set relay 1 action Auto Automatic Set relay for automatic reset A nman Auto manual Set relay for automatic manual reset any time L...

Page 34: ... 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 unloc Unlocked Program password to lock meter locd Locked Enter password to unlock meter 999999 99999 Flashing Over under range condition Main Menu The main menu consist...

Page 35: ...int position 5 Programming Menu 6 Display parameter and intensity 7 Relay operation 8 4 20 mA analog output scaling Press the Enter button to access any menu or press Up arrow button to scroll through choices Press the Menu button to exit at any time Setting the Input Signal Input Enter the Input menu to set up the meter to display current nmA or voltage Volt inputs The current input is capable of...

Page 36: ... Z g G 9 g H H h h I I I i Degree j J Space Notes 1 Degree symbol represented by if programming with MeterView Pro 2 The letters m and w use two 7 segment LEDs each when selected the characters to the right are shifted one position 3 Press and hold up arrow to auto scroll the characters in the display Setting the Decimal Point dEc pt The decimal point may be set with up to five decimal places or w...

Page 37: ...ingle Scale Process Program Menu for Dual Scale Level Applications Additional parameters not needed for most applications are programmed in the Advanced Features menu See Advanced Features Menu on page 50 Multi Point Calibration Scaling The meter is set up at the factory for 2 point linear calibration The number of points for multi point calibration scaling is set up in the Advanced Features menu ...

Page 38: ...ng the meter For instructions on how to program numeric values see Setting Numeric Values page 34 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 10 VDC Calibrating the Meter with External Source Cal Note To scale the meter w...

Page 39: ...ing and units 11 Display gross 12 Toggle net gross These menu items will only appear if Dual Scale feature is turned on After setting up the input and display press the Menu button to exit programming and skip the rest of the setup menu Display Intensity d Inty The meter has eight display intensity levels to give the best performance under various lighting conditions Select intensity 8 for outdoor...

Page 40: ...d by Interlock feature 2 Set point 3 Reset point 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 Setting the Relay Action Operation of the relays is programmed in the Action menu The relays may be set up for any of the following modes of operation 1 Automatic reset non...

Page 41: ...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 Action for Loss of 4 20 mA Input Loop Break A loop break condition is triggered when the 4 20 mA input...

Page 42: ...Relay coil is energized in non alarm condition In case of power failure relay will go to alarm state Time Delay Operation The following graphs show the operation of the time delay function When the signal crosses the set point the On time delay timer starts and the relay trips when the time delay has elapsed If the signal drops below the set point high alarm before the time delay has elapsed the O...

Page 43: ...ing Operation When the signal crosses the set point the relay trips and the sample time starts After the sample time has elapsed the relay resets The cycle repeats every time the set point is crossed going up for high alarms and going down for low alarms The sample time can be programmed between 0 1 and 5999 9 seconds ...

Page 44: ...provide status indication for the following LED Status 1 Alarm 1 2 Alarm 2 3 Alarm 3 4 Alarm 4 The meter 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 reach...

Page 45: ...f Off Latching Relay LatcH In this application the meter is set up for manual reset at any time Acknowledging the alarm even if the alarm condition is still present resets the relay and turns off the LED Manual reset any time Condition LED Relay Normal Off Off Alarm On On Ack Off Off Latching Relay with Clear Lt Clr In this application the meter is set up for manual reset only after the signal pas...

Page 46: ...amming Relay Set Point Reset Point Function 1 30 000 10 000 Controls pump 1 2 35 000 5 000 Controls pump 2 3 4 000 9 000 Controls low alarm 4 40 000 29 000 Controls high alarm Pump Alternation Operation 1 Pump 1 turns on when level reaches 30 000 when level drops below 10 000 pump 1 turns off 2 The next time level reaches 30 000 pump 2 turns on when level drops below 10 000 pump 2 turns off 3 If t...

Page 47: ...ture 1 Access the Setup Relay Action menu and set the action to off 2 In the Advanced features User menu program any of the digital inputs to Force On any of the internal relays 1 4 3 Connect a switch or dry contact between the 5V terminal and the corresponding digital input dI 1 to dI 4 terminal Interlock Relay Operation Example Relays 1 2 are configured to energize their front panel LEDs are ste...

Page 48: ...lues on page 34 Analog Output Value for Loss of 4 20 mA Input Loop Break on page 54 Reset Menu reset The Reset menu is used to reset the maximum or minimum reading peak or valley reached by the process both may be reset at the same time by selecting reset high low rst HL The tare value used to zero the display may be reset by selecting reset tare rst tr Manual Control Menu Contrl The Manual Contro...

Page 49: ...on is pressed Press the Enter button while the message is being displayed and enter the correct password to gain access to the menu After exiting the programming mode the meter returns to its password protected condition Disabling Password Protection To disable the password protection access the Password menu and enter the correct password twice as shown below The meter is now unprotected until a ...

Page 50: ...y Parameter Action Setting No PtS Number of points Set PV1 for 2 to 32 point linearization Set PV2 for 2 to 8 point linearization Square Square root Set meter for square root extraction Prog E Programmable exponent Set meter for programmable exponent and enter exponent value rht Round horizontal tank Set meter for round horizontal tank volume calculation Inch Dimension Calculate volume in gallons ...

Page 51: ...o be displayed immediately All signal changes smaller than the bypass value are filtered or averaged by the meter 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...

Page 52: ... using weirs and flumes For more information on how the Programmable Exponent Linearization feature works see the PD8 6200 manual Multi Point Linearization Linear Meters are set up at the factory for linear function with 2 point linearization Up to 32 linearization points can be selected for PV1 under the linear function The multi point linearization can be used to linearize the display for non li...

Page 53: ...splay 4 Press Enter and change the display 2 value to 3558 4 5 The meter is now displaying the volume in liters Note The display can be scaled to display the volume in any engineering units Another way to display the volume in liters is to enter the dimensions in cm The meter automatically calculates the volume in liters Low Flow Cutoff CutofF The low flow cutoff feature allows the meter to be pro...

Page 54: ...ion factors and store them 7 Press Menu to exit and return to Run mode Programmable Function Keys User Menu user The User menu allows the user to assign the front programming buttons function keys F1 F2 and F3 the digital input F4 located on the input signal connector and four digital inputs located on the digital I O connector to access most of the menus or to activate certain functions immediate...

Page 55: ... new capture tare is entered Internal Source Calibration ICAL The meter is factory calibrated prior to shipment for milliamps and volts with calibration equipment that is certified to NIST standards The use of calibrated signal sources 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 ca...

Page 56: ...Meter Operation When installed the primary way to operate the meter is with the SafeTouch through glass buttons that allow the user to perform various operations without removing the cover and exposing the electronics to the hazardous environment The user can also operate the meter by connecting a suitable control station or switch to one of the digital inputs that can be used to perform various o...

Page 57: ...unction keys operate according to the way they have been programmed in the Advanced Features User menu See Programmable Function Keys User Menu user on page 54 for details The table above shows the factory default settings for F1 F2 and F3 Digital Inputs Operation Five 5 digital inputs F4 DI 1 to DI 4 come standard on the meter These digital inputs are programmed identically to function keys F1 F2...

Page 58: ...ess the Enter button to activate the LED Test The meter will cycle through all digits decimal points and relay indicators to enable the operator to check that all LEDs are functioning properly 4 Press the Enter button again to access the Information menu info or press the Menu button to return to Run Mode Determining Software Version To determine the software version of a meter 1 Go to the Diagnos...

Page 59: ...lay 4 Fls 4 Off On delay relay 1 On 1 0 0 sec Off delay relay 1 Off 1 0 0 sec On delay relay 2 On 2 0 0 sec Off delay relay 2 Off 2 0 0 sec Parameter Display Default Setting On delay relay 3 On 3 0 0 sec Off delay relay 3 Off 3 0 0 sec On delay relay 4 On 4 0 0 sec Off delay relay 4 Off 4 0 0 sec Loop break relay 1 ignore Ignore Loop break relay 2 ignore Ignore Loop break relay 3 ignore Ignore Loo...

Page 60: ...alue greater than zero Meter displays error message during calibration Error Check 1 Signal connections 2 Input selected in Setup menu 3 Minimum input span requirements Meter displays 1 999999 2 99999 Check 1 Input selected in Setup menu 2 Corresponding signal at Signal connector Display is unstable Check 1 Input signal stability and value 2 Display scaling vs input signal 3 Filter and bypass valu...

Page 61: ...on device 3 Instrument address baud rate 4 Program address baud rate If both data status LEDs TX and RX are off when trying to communicate Remove all unnecessary cables and instruments from the bus Try getting the system to work with only one device to ease troubleshooting and then expand the system one device at a time Communications slow Increase the baud rate Random communication errors 1 Incre...

Page 62: ...ProtEX MAX PD8 6000 Explosion Proof Process Meter Instruction Manual 62 NOTES ...

Page 63: ...63 ...

Page 64: ... 8990 www predig com LIM8 6000_F SFT039 Ver 4 010 up 04 22 Contact Precision Digital Technical Support Call 800 610 5239 or 508 655 7300 Fax 508 655 8990 Email support predig com Sales Support Call 800 343 1001 or 508 655 7300 Fax 508 655 8990 Email sales predig com Place Orders Email orders predig com For the latest version of this manual please visit www predig com ...

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