Precision Digital Corporation ProVu PD6210 Instruction Manual Download Page 43

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™ PD6210 Analog Input Batch Controller 

Instruction Manual 

 

43 

Automatic Batch Control 
Operation 

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. 

 

 

2.  The START button is pressed. Both valves 

open. The barrel begins to fill. 

 

 

3.  When the batch total reaches a value of 

50.00 (Preset [55.00] 

– Pre-close [5.00]) the 

full-flow valve closes. The fill rate of the tank 
slows as a result. 

 

 

4.  When the batch is complete, the restricted-

flow valve closes. If overrun occurs, then the 
next batch will adjust for this offset amount to 
maintain accuracy. 

 

 

5.  After the batch is completed, the operator 

removes the full barrel and places an empty 
barrel; the new batch starts automatically 
after 60 seconds (Time Delay). 

 

 

6.  The new batch begins automatically after 60 

seconds, both relays activate and both 
valves open. 

 

 

7.  At the end of the shift, press STOP twice to 

stop the batch process. 

Summary of Contents for ProVu PD6210

Page 1: ...h Front Panel Buttons Display Batch Total Rate Grand Total Count or Preset Single or Multi Stage Batch Control Up to 8 Relays Automatic Overrun Correction Automatic or Manual Batch Control Low or High Flow Alarms while Batching 9 Digit Grand Total with Overflow Feature Count Up or Down Independent for Batch Grand Total Optional SunBright Display Models for Outdoor Applications Operating Temperatur...

Page 2: ...espective owners 2021 Precision Digital Corporation All rights reserved FREE MeterView Pro Programming Software The controller can be powered from the Micro USB connection When using the Micro USB connection DO NOT apply AC or DC power to the controller The easiest and quickest way to program your PROVU batch controller is to use the FREE MeterView Pro programming software This software is loaded ...

Page 3: ...s 18 F4 Digital Input Connections 18 4 20 mA Output Connections 18 Analog Output Transmitter Power Supply 18 External Relay Digital I O Connections 19 Remote Batch Control Connections 19 Interlock Relay Feature 19 Basic Setup Programming 20 Overview 20 Front Panel Buttons and Status LED Indicators 20 Display Functions and Messages 21 Main Menu 23 Setting Numeric Values 23 Setting Up the Batch Cont...

Page 4: ...ed Controller 39 Disabling Password Protection 39 Controller Operation 40 Default Batch Control Operation 40 Batch Control Operation Example 40 Manual Batch Control 41 Manual Batch Control Operation 41 Additional Features 42 Automatic Batch Control 42 Setup for Automatic Batch Control 42 Automatic Batch Control Operation 43 Setup with MeterView Pro 44 Operate with MeterView Pro 44 Advanced Setup P...

Page 5: ...17 Figure 10 Transmitter Powered by Internal Supply 17 Figure 11 Transmitter Powered by Ext Supply or Self Powered 17 Figure 12 Voltage Input Connections 17 Figure 13 Relay Connections 17 Figure 14 AC and DC Loads Protection 18 Figure 15 Low Voltage DC Loads Protection 18 Figure 16 F4 Digital Input Connections 18 Figure 17 4 20 mA Output Connections 18 Figure 18 Analog Output Supply Powering Other...

Page 6: ...atures including an isolated 24 VDC transmitter power supply and Modbus RTU Serial communications Ordering Information Standard Models 85 265 VAC Model 12 24 VDC Model Options Installed PD6210 6R2 PD6210 7R2 2 relays PD6210 6R4 PD6210 7R4 4 relays PD6210 6R5 PD6210 7R5 2 relays 4 20 mA output PD6210 6R7 PD6210 7R7 4 relays 4 20 mA output SunBright Display Models 85 265 VAC Model 12 24 VDC Model Op...

Page 7: ...ow Blue or White Light Button and Holes Drilled in Enclosure 1 Note 1 This MOD supplies the Light Horn and Button The enclosure comes pre drilled with holes for Light Horn and Button and the user performs the installation and wiring Meter and enclosure are sold separately The Light Horn hole is in the back left corner of the enclosure and the Button is centered on the cover of the enclosure below ...

Page 8: ...puts module is required to operate the control stations of more than one button See Remote Batch Control on page 19 for details Signal Splitter Conditioner Accessories Model Description PD659 1MA 1MA Signal Isolator with One 4 20 mA Input and One 4 20 mA Output PD659 1MA 2MA Signal Splitter with One 4 20 mA Input and Two 4 20 mA Outputs PD659 1V 1MA Signal Conditioner with One 0 10 VDC Input and O...

Page 9: ...words 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 inputs 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 ...

Page 10: ...rocess Automatic Overrun Correction Adjusts the closing of the batch control relays to compensate for inaccuracies from batch to batch The overrun correction feature is capable of compensating for inaccuracies of up to 1 of the programmed preset value To achieve an accurate batch the flow rate must be slowed down such that the total most right digit increments at a rate of less than 10 counts seco...

Page 11: ...s the HART communications to pass through without interruption The controller is not affected if a HART communicator is connected to the loop The controller does not display secondary HART variables 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 ...

Page 12: ...ort is in use On Board Digital Input F4 Function Start Stop batch remote operation of front panel buttons acknowledge reset relays reset max min values See Function Keys Digital I O Available Settings on page 49 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 Low 0 to 1 25 VDC Additional I O Up...

Page 13: ...0 A m 70 V for 0 5 period Voltage Dips 40 V for 5 50 periods 70 V for 25 periods Voltage Interruptions 5 V for 250 periods Note Testing was conducted on controllers installed through the covers of grounded metal enclosures with cable shields grounded at the point of entry representing installations designed to optimize EMC performance Safety Information Read complete instructions prior to installa...

Page 14: ...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 DO NOT apply AC or DC power to the c...

Page 15: ...tware Video at www predig com meterviewpro MeterView Pro Installation 1 Connect one end of the provided USB cable to the controller and the other end to the computer The computer will automatically install the driver software it needs to talk to the controller Follow the on screen instructions and allow sufficient time for the process to complete This can take a few minutes If the process is inter...

Page 16: ...to prevent damage to the controller and ensure personnel safety Connectors Labeling The connectors label affixed to the controller shows the location of all connectors available with requested configuration Note on the following figures refers to power and display options Example PD6210 6H5 Figure 5 PD6210 2 Connectors Label Figure 6 PD6210 4 Connectors Label Figure 7 PD6210 5 Connectors Label Fig...

Page 17: ...erload 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 12 Voltage Input Connections The controller is capable of accepting any voltage from 10 VDC to 10 VDC Modbus RTU Serial Communica...

Page 18: ...o each relay contact switching an inductive load Part number PDX6901 Note Relays are de rated to 1 14th HP 50 watts with an inductive load F4 Digital Input Connections A digital input F4 is standard on the controller This digital input should be connected with a normally open contact across F4 and COM or with an active low signal applied to F4 It can be used to start stop the batch reset the total...

Page 19: ...ted in Figure 22 Controller to Control Station Connection Figure 22 Controller to Control Station Connection 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 activate the interlock relay This feature is enabled by configuring the relay and the correspo...

Page 20: ...icators Button Symbol Description LED Status Menu 1 8 Relay 1 8 indicators START Right arrow F1 R Rate indicator BATCH Up arrow F2 T Batch Total indicator STOP Enter F3 G T Grand Total indicator Note F4 is a digital input Alarms 5 8 enabled when relay expansion module is installed Total overflow indicator Note LEDs for relays in manual mode flash with the M LED every 10 seconds M flashing by itsel...

Page 21: ...T dly Time delay Set time delay for automatic batch restart GT tb Grand total time base Program grand total time base Display Functions and Messages Display Parameter Action Setting Description GT CF Grand total conversion factor Program grand total conversion factor GT rst Grand total reset Program grand total reset mode auto or manual dsplay Display Enter the Display menu Line 1 Display Line 1 P...

Page 22: ... mA reset Reset Press Enter to access the Reset menu Rst Hi Reset high Press Enter to reset max display Rst Lo Reset low Press Enter to reset min display Rst HL Reset high low Press Enter to reset max min displays Rst t Reset total Press Enter to reset total Rst Gt Reset grand total Press Enter to reset grand total Rst bc Reset batch count Press Enter to reset batch count Contrl Control Enter Manu...

Page 23: ...r 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 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 ...

Page 24: ...e totalizer and batching features 3 Select the display units tags 4 Decimal point position 5 Program menu for scaling or calibration totalizer setup manual or automatic batch mode 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 ...

Page 25: ...s 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 units menu or d unit is selected as the Lower display parameter See the Setting the Display Parameter Intensity dsplay flow chart on page 29 to access the display menu to show the unit or tag on the display line 2 The engineering units or custom leg...

Page 26: ...he controller 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 menu prior to scaling and calibration of the controller See Multi Point Linearization Linear menu on page 48 for details Additional parameters not needed for most applications ar...

Page 27: ...n or scaling of the controller Input range Input 1 input 2 span 4 20 mA 0 15 mA 10 VDC 0 10 VDC 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 l...

Page 28: ...set In the automatic reset mode a programmable time delay is available to reset the grand total after the assigned preset is reached The grand total can also be reset via the front panel button via a switch across the on board F4 terminal the PDA1044 digital I O expansion module or via a Modbus command Non Resettable Totalizer The grand total can be programmed as a non resettable total see Grand T...

Page 29: ...d 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 controller Display Menu Display Intensity d Inty The controller has eight display intensity levels to give the best performance under various lighting conditions Select intensity 8 for outdo...

Page 30: ...manual reset when not in a batch process only after alarm condition has cleared e Pump alternation control Not applicable 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 can be controlled by Interlock feature 3 Set and reset points batch preset 4 Fail safe operation a On enabled b Off disabled 5 Time delay a ...

Page 31: ...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 or sampling Relay 1 should always be assigned to total for batch control applications ...

Page 32: ...otal Programming Alarm Set and Reset Points High alarm program set point above reset point Low alarm 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 ...

Page 33: ...tivated Each relay can be programmed with additional ON delay to satisfy various conditions and applications 1 START button is pressed 2 Both relays are energized opening both valves controlling the flow 3 At 50 gallons pre close 5 gal relay 2 closes the main valve 4 At 55 gallons preset 55 gal relay 1 closes the dribble valve 5 After the Batch Time Delay elapses a new batch starts automatically w...

Page 34: ...go below the set point and then go above it Low Alarm Operation Set Reset For Manual reset mode ACK can be pressed anytime to turn off relay To detect a new alarm condition the signal must go below the set point and then go above it High Alarm with Fail Safe Operation Set Reset Note Relay coil is energized in non alarm condition In case of power failure relay will go to alarm state Low Alarm with ...

Page 35: ...cted the LED follows the reset point and not the relay state when the relay is acknowledged 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 bet...

Page 36: ...ate Alarm State Power Failure NO NC NO NC Off Open Closed Closed Open Relays in de energized state On Closed Open Open Closed Relays in energized state Note NO Normally Open NC Normally Closed This refers to the condition of the relay contacts when the power to the controller is off Front Panel LEDs The LEDs on the front panel provide status indication for the following LED Status LED Status 1 Ala...

Page 37: ...n Feature Relays 1 4 can be set up as interlock relays To set up the relays for the interlock feature 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 Inter...

Page 38: ...nstructions on how to program numeric values see Setting Numeric Values on page 23 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 Manual Control Menu Contrl The Manual Control menu is used to control the 4 20...

Page 39: ...s been programmed as non resettable the feature CANNOT be disabled Making Changes to a Password Protected Controller If the controller is password protected the controller will display the message Locd Locked when the Menu button is pressed Press the Enter button while the message is being displayed and enter the correct password to gain access the menu After exiting the programming mode the contr...

Page 40: ...ause stop functions are operational other buttons are deactivated Batch Control Operation Example The following example shows how two stage batch control functions with a PD6210 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 ...

Page 41: ... The START button is pressed Both valves open The barrel begins to fill 3 When the batch total reaches a value of 50 00 Preset 55 00 Pre close 5 00 the full flow valve closes The fill rate of the tank slows as a result 4 When the batch is complete the restricted flow valve closes If overrun occurs then the next batch will adjust for this offset amount to maintain accuracy 5 After placing a new emp...

Page 42: ... 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 Automatic Batch Control The automatic batch control feature is used for batch processes where the batch size does not change Setup for Automatic Batch Control The batch controller can be configured to automatically start a new batch after ...

Page 43: ...eset 55 00 Pre close 5 00 the full flow valve closes The fill rate of the tank slows as a result 4 When the batch is complete the restricted flow valve closes If overrun occurs then the next batch will adjust for this offset amount to maintain accuracy 5 After the batch is completed the operator removes the full barrel and places an empty barrel the new batch starts automatically after 60 seconds ...

Page 44: ...on and set time delay if automatic mode Count Direction Program the batch controller to count up or count down and set a starting count value if desired Operate with MeterView Pro Meterview Pro software also shows the Batch Size and Current Batch Total as well as allowing the user to start and stop the batch Real Time Batch in Progress MeterView Pro software shows all the important batch control i...

Page 45: ...Action Setting t byt Time byte Set byte to byte timeout SelEct Select Enter the Select menu function cutoff out Functn Input Signal Conditioning Select linear square root or programmable exponent Linear Linear Set controller for linear function and select number of linearization points No PtS Number of points Set controller for 2 to 32 point linearization Square Square root Set controller for squa...

Page 46: ...are firmware information erase Erase Erase MeterView Pro software stored in controller s memory Function Keys Operation During operation the programmable function 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 49 for details The following table shows the default setting for each of the function ke...

Page 47: ...er level to zero disables the filter function 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 va...

Page 48: ...plex 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 can be disabled to display negative values The cutoff value may be programmed from 0 1 to 999999 The controller will display zero below the cutoff value ...

Page 49: ...ld current relay states and analog output as they are until a button assigned to enable relays Rly E is pressed d Hold Hold the current display value relay states and analog output momentarily while the function key or digital input is active The process value will continue to be calculated in the background Ln1 Hi Display maximum display value on line 1 Ln1 Lo Display minimum display value on lin...

Page 50: ...s 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 Press the Right arrow button to move to the next digit 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 calibration C Hi Apply the high input signal...

Page 51: ...cimal 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 controller 1 Go to the Diagnostics menu diAG and press Enter button 2 Press Up arrow button and scroll to Informa...

Page 52: ...utomatic Relay 2 set point Set 2 200 0 Relay 3 action Act 3 Automatic Relay 3 set point Set 3 3 000 Relay 3 reset point RSt 3 2 500 Relay 4 action Act 4 Automatic Factory Defaults User Settings Parameter Display Default Setting Relay 4 set point Set 4 4 000 Relay 4 reset point RSt 4 3 500 Fail safe relay 1 Fls 1 Off Fail safe relay 2 Fls 2 Off Fail safe relay 3 Fls 3 Off Fail safe relay 4 Fls 4 Of...

Page 53: ...4 function F4 Start Stop Digital input 1 dI 1 Menu Digital input 2 dI 2 Right arrow Digital input 3 dI 3 Up arrow Digital input 4 dI 4 Enter Digital output 1 4 dO 1 Alarm 1 4 Password 1 Pass 1 000000 unlocked Password 2 Pass 2 000000 unlocked Password 3 Pass 3 000000 unlocked Total password Total 000000 unlocked Grand total password Gtotal 000000 unlocked ...

Page 54: ...etup menu 3 Minimum input span requirements Controller displays 999999 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 values increase Display response is too slow Check filter and bypass values Display reading is not accurate 1 Input signal condi...

Page 55: ...icable technical standards and when applicable or required a European Union notified body certification Standards EN 55022 2003 EN 61000 6 2 2001 EN 61010 1 2001 EN 61326 2006 The standards EN 55022 2003 EN 61000 6 2 2001 EN 61010 1 2001 and EN 61326 2006 are no longer harmonized The requirements of these standards have been checked against the harmonized standards EN 55022 2010 EN 61000 6 2 2005 ...

Page 56: ...90 www predig com LIM6210_H SFT039 Ver 4 010 up 04 21 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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