Canadian Standards Association Atmosphères ExplosiblesEuropean ConformityIECEx Approval

Features

  • Fully Approved Explosion-Proof Batch Controllers
  • 0-20 mA, 4-20 mA, 0-5 V, 1-5 V, and ±10 V Inputs with ±0.03% Accuracy
  • Dual-Line 6-Digit Display, 0.6" (15 mm) & 0.46" (12 mm)
  • SafeTouch Through-Glass Button Programming
  • Display Mountable at 0°, 90°, 180°, & 270°
  • Isolated 24 VDC @ 25 mA Transmitter Power Supply
  • Easy Field Scaling in Engineering Units without Applying an Input
  • 4 Relays with Interlocking Capability + Isolated 4-20 mA Output
  • Free PC-Based, On-Board, MeterView Pro USB Programming Software
  • SunBright Display Standard Feature; Great for Outdoor Applications
  • Start / Pause / Stop, Change Batch with Front Panel Buttons
  • Display Batch Total, Rate, Grand Total, Count or Preset
  • Single or Multi-Stage Batch Control (Up to 4 Relays)
  • Front Panel or Remote Total Reset
  • Automatic Overrun Correction
  • Automatic or Manual Batch Control
  • Low or High Flow Alarms while Batching
  • 32-Point Linearization, Square Root Extraction and Programmable Exponent Function
  • Operating Temperature Range: -55 to 65°C (-67 to 149°F)
  • 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
  • Programmable Display, Function Keys & Digital Inputs
  • Flanges for Wall or Pipe Mounting
  • Explosion-Proof Aluminum or Stainless Steel NEMA 4X / IP68 Enclosures
  • On-Board RS-485 Serial Communications
  • Modbus RTU Communication Protocol Standard
  • Password Protection
  • Four 3/4" NPT Threaded Conduit Openings
  • 3-Year Warranty

Overview

Front

PD8-6210 Front

Connections

PD8-6210 Connections

Introduction

The ProtEX-MAX PD8-6210 is an explosion-proof analog input batch controller ideal for simplifying independent batch control operations where local control is preferred to expensive and expansive plant operation systems. The controller features a dual-line display, with a main display 0.60" (15 mm) high, and a second display of 0.46" (12 mm) high superluminous LED digits, which can be read in any lighting condition, including direct sunlight. The controller is housed in a field-mountable, NEMA 4X/IP68 rated enclosure available in either aluminum or stainless steel for convenient indoor and outdoor installation.

The controller comes programmed for easy start, pause, stop, and batch size (preset) changes. The second display can be programmed to display rate, grand total, batch count, or preset by cycling the Stop (F3) button. Digital inputs come standard.

Single and multi-stage batching is possible with four (4) on-board relays. Each batch control relay may have a unique preclose amount when used for multi-stage batching. Manual start batching is default, but automatic batching with a restart after a programmed time delay from the completion of the last batch is also possible.

Overrun correction adjusts the closing of the batch control relays to adjust for inaccuracies from batch to batch. This increases accuracy over time as systems wear out. The overrun correction feature is capable of compensating for inaccuracies of up to 1% of the programmed preset value.

The controller accepts current and voltage signals (e.g. 4-20 mA, 0-10 V). The PD8-6210 batch controller comes with four SPDT relays, a 4-20 mA output, two 24 VDC power supplies, five digital inputs and four digital outputs, and RS-485 serial communications, making it an excellent addition to any system.

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 front panel buttons, digital inputs, or PC and MeterView Pro software.
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 model 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 models transmitter supply rated @ 25 mA 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 = -55 to 60°C
T5 Class operating temperature range: Ta = -55 to 65°C
Storage temperature range: -55 to 85°C (-67 to 185°F)
Relative humidity: 0 to 90% non-condensing
Max Power Dissipation: Maximum power dissipation limited to 15.1 W
Connections: Removable screw terminal blocks accept 12 to 22 AWG wire, RJ45 for external relays, digital I/O, and serial communication adapters.
Weight: Aluminum: 14.7 lbs (6.67 kg); Stainless Steel: 23.5 lbs (10.66 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

Analog Input

Inputs: Field selectable: 0-20, 4-20 mA, ±10 VDC (0-5, 1-5, 0-10 V), Modbus PV (Slave)
Accuracy: ±0.03% of calibrated span 1 count, square root & programmable exponent accuracy range: 10-100% of calibrated span
Temperature Drift: 0.005% of calibrated span/°C max from 0 to 65°C ambient, 0.01% of calibrated span/°C max from -40 to 0°C ambient
Signal Input Conditioning: Linear, square root, programmable exponent, or round horizontal tank volume calculation.
Multi-Point Linearization: 2 to 32 points
Programmable Exponent: 1.0001 to 2.9999
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 Range:
Input RangeMinimum Span Input 1 & 2
4-20 mA0.15 mA
10 V0.10 V
An error message will appear if input 1 and input 2 signals are too close together.
Input Impedance: Voltage ranges: greater than 1 MΩ.
Current ranges: 50 - 100 Ω (depending on resettable fuse impedance).
Input Overload: Current input protected by resettable fuse, 30 VDC max. Fuse resets automatically after fault is removed.
HART Transparency: Analog input will not interfere with existing HART communications on the wired 4-20 mA signal

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: 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 models @ 25 mA max.
External Loop Power Supply: 35 VDC maximum
Output Loop Resistance:
Power supplyMinimumMaximum
24 VDC10 Ω700 Ω
35 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.


Enclosure

Material-AL Models: ASTM A413 LM6 die-cast aluminum, copper-free, enamel coated
-SS Models: ASTM A743 CF8M investment-cast 316 stainless steel
GasketFluoroelastomer
RatingNEMA 4X, IP68 Explosion-proof
Color-AL: Blue
-SS: Silver
WindowBorosilicate glass
ConduitsFour ¾" NPT threaded conduit openings
Conduit Stopping PlugsSold separately
FlangesTwo built-in flanges for wall and pipe mounting.
Tamper-Proof SealCover may be secured with tamper-proof seal.
Overall Dimensions6.42" x 7.97" x 8.47" (W x H x D)
(163 mm x 202 mm x 215 mm)
WeightAL: 14.7 lbs (6.67 kg)
SS: 23.5 lbs (10.66 kg)
ATEXFlameproof
ATEXII 2GD
Ex db IIC Gb
Ex tb IIIC Db
IP66/IP68
Tamb: -55°C to +85°C
Certificate No.: Sira 19ATEX1252U
IECExFlameproof and dust protection
Ex db IIC Gb
Ex tb IIIC Db
IP66/IP68
Tamb: -55°C to +85°C
Certificate No.: IECEx SIR 19.0075U
CSAClass I, Division 1, Groups A, B, C, D
Class II, Division 1, Group E, F, G
Class III
Ex db IIC Gb
Ex tb IIIC Db
Class I, Zone 1, AEx db IIC Gb
Zone 21, AEx tb IIIC Db
IP66/IP68/TYPE 4X
Tamb: -55°C to +85°C
Certificate No.: 80011200
ULClass I, Division 1, Groups A, B, C, D
Class II, Division 1, Groups E, F, G
Class III
Class I, Zone 1, AEx db IIC Gb
Zone 21, AEx tb IIIC
Ex db IIC Gb
Ex tb IIIC Db
IP66/IP68/TYPE 4X
Tamb: -55°C to +85°C
Certificate Number: E518920
Note: The above approvals are for the enclosure only. See below for approvals on the entire instrument.


General Compliance Information

Electromagnetic Compatibility

EmissionsEN 55022
Class A ITE emissions requirements
Radiated EmissionsClass A
AC Mains Conducted EmissionsClass A
ImmunityEN 61326-1
Measurement, control, and laboratory equipment
EN 61000-6-2
EMC heavy industrial generic immunity standard
RFI - Amplitude Modulated80 -1000 MHz 10 V/m 80% AM (1 kHz)
1.4 - 2.0 GHz 3 V/m 80% AM (1 kHz)
2.0 - 2.7 GHz 1 V/m 80% AM (1 kHz)
Electrical Fast Transients±2kV AC mains, ±1kV other
Electrostatic Discharge±4kV contact, ±8kV air
RFI - Conducted10V, 0.15-80 MHz, 1kHz 80% AM
AC Surge±2kV Common, ±1kV Differential
Surge1KV (CM)
Power-Frequency Magnetic Field30 A/m 70%V for 0.5 period
Voltage Dips40%V for 5 & 50 periods
70%V for 25 periods
Voltage Interruptions<5%V for 250 periods
Note: Testing was conducted on meters with cable shields grounded at the point of entry representing installations designed to optimize EMC performance.


Product Ratings and Approvals

CSAClass I, Division 1, Groups B, C, D
Class II, Division 1, Groups E, F, G
Class III, Division 1
Class I Zone 1 Ex db IIC
Zone 21 Ex tb IIIC T90°C
-55°C < Tamb. < +60° C; Temperature Code T6
-55°C < Tamb. < +65° C; Temperature Code T5
Enclosure Type 4X & IP66 / IP68
Certificate Number: 2531731
ATEXII 2 G D
Ex db IIC T* Gb
Ex tb IIIC T90°C Db IP68
Ta = -55°C to +*°C
*T6 = -55°C to +60°C
*T5 = -55°C to +65°C
Certificate Number: Sira 12ATEX1182X
IECExEx db IIC T* Gb
Ex tb IIIC T90°C Db IP68
Ta = -55°C to +*°C
*T6 = -55°C to +60°C
*T5 = -55°C to +65°C
*T5 = -55°C to +65°C
Certificate Number: IECEx SIR 12.0073X
ATEX/IECEx Specific Conditions of Use:
  1. The equipment label and epoxy coating may generate an ignition-capable level of electrostatic charges under certain extreme conditions. The user should ensure that the equipment is not installed in a location where it may be subjected to external conditions (such as high-pressure steam) which might cause a build-up of electrostatic charges on non-conducting surfaces. Additionally, cleaning of the equipment should be done only with a damp cloth.
  2. Flameproof joints are not intended to be repaired.
  3. All entry closure devices shall be suitably certified as “Ex d”, “Ex t” and “IP66/68” as applicable. Suitable thread sealing compound (non-setting, non-insulating, non-corrosive, not solvent based, suitable for the ambient rating) must be used at the NPT conduit entries to achieve the IPx8 rating while maintaining the Ex protection concept.
Year of Construction

This information is contained within the serial number with the first four digits representing the year and month in the YYMM format.

For European Community:

The ProtEX-MAX must be installed in accordance with the ATEX directive 2014/34/EU, and the product certificate Sira 12ATEX1182X.

Dimensions

PD8-6000 Dimensions Front View

Front View

PD8-6000 Dimensions Side View

Side View

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.

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