PD6300 Pulse Input Rate/Totalizer Instruction Manual

Transcription

1 PD6300 Pulse Input Rate/Totalizer Pulse, Open Collector, NPN, PNP, TTL, Switch Contact, Sine Wave (Coil), Square Wave Inputs Gate Function for Rate Display of Slow Pulse Rates NEMA 4X, IP65 Front Universal VAC or 12/24 VDC Input Power Large Dual-Line 6-Digit Display, 0.60" & 0.46" Isolated ma Transmitter Power Supply Programmable Displays & Function Keys Sunlight Readable Display Rate Displayed as Units per Second, Minute, Hour, or Day Total, Grand Total or Non-Resettable Grand Total 9-Digit Totalizer with Total Overflow Feature K-Factor Calibration or Scale with up to 32-Point Linearization 2 or 4 Relays + Isolated 4-20 ma Output for Rate or Total External 4-Relays & Digital I/O Expansion Modules RS-232 & RS-422/485 Serial Communication Options -40 to 65 C Operating Temperature Range PRECISION DIGITAL CORPORATION 89 October Hill Road Holliston MA USA Tel (800) Fax (508)

2 Disclaimer The information contained in this document is subject to change without notice. Precision Digital makes no representations or warranties with respect to the contents hereof; and specifically disclaims any implied warranties of merchantability or fitness for a particular purpose.! CAUTION: Read complete instructions prior to installation and operation of the meter. WARNING: Risk of electric shock or personal injury. Warning This product is not recommended for life support applications or applications where malfunctioning could result in personal injury or property loss. Anyone using this product for such applications does so at his/her 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 Digital s liability under this limited warranty shall not exceed the purchase value, repair, or replacement of the defective unit. Registered Trademarks All trademarks mentioned in this document are the property of their respective owners Precision Digital Corporation. All rights reserved. 2

3 Table of Contents INTRODUCTION ORDERING INFORMATION SPECIFICATIONS General Rate Input Rate/Totalizer Relays Isolated 4-20 ma Transmitter Output Serial Communications PDA1044 Digital Input & Output Expansion Module COMPLIANCE INFORMATION Safety Electromagnetic Compatibility SAFETY INFORMATION INSTALLATION Unpacking Panel Mounting Instructions Configuration for 12 or 24 VDC Power Option Transmitter Supply Voltage Selection (P+, P-) Connections Connectors Labeling Power Connections Signal Connections Serial Communications Relay Connections Switching Inductive Loads ma Output Connections Analog Output Transmitter Power Supply External Relay & Digital I/O Connections SETUP AND PROGRAMMING Front Panel Buttons and Status LED Indicators Display Functions and Messages Main Menu Setting Numeric Values Reset Menu (reset)

4 Control Menu (Contrl) Setting Up the Rate/Totalizer Meter (setup) Setting the Input Signal (Input) Setting the Totalizer Features (total) Setting the Decimal Point (dec pt) Setting the Display Parameter & Intensity (dsplay) Programming the Rate/Totalizer (prog) Multi-Point Calibration & Scaling Multi-Point Linearization Utility Scaling the Meter (SCALE) Gate Function (Gate) Contact De-Bounce Filter (FiLter) Calibrating the Meter with External Source (Cal) Setting the Relay Operation (relay) Relay Assignment (Assign) Setting the Relay Action Programming Set and Reset Points Setting Fail-Safe Operation Programming Time Delay Relay and Alarm Operation Diagrams High Alarm Operation (Set > Reset) Low Alarm Operation (Set < Reset) High Alarm with Fail-Safe Operation (Set > Reset) Low Alarm with Fail-Safe Operation (Set < Reset) Pump Alternation Control Operation Rate Relay Sampling Operation Total Relay Sampling Operation Time Delay Operation Relay Operation Details Overview Relays Auto Initialization Fail-Safe Operation Front Panel LEDs Latching and Non-Latching Relay Operation Non-Latching Relay (Auto) Non-Latching Relay (A-nman) Latching Relay (LatcH) Latching Relay (Lt-Clr) Acknowledging Relays Pump Alternation Control Applications (Altern) Scaling the 4-20 ma Analog Output (Aout) Setting Up the Password (pass)

5 Protecting or Locking the Meter Total Reset Password & Non-Resettable Total Making Changes to a Password Protected Meter Disabling Password Protection Advanced Features Menu Advanced Features Menu & Display Messages Serial Communications (serial) Select Menu (SElEct) Math Function Selection (Functn) Low-Flow Cutoff (CutofF) Analog Output Programming (AoutPr) Programmable Function Keys User Menu (user) Meter Copy Function (Copy) METER OPERATION Front Panel Buttons Operation Function Keys Operation Maximum/Minimum Readings TROUBLESHOOTING Diagnostics Menu (diag) Determining Software Version Reset Meter to Factory Defaults Factory Defaults & User Settings Troubleshooting Tips Alphabetical List of Display Functions & Messages

6 Table of Figures Figure 1: 1/8 DIN Panel Cutout and Mounting Figure 2: Meter Dimensions - Side View Figure 3: Meter Dimensions - Top View Figure 4: Jumper Configuration for 12/24 VDC Power Figure 5: Transmitter Supply Voltage Selection Figure 6: Connector Labeling for Fully Loaded PD Figure 7: Power Connections Figure 8: Flowmeter Powered by Internal Power Supply Figure 9: Flowmeter Powered by External Supply Figure 10: Self-Powered Magnetic Pickup Coil Flowmeter Figure 11: Relay Connections Figure 12: AC and DC Loads Protection Figure 13: Low Voltage DC Loads Protection Figure 14: 4-20 ma Output Connections Figure 15: Expansion Modules & DIN Rail Mounting Kit Figure 16: External Relays Module Connections Figure 17: Digital I/O Module Connections Figure 18: Acknowledge Relays w/function Key or Digital Input Figure 19: Meter Copy Connection

7 INTRODUCTION The PD6300 is a multipurpose, easy to use pulse rate/totalizer ideal for flow rate, total, and control applications. It accepts pulse (e.g. ±40 mv to ±8 V), square wave (0-5 V, 0-12 V, or 0-24 V), open collector, NPN, PNP, TTL or switch contact signals. Three of the front panel buttons can be custom-programmed for specific operation. The basic model includes an isolated 24 VDC transmitter power supply that can be used to power the input transmitter or other devices. An additional isolated 24 VDC power supply is included with the 4-20 ma output option. A fully loaded PD6300 pulse rate/totalizer meter has the following: four SPDT relays, 4-20 ma output, and two 24 VDC power supplies. The PD6300 capabilities may be enhanced by adding the following external expansion modules: four SPST relays (creating an eight-relay rate/totalizer), two digital I/O modules with four inputs and four outputs each, and RS-232 or RS-485 communication adapters. The eight relays can be used for alarm indication or process control applications. The 4-20 ma isolated output, serial communications, and digital I/O options make the PD6300 an excellent addition to any system. ORDERING INFORMATION VAC* Model 12/24 VDC* Model Options Installed PD6300-6R0 PD6300-7R0 No options PD6300-6R2 PD6300-7R2 2 relays PD6300-6R3 PD6300-7R ma output PD6300-6R4 PD6300-7R4 4 relays (PD1104**) PD6300-6R5 PD6300-7R5 2 relays &4-20 ma output PD6300-6R7 PD6300-7R7 4 relays & 4-20 ma output (PD1107**) *All models may be powered from AC or DC, see Specifications for details. **Model number for replacement option card. Accessories Model PDA1002 PDA1004 PDA1044 PDA1200 PDA1232 PDA1485 PDA7485-I PDA8232-N PDA8485-I PDA2811 PDA2812 PDX6901 Description DIN-Rail mounting kit for two expansion modules 4 SPST (Form A) relays 4 digital inputs & 4 digital outputs (2 may be connected) Meter copy cable RS-232 serial adapter RS-422/485 serial adapter RS-232 to RS-422/485 isolated converter USB to RS-232 non-isolated converter USB to RS-422/485 isolated converter 1 Meter Plastic NEMA 4X Enclosure 2 Meter Plastic NEMA 4X Enclosure Suppressor (snubber): 0.01 µf/470 Ω, 250 VAC 7

8 SPECIFICATIONS Except where noted all specifications apply to operation at +25 C. General DISPLAY DISPLAY INTENSITY DISPLAY UPDATE RATE Main display: 0.6" (15 mm) high, red LEDs Second display: 0.46" (12 mm) high, red LEDs 6 digits: each ( to ), with lead zero blanking. Eight user selectable intensity levels Rate: 10 per second; up to 1 per 100 seconds (and is a function of Low Gate setting) Total: 10 per second (fixed) OVERRANGE Display flashes PROGRAMMING METHODS Four front panel buttons, digital inputs, PC and multi-point linearization utility, or cloning using Copy function. RECALIBRATION All ranges are calibrated at the factory to read frequency in Hz. No recalibration required. MAX/MIN DISPLAY PASSWORD NON-VOLATILE MEMORY POWER OPTIONS FUSE ISOLATED TRANSMITTER POWER SUPPLY ISOLATION Max/min readings reached by the process are stored until reset by the user or until power to the meter is turned off. Three programmable passwords restrict modification of programmed settings and two prevent resetting the totals. Pass 1: Allows use of the F1 F3 function keys Pass 2: Allows use of the F1 F3 function keys and changing the set/reset points Pass 3: Restricts all programming and F1 F3 keys and Digital Inputs Total: Prevents resetting the total manually Gtotal: Prevents resetting the grand total manually All programmed settings are stored in non-volatile memory for a minimum of ten years if power is lost VAC 50/60 Hz, VDC, 20 W max or jumper selectable 12/24 VDC ± 10%, 15 W max Required external fuse: UL Recognized, 5 A max, slow blow; up to 6 meters may share one 5 A fuse Terminals P+ & P-: 24 VDC ± 200 ma max (standard), (12/24 VDC powered models 100 ma max). 5 or ma max, selectable with internal jumper J4. 4 kv input/output-to-power line 500 V input-to-output or output-to-p+ supply 8

9 OVERVOLTAGE Installation Overvoltage Category II: CATEGORY Local level with smaller transient overvoltages than Installation Overvoltage Category III. ENVIRONMENTAL Operating temperature range: -40 to 65 C Storage temperature range: -40 to 85 C Relative humidity: 0 to 90% non-condensing CONNECTIONS Removable screw terminal blocks accept 12 to 22 AWG wire, RJ45 for external relays, digital I/O, and serial communication adapters. ENCLOSURE 1/8 DIN, high impact plastic, UL 94V-0, color: black MOUNTING 1/8 DIN panel cutout required: 3.622" x 1.772" (92 mm x 45 mm) Two panel mounting bracket assemblies are provided. TIGHTENING Screw terminal connectors: 5 lb-in (0.56 Nm) TORQUE OVERALL DIMENSIONS 4.68" x 2.45" x 5.64" (119 mm x 62 mm x 143 mm) (W x H x D) WEIGHT 9.5 oz (269 g) WARRANTY 3 years parts & labor Rate Input INPUTS LOW VOLTAGE MAG PICKUP (Isolated) MINIMUM INPUT FREQUENCY MAXIMUM INPUT FREQUENCY INPUT IMPEDANCE ACCURACY TEMPERATURE DRIFT MULTI-POINT LINEARIZATION LOW-FLOW CUTOFF Field selectable: Pulse or square wave 0-5 V, 0-12 V, or khz; TTL; open collector 4.7 kω pull-up to 5 30 khz; NPN or PNP transistor, switch contact 4.7 kω pull-up to 5 40 Hz. Sensitivity: 40 mvp-p to 8Vp-p Hz Minimum frequency is dependent on high gate setting. 30,000 Hz Pulse input: Greater than khz. Open collector/switch input: 4.7 kω pull-up to 5 V. ±0.03% of calibrated span ±1 count Rate display is not affected by changes in temperature. 2 to 32 points (0 disables cutoff function) 9

10 DECIMAL POINT CALIBRATION K-FACTOR CALIBRATION RANGE FILTER TIME BASE GATE Rate/Totalizer Up to five decimal places or none: d.ddddd, d.dddd, d.ddd, d.dd, d.d, or dddddd May be calibrated using K-factor, internal calibration, or by applying an external calibration signal. Field programmable K-factor converts input pulses to rate in engineering units. May be programmed from to 999,999 pulses/unit. Input 1 signal may be set anywhere in the range of the meter; input 2 signal may be set anywhere above or below input 1 setting. Minimum input span between any two inputs is 10 Hz. An Error message will appear if the input 1 and input 2 signals are too close together. Programmable contact de-bounce filter: 40 to 999 Hz maximum input frequency allowed with low speed filter. Second, minute, hour, or day Low gate: seconds High gate: seconds DISPLAY ASSIGNMENT RATE DISPLAY INDICATION TOTAL DISPLAY & TOTAL OVERFLOW ALTERNATING DISPLAY TOTAL DECIMAL POINT TOTALIZER TOTALIZER ROLLOVER The main (Big) and small (Little) displays may be assigned to rate, total, grand total, alternate R & T, units, and set point to , lead zero blanking. R LED illuminates while displaying rate or frequency. 0 to 999,999; automatic lead zero blanking. T LED is illuminated while displaying total or grand total. Up to 999,999,999 with total-overflow feature. of is displayed to the left of total overflow and LED is illuminated. Either display may be programmed to alternate between rate and total or rate and grand total every 10 seconds. Up to five decimal places or none: d.ddddd, d.dddd, d.ddd, d.dd, d.d, or dddddd Total decimal point is independent of rate decimal point. 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. Totalizer rolls over when display exceeds 999,999,999. Relay status reflects display. 10

11 TOTALIZER Up to eight, user selectable under setup menu. Any set PRESETS point can be assigned to total and may be programmed anywhere in the range of the meter for total alarm indication. PROGRAMMA- BLE DELAY ON RELEASE TOTAL RESET TOTAL RESET PASSWORD NON- RESETTABLE TOTAL Relays 0.1 and seconds; applied to the first relay assigned to total or grand total. If the meter is programmed to reset total to zero automatically when the preset is reached, then a delay will occur before the total is reset. Via front panel button, external contact closure on digital inputs, automatically via user selectable preset value and time delay, or through serial communications. Total and grand total passwords may be entered to prevent resetting the total or grand total from the front panel. The grand total can be programmed as a non-resettable total by entering the password ! Caution! Once the Grand Total has been programmed as non-resettable the feature cannot be disabled. RATING 2 or 4 SPDT (Form C) internal and/or 4 SPST (Form A) external; rated 3 30 VDC and 125/250 VAC resistive load; 1/14 125/250 VAC for inductive loads NOISE SUPPRESSION RELAY ASSIGNMENT DEADBAND HIGH OR LOW ALARM RELAY OPERATION Noise suppression is recommended for each relay contact switching inductive loads; see page 24 for details. Relays may be assigned to rate, total, or grand total % of span, user programmable User may program any alarm for high or low trip point. Unused alarm LEDs and relays may be disabled (turn off). Automatic (non-latching) Latching (requires manual acknowledge) Sampling (based on time) Pump alternation control (2 to 8 relays) Off (disable unused relays) Manual control mode 11

12 RELAY RESET TIME DELAY FAIL-SAFE OPERATION AUTO INITIALIZATION User selectable via front panel buttons, digital inputs, or PC 1. Automatic reset only (non-latching), when the input passes the reset point or total is reset to zero. 2. Automatic + manual reset at any time (non-latching) 3. Manual reset only, at any time (latching) 4. Manual reset only after alarm condition has cleared (L) Note: Front panel button or digital input may be assigned to acknowledge relays programmed for manual reset. 0 to seconds, on & off relay time delays Programmable and independent for each relay. 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. When power is applied to the meter, relays will reflect the state of the input to the meter. Isolated 4-20 ma Transmitter Output OUTPUT SOURCE Rate/process, total, grand total, max, min, set points 1-8, or manual control mode SCALING RANGE to ma for any display range. CALIBRATION Factory calibrated: to = 4-20 ma output ANALOG OUT PROGRAMMING ACCURACY TEMPERATURE DRIFT ISOLATED TRANSMITTER POWER SUPPLY EXTERNAL LOOP POWER SUPPLY OUTPUT LOOP RESISTANCE ma maximum for all parameters: Overrange, underrange, max, min, and break ± 0.1% FS ± ma 0.005% of calibrated span/ C from 0 to 65 C ambient, 0.01% of calibrated span/ C from -40 to 0 C ambient Note: Analog output drift is separate from input drift. Terminals I+ & R: 24 VDC ± 40 ma maximum; may be used to power the 4-20 ma output or other devices. Refer to Figure 6 on page 20 and Figure 14 on page VDC maximum Power supply Minimum Maximum 24 VDC 10 Ω 700 Ω 35 VDC (external) 100 Ω 1200 Ω 12

13 Serial Communications METER ADDRESS BAUD RATE TRANSMIT TIME DELAY DATA PARITY TURN AROUND DELAY ,200 bps Programmable between 0 and 199 ms or transmitter always on for RS-422 communication 8 bit (1 start bit, 1 stop bit) None Less than 2 ms (fixed) Note: Refer to the PDC Serial Communication Protocol manual located at for details. PDA1044 Digital Input & Output Expansion Module CHANNELS 4 digital inputs & 4 digital outputs per module SYSTEM Up to 2 modules for a total of 8 inputs & 8 outputs DIGITAL INPUT 3 to 5 VDC LOGIC HIGH DIGITAL INPUT 0 to 1.25 VDC LOGIC LOW DIGITAL OUTPUT 4.75 to 5 VDC LOGIC HIGH DIGITAL OUTPUT 0 to 0.4 VDC LOGIC LOW SOURCE 10 ma maximum output current CURRENT SINK 1.5 ma minimum input current CURRENT +5 V To be used as pull-up for digital inputs only TERMINAL Connect normally open pushbuttons across +5 V & DI

14 COMPLIANCE INFORMATION Safety UL & c-ul LISTED UL FILE NUMBER FRONT PANEL LOW VOLTAGE DIRECTIVE USA & Canada UL 508 Industrial Control Equipment E UL Type 4X, NEMA 4X, IP65; panel gasket provided EN :2001 Safety requirements for measurement, control, and laboratory use Electromagnetic Compatibility EMISSIONS Radiated Emissions AC Mains Conducted Emissions EN 55022:1998/A1:2000/A2:2003 Class A ITE emissions requirements Class A Class A IMMUNITY EN :2001 EMC heavy industrial generic immunity standard RFI - Amplitude MHz 10 V/m 80% AM (1 khz) Modulated Electrical Fast ±2kV AC mains, ±1kV other Transients Electrostatic ±4kV contact, ±8kV air Discharge RFI - Conducted 10V, MHz, 1kHz 80% AM AC Surge ±2kV Common, ±1kV Differential Surge 1KV (CM) Power-Frequency 3 A/m 70%V for 0.5 period Magnetic Field Voltage Dips 40%V for 5 & 50 periods Voltage <5%V for 250 periods Interruptions 14

15 Note: Testing was conducted on PD6300 meters installed through the covers of grounded metal enclosures with cable shields grounded at the point of entry representing installations designed to optimize EMC performance. Declaration of Conformity available at SAFETY INFORMATION! CAUTION: Read complete instructions prior to installation and operation of the meter. WARNING: Risk of electric shock or personal injury. Warning! Hazardous voltages exist within enclosure. Installation and service should be performed only by trained service personnel. 15

16 INSTALLATION There is no need to remove the meter from its case to complete the installation, wiring, and setup of the meter for most applications. Instructions are provided for 12 VDC meter power and for 5 or 10 V transmitter power applications, see page 18. 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 assistance. Panel Mounting Instructions Prepare a standard 1/8 DIN panel cutout 3.622" x 1.772" (92 mm x 45 mm). Refer to Figure 1 for more details. Clearance: allow at least 6.0" (152 mm) behind the panel for wiring. Panel thickness: 0.04" " (1.0 mm mm). Recommended minimum panel thickness to maintain Type 4X rating: 0.06" (1.5 mm) steel panel, 0.16" (4.1 mm) plastic panel. Remove the two mounting brackets provided with the meter (back-off the two screws so that there is ¼" (6.4 mm) or less through the bracket. Slide the bracket toward the front of the case and remove). Insert meter 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 meter is snug to the panel along its short side. DO NOT OVER TIGHTEN, as the rear of the panel may be damaged. A 3.622" (92mm) Gasket Panel Removable Connectors 1.772" B (45mm) Square Corners to 0.060" (1.5mm) Max Radius Panel Cutout to DIN Tolerances: A: (+0.8mm) (-0.0mm) B: (+0.6mm) (-0.0mm) Mounting Bracket Mounting Screw Figure 1: 1/8 DIN Panel Cutout and Mounting 16

17 Mounting Dimensions 1.76" (45 mm) 2.45" (62 mm) 0.59" (15 mm) 4.77" (121 mm) 5.05" (128 mm) Figure 2: Meter Dimensions - Side View 4.17" (106 mm) 3.61" (92 mm) 4.68" (119 mm) Figure 3: Meter Dimensions - Top View 17

18 Configuration for 12 or 24 VDC Power Option Warning! Do not exceed voltage rating of the selected configuration. Meters equipped with the 12/24 VDC power option are shipped from the factory ready to operate from 24 VDC. To configure the meter for 12 VDC power: 1. Remove all the connectors. 2. Unscrew the back cover. 3. Slide the back cover about 1 inch. 4. Configure the J9 jumper, located behind the power connector, for 12 V as shown below. M-LINK 24 VDC 12 VDC POWER + _ MAIN BOARD J9 J9 CONFIGURATION 12 V 24 V Factory Default Figure 4: Jumper Configuration for 12/24 VDC Power 18

19 Transmitter Supply Voltage Selection (P+, P-) All meters, including models equipped with the 12/24 VDC power option, are shipped from the factory configured to provide 24 VDC power for the transmitter or sensor. If the transmitter requires 5 or 10 VDC excitation, the internal jumper J4 must be configured accordingly. To access the voltage selection jumper: 1. Remove all the connectors. 2. Unscrew the back cover. 3. Slide the back cover about 1 inch. 4. Configure the J4 jumper, located behind the input signal connector, for the desired excitation voltage as shown. J4 CONFIGURATION MAIN BOARD Factory Default 5 V 10 V 24 V J4 INPUT SIGNAL COM S+ S- P- P+ Figure 5: Transmitter Supply Voltage Selection Connections All connections are made to removable screw terminal connectors located at the rear of the meter.! Caution! Use copper wire with 60 C or 60/75 C insulation for all line voltage connections. Observe all safety regulations. Electrical wiring should be performed in accordance with all applicable national, state, and local codes to prevent damage to the meter and ensure personnel safety. 19

20 Connectors Labeling The connectors label, affixed to the meter, shows the location of all connectors available with requested configuration. Warning! Do not connect any equipment other than Precision Digital s expansion modules, cables, or meters to the RJ45 M-LINK connector. Otherwise damage will occur to the equipment and the meter. Figure 6: Connector Labeling for Fully Loaded PD6300 Power Connections Power connections are made to a two-terminal connector labeled POWER on Figure 6. The meter will operate regardless of DC polarity connection. The + and - symbols are only a suggested wiring convention. POWER + - AC or DC POWER Required External Fuse: 5 A max, 250 V Slow Blow Figure 7: Power Connections 20

21 Signal Connections Signal connections are made to a five-terminal connector labeled SIGNAL on Figure 6. The COM (common) terminal is the return for the input signals. The following figures show examples of signal connections. Setup and programming is performed through the front panel buttons. INPUT SIGNAL P+ P- S- S+ COM V mv PNP NPN Flowmeter (Pulse Output) LEVEL TYPE Figure 8: Flowmeter Powered by Internal Power Supply + - External Power Supply INPUT SIGNAL P+ P- S- S+ COM V mv PNP NPN Flowmeter (Pulse Output) LEVEL TYPE Figure 9: Flowmeter Powered by External Supply INPUT SIGNAL P+ P- S- S+ COM V mv PNP NPN LEVEL TYPE Flowmeter (Magnetic Pickup Coil) Figure 10: Self-Powered Magnetic Pickup Coil Flowmeter 21

22 INPUT SIGNAL P+ P- S- S+ COM V 4.7 k-ohm Internal pull-up V mv PNP NPN NPN LEVEL TYPE SENSOR Figure 11: NPN open Collector Input INPUT SIGNAL P+ P- S- S+ COM 4.7 k-ohm Internal pull-down V mv PNP NPN PNP LEVEL TYPE SENSOR Figure 12: PNP Sensor Powered by Internal Supply INPUT SIGNAL P+ P- S- S+ COM V 4.7 k-ohm Internal pull-up V mv PNP NPN SWITCH INPUT LEVEL TYPE Figure 13: Switch Input Connections Serial Communications Serial communications connection is made to an RJ45 connector labeled M-LINK on Figure 6. Use PDA1232 for RS-232 interfacing or the PDA1485 for RS-422/485 interfacing. The same port is used for interfacing with all expansion modules (e.g. external relays, digital I/O). 22

23 Use the PDA1200 meter copy cable for meter-to-meter interfacing for cloning purposes (i.e. copying settings from one meter to other meters). Relay Connections Relay connections are made to two six-terminal connectors labeled RELAY1 RELAY4 on Figure 6. Each relay s C terminal is common only to the normally open (NO) and normally closed (NC) contacts of the corresponding relay. The relays C terminals should not be confused with the COM (common) terminal of the INPUT SIGNAL connector. RELAY4 RELAY RELAY2 RELAY NO NC C NO NC C NO NC C NO NC C Figure 11: Relay Connections 23

24 Switching Inductive Loads The use of suppressors (snubbers) is strongly recommended when switching inductive loads to prevent disrupting the microprocessor s operation. The suppressors also prolong the life of the relay contacts. Suppression can be obtained with resistor-capacitor (RC) networks assembled by the user or purchased as complete assemblies. Refer to the following circuits for RC network assembly and installation: C R C R Figure 12: AC and DC Loads Protection Choose R and C as follows: R: 0.5 to 1 Ω for each volt across the contacts C: 0.5 to 1 µf for each 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. Use a diode with a reverse breakdown voltage two to three times the circuit voltage and forward current at least as large as the load current. Figure 13: Low Voltage DC Loads Protection RC Networks Available from Precision Digital RC networks are available from Precision Digital and should be applied to each relay contact switching an inductive load. Part number: PDX

25 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 may be powered internally or from an external power supply. 24 V 24 V RELAY MA OUT I- I+ R RELAY MA OUT I- I+ R ma Input Remote Display, Chart Recorder, Etc ma Input Meter VDC Power Supply Figure 14: 4-20 ma Output Connections Analog Output Transmitter Power Supply The internal 24 VDC power supply powering the analog output may be used to power other devices, if the analog output is not used. The I+ terminal is the +24 V and the R terminal is the return. This power supply is capable of sourcing up to 40 ma. 25

26 External Relay & Digital I/O Connections The relay and digital I/O expansion modules PDA1004 & PDA1044 are connected to the meter using the CAT5 cable provided with each module. The two RJ45 connectors on the expansion modules are identical and interchangeable; they are used to connect additional modules to the system. Note: The jumper located between the RJ45 connectors of the PDA1044 must be removed on the second digital I/O module in order for the system to recognize it as module #2. Do not connect or disconnect the expansion modules with the power on! More detailed instructions are provided with each optional expansion Warning! module. Figure 15: Expansion Modules & DIN Rail Mounting Kit RLY5 RLY6 RLY7 RLY NO C NO C NO C NO C Figure 16: External Relays Module Connections I1 I2 I3 I4 O1 O2 O3 O4 G 5 VDC DI 1-4 DO 1-4 GND Figure 17: Digital I/O Module Connections 26

27 SETUP AND PROGRAMMING The meter has been factory calibrated to read input frequencies in Hz (pulses/sec). The calibration equipment is certified to NIST standards. Use the K-Factor menu to match the rate/totalizer with a flowmeter s k-factor (pulse/unit of measure). Or use the Scale menu to scale the pulse input (pulse/sec) without a signal source. Or use Cal menu to calibrate the rate/totalizer using a signal source. Overview There are two switches, located to the right of the input connector, which must be configured according to the input level and type. Jumper J4 located inside the meter, behind the input signal connector, is used to select the excitation voltage (24 V*, 10 V or 5 V) which is supplied to the P+ and P- wiring terminals. Setup and programming is done through the front panel buttons. After power and input signal connections have been completed and verified, apply power to the meter. *Default setting 27

28 Front Panel Buttons and Status LED Indicators Button Symbol Description LED Status Menu 1-8 Alarm 1 8 indicator Right arrow/f1 R Rate indicator Up arrow/f2 T Total indicator Enter/F3 Total overflow indicator 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 the Up arrow button to scroll through the menus, decimal point, or to increment the value of a digit. Press the Enter button to access a menu or to accept a setting. Press and hold the Menu button for three seconds to access the advanced features of the meter. 28

29 Display Functions and Messages The meter displays various functions and messages during setup, programming, and operation. The following table shows the main menu functions and messages in the order they appear in the menu. Display Parameter Action/Setting Description reset Reset Press Enter to access the Reset menu Rst t Reset total Press Enter to reset total Rst Gt Reset Press Enter to reset grand total grand total Rst Hi Reset high Press Enter to reset max display Rst Lo Reset low Press Enter to reset min display Rst HL Reset Press Enter to reset max & min displays high & low Contrl Control Enter Control menu Auto Automatic Press Enter to set meter for automatic operation nman Manual Press Enter to manually control relays or analog output operation setup Setup Enter Setup menu Input Input Enter Input selection menu Total Total Enable or disable totalizer features Dec pt Decimal point Set decimal point for rate, total, grand total dsplay Display Enter the Display menu big Big display Press Enter to assign the Main display parameter (default: PV or rate) Little Little display Press Enter to assign the small display parameter (default: total) d-inty Display Set display intensity level from 1 to 8 intensity RELaY Relay Enter the Relay menu Assign Assignment Assign relays to rate, total, or grand total Asign1 Assign 1 Relay 1 assignment rate Rate Assign relay to rate 29

30 Display Parameter Action/Setting Description total Total Assign relay to total G total Grand total Assign relay to grand total RLY 1 Relay 1 Relay 1 setup Act 1 Action 1 Set relay 1 action Auto Automatic Set relay for automatic reset 30 A-nman Auto-manual Set relay for automatic & manual reset any time LatCH Latching Set relay for latching operation (relays assigned to rate) Lt-CLr Latchingcleared Set relay for latching operation with manual reset only after alarm condition has cleared (relays assigned to rate) Altern Alternate Set relay for pump alternation control (relays assigned to rate) Sampl Sampling Set relay for sampling operation OFF Off Disable relay and front panel status LED Set 1 Set 1 Program set point 1 RSt 1 Reset 1 Program reset point 1 RLY 2 Relay 2 Relays 2-8 setup Note: Relays 5-8 are shown, only if expansion relay module is installed. FaiLSF Fail-safe Enter Fail-safe menu FLS 1 Fail-safe 1 Set relay 1 fail-safe operation on On Enable fail-safe operation off Fail-safe off Disable fail-safe operation DeLAY Delay Enter relay Time Delay menu DLY 1 Delay 1 Enter relay 1 time delay setup On 1 On Set relay 1 On time delay OFF 1 Off Set relay 1 Off time delay Aout Analog output Enter the Analog output scaling menu Dis 1 Display 1 Program display 1 value Out 1 Output 1 Program output 1 value (e.g ma)

31 Display Parameter Action/Setting Description Dis 2 Display 2 Program display 2 value Out 2 Output 2 Program output 2 value (e.g ma) prog Program Enter the Program menu factor K-factor Scaling Programs unit to convert input pulse to rate in engineering units scale Scale Enter the Scale menu Cal Calibrate Enter the Calibrate menu Inp 1 Input 1 Calibrate input 1 signal or program input 1 value Dis 1 Display 1 Program display 1 value Inp 2 Input 2 Calibrate input 2 signal or program input 2 value (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 Program total time base base T CF Total conversion Program total conversion factor factor T rst Total reset Program total reset mode: auto or manual GT tb Grand total Program grand total time base time base GT CF Grand total Program grand total conversion factor conversion factor GT rst Grand total reset Program grand total reset mode: auto or manual Auto Automatic Press Enter to set automatic total reset T dly Time delay Program time delay for total auto reset nman Manual Press Enter to reset total manually pass Password Enter the Password menu Pass 1 Password 1 Set or enter Password 1 Pass 2 Password 2 Set or enter Password 2 31

32 Display Parameter Action/Setting Description Pass 3 Password 3 Set or enter Password 3 Total Gtotal nonrst Total password Grand total password Nonresettable Set or enter password for manual reset Set or enter password for manual reset Non-resettable grand total set after entering for Gtotal password unloc Unlocked Program password to lock meter locd Locked Enter password to unlock meter Flashing display Overrange condition 32

33 Main Menu The main menu consists of the most commonly used functions: Reset, Control, Setup, Program, and Password. Press Menu button to enter Programming Mode then press the Up arrow button to scroll through the main menu. Run Mode Pulse reset Contrl setup prog Pass rst Hi reset auto Contrl Input setup FActor Prog Pass 1 Pass rst Lo reset nman Contrl dec pt setup scale Prog Pass 2 Pass rst HL reset dsplay setup Cal Prog Pass 3 Pass rst t reset relay setup t tb Prog total Pass rst Gt reset aout setup t CF Prog Gtotal Pass t rst Prog Grand Total Settings Press Menu, at any time, to exit and return to Run Mode. Changes made to settings prior 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. 33

34 Setting Numeric Values The numeric values are set using the Right and Up arrow buttons. Press the Right arrow to select the next digit and Up arrow to increment digit value. The digit being changed is displayed brighter than the rest. Press the Enter button, at any time, to accept a setting or Menu button to exit without saving changes dis dis dis 1 Next Setting Select Next Digit Increment Digit Value Accept Setting Note: The decimal point is set in the Setup-decimal point menu. 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). 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 analog output can be programmed independently for manual control. Selecting automatic control sets all relays and the analog output for automatic operation. Contrl auto contrl nman contrl A out nman rly 1 nman rly 8 nman A out off rly 1 on rly 8 34

35 Setting Up the Rate/Totalizer Meter (setup) The Setup menu is used to select: 1. Enable or disable totalizer features 2. Decimal point position 3. Display parameter and intensity 4. Relay operation 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. setup Press Enter to Accept Input setup total yes total no total dec pt setup rate dec pt total dec pt Gtotal dec pt Dsplay setup big dsplay Little dsplay d-inty dsplay relay setup Assign relay rly 1-8 relay Fail-Safe Delay Break Aout setup dis 1 Aout dis 1 Out 1 Aout 35

36 Setting the Input Signal (Input) There are two switches, located to the right of the input connector, which must be configured according to the input level and type. Jumper J4 located inside the meter, behind the input signal connector, is used to select the excitation voltage (24 V*, 10 V or 5 V) which is supplied to the P+ and P- wiring terminals. *Default setting Enter the Input menu to enable or disable the totalizer features. Setting the Totalizer Features (total) Enable or disable the totalizer features by selecting Yes or no after the input type has been set up. If the totalizer features are disabled, all the totalizer features and functions are hidden from the menus. Note: The totalizer continues working in the background. Setting the Decimal Point (dec pt) The decimal point may be set with up to five decimal places or with no decimal point at all. The rate, total, and grand total decimal points are independent. Pressing the Right arrow moves the decimal point one place to the right until no decimal point is displayed then it moves to the leftmost position. Setting the Display Parameter & Intensity (dsplay) The main display (Big) can be programmed to display: 1. Rate value 2. Total or grand total 3. Relay set points 4. Max & min values The small display (Little) can be programmed to display: 1. Rate value 2. Total or grand total 3. Relay set points 4. Max & min values 5. Engineering units or custom legends 6. Off (no display) Display Intensity: The meter has eight display intensity levels to give the best performance under various lighting conditions. Select intensity 8 for outdoor applications. 36

37 Character Set for Engineering Units Display (d unit) The small display can be programmed to show engineering units or custom legends using the following 7-segment character set AbCcdefg9HhIijkl noopqrstuvxyz-/=[]=mw! To create the letter m use the characters n followed by m to get nm. To create the letter w use the characters u followed by w to get uw. See the flow chart on the next page to access the display units menu. 37

38 Display Setup Menu 1. Press the Up arrow to change selection 2. Press Enter to accept setting 3. Press Menu to exit programming Dsplay setup big dsplay Little dsplay d-inty dsplay d rate big Rate Total Grand total Batch Int 1 d-inty d tot big dset 1 Little Int 2 d-inty d Gtot big d Hi Little Alternate rate & total/ grand total d Lo Little Int 8 d-inty Select Set Points 1-8 dset 1 big d HL Little Display max, min, max & min d off Little d unit Little d rate Little After setting up the input and 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 meter. 38

39 Programming the Rate/Totalizer (prog) It is very important that one reads the following information before programming the meter: The meter has been factory calibrated to read input frequencies in Hz (pulses/sec). The calibration equipment is certified to NIST standards. Use the K-Factor menu to match the rate/totalizer with a flowmeter s k-factor (pulse/unit of measure). Or use the Scale menu to scale the pulse input (pulse/sec) without a signal source. Or use Cal menu to calibrate the rate/totalizer using a signal source. The Program menu contains the following menus: 1. K-Factor calibration 2. Scale without a signal source 3. Calibrate with a calibrated signal source 4. Total time base & conversion factor 5. Grand total time base & conversion factor 6. Total reset mode for total & grand total The process inputs may be calibrated or scaled to any display value within the range of the meter. prog FActor scale Cal Prog Prog Prog Grand Total Settings t rst Prog t CF Prog t tb Prog Additional parameters, not needed for most applications, are programmed in the Advanced Features menu; see Advanced Features Menu, page 65. 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. Up to 32 linearization points may be selected. See page 69 for details. 39

40 Multi-Point Linearization Utility The meter can be programmed for multi-point scaling using the free PCbased Multi-Point Linearization Utility available at In order to program the meter using a computer, the meter must be connected using an RS-232 or RS-485 serial adapter, see ORDERING IN- FORMATION on page 7 for details. Scaling the Meter (SCALE) The pulse inputs can be scaled to display the process variable in engineering units. A signal source is not needed to scale the meter; simply program the inputs and corresponding display values. SCALE Prog Inp 1 SCALE Inp 2 SCALE Inp Inp 2 dis 1 SCALE dis 2 SCALE dis dis 2 For instructions on how to program numeric values see Setting Numeric Values, page

41 Error Message (Error) An error message indicates that the calibration or scaling process was not successful. After the error message is displayed, the meter reverts to input 2 during calibration or scaling and to input 1 during internal calibration, allowing the appropriate input signal to be applied or programmed. The error message might be caused by any of the following conditions: 1. Input signal is not connected to the proper terminals or it is connected backwards. 2. Wrong signal selection in Setup menu. 3. Minimum input span requirements not maintained. 4. Input 1 signal inadvertently applied to calibrate input 2. Minimum Input Span The minimum allowed input span is 10 Hz, which is the minimum difference between input 1 and input 2 signals required to complete the calibration or scaling of the meter. 41

42 Gate Function (Gate) The gate function is used for displaying slow pulse rates. Using the programmable gate, the meter is able to display pulse rates as slow as 0.1 pulse every 99.9 seconds. The gate function can also be used to obtain a steady display reading with a fluctuating input signal. The gate function (Gate) is the first option in the Advanced Features menu. There are two settings for the Gate, low gate (Lo G) and high gate (Hi G). Low Gate (Lo G) For most applications, low gate setting should be left at 1.0 second. Increase low gate setting to obtain a steadier rate display. The rate display will update in accordance with the low gate setting, for example if low gate is set at 10.0, the display will update every 10 seconds; changes in rate between updates will not be reflected until next display update. High Gate (Hi G) Set the high gate value to correspond to the highest expected pulse (lowest pulse rate). For instance if the meter must display a rate when there is 1 pulse coming into the meter every 10 seconds, set the high gate to 11.0 seconds. When the signal is removed from the meter, the display will show the last reading for 11 seconds; then it will read zero. 42

43 Contact De-Bounce Filter (FiLter) The filter function (FiLter) can be used for applications where the meter is set up to count pulses generated by switch contacts. The filter value can be set anywhere between 2 and 50, the higher the value, the greater the filtering. The filter function (Filter) is the second option in the Advanced Features menu. There are two settings, Hi SPd (high speed) and Lo SPd (low speed), press ENTER when Lo SPd is displayed to enable filter function. Program the filter value, so that there are no extra counts when contact closure is completed. Gate Settings Slow Pulse Rate Low Gate* (sec) High Gate (sec) Min Freq** (Hz) *Low gate setting is the rate display update and can be used to stabilize display reading with fluctuating signal. **Minimum frequency is dependent on high gate setting. Filter Settings Contact De-Bounce Filter Filter Setting Speed Setting Max Freq (Hz) 2 Lo SPd Lo SPd Lo SPd Lo SPd Lo SPd Lo SPd Lo SPd 40 N/A Hi SPd 30,000 43

44 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, liters, m 3, etc. Total & Grand Total Reset The totals can be programmed for manual or automatic reset. In the automatic reset mode, a programmable time delay is available to reset the total or grand total after the assigned preset is reached. t tb Prog sec t tb nmin t tb Hour t tb day t tb t CF Prog d.ddddd t CF t CF t rst Prog nman t rst Auto t rst t dly Auto To Grand Total Settings Non-Resettable Totalizer The total and grand total can be password-protected to prevent unauthorized resets. The grand total can be programmed as a non-resettable total, see page 63 for details. 44

45 Calibrating the Meter with External Source (Cal) To scale the meter without a signal source refer to Scaling the Meter (SCALE) page 40. The meter can be calibrated to display the process variable in engineering units by applying the appropriate input signal and following the calibration procedure. The use of a calibrated signal source is strongly recommended to calibrate the meter. CAL Prog Inp 1 CAL Inp 2 CAL The display flashes while sensing the inputs Inp 1 Inp 1 Inp 2 Inp 2 dis 1 Inp 1 dis 2 Inp dis dis 2 Warm up the meter for at least 15 minutes before performing calibration to ensure specified accuracy. 45

46 Setting the Relay Operation (relay) This menu is used to set up the operation of the relays. CAUTION! During setup, the relays do not follow the input and they will remain in the state found prior to entering the Relay menu. 1. Relay assignment a. Rate for low and high alarm b. Total c. Grand total 2. Relay action a. Automatic reset only (non-latching) b. Automatic + manual reset at any time (non-latching) c. Latching (manual reset only) d. Latching with Clear (manual reset only after alarm condition has cleared) e. Pump alternation control (automatic reset only) f. Sampling (the relay is activated for a user-specified time) g. Off (relay and status LED disabled) 3. Set and reset points 4. Fail-safe operation a. On (enabled) b. Off (disabled) 5. Time delay a. On delay ( seconds) b. Off delay ( seconds) 46

47 relay setup Assign relay rly 1 relay Failsf relay delay relay Asign1 Assign Act 1 rly 1 Fls 1 Failsf dly 1 delay set 1 rly 1 on Fls 1 on dly 1 Asign8 Assign rst 1 rly 1 off Fls 1 off dly 1 Note: The setup of relays 2-8 follows the same pattern shown here for relay 1. Relay Assignment (Assign) The relays can be assigned to any of the following parameters: 1. Rate for low or high alarm indication 2. Total for alarm indication 3. Grand total for alarm indication Assign relay Asign1 Assign rate Asign1 total Asign1 Gtotal Asign1 47

48 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-latching) 2. Automatic + manual reset at any time (non-latching) 3. Latching (manual reset only, at any time) 4. Latching with Clear (manual reset only after alarm condition has cleared) 5. Pump alternation control (automatic reset only) 6. Sampling (the relay is activated for a user-specified time) 7. Off (relay and status LED disabled) The following graphic shows relay 1 action setup; relay 2-8 are set up in a similar fashion. From Relay 1 Menu Act 1 rly 1 Auto Act 1 A-nmAn Act 1 LatcH Act 1 Lt-Clr Act 1 Altern Act 1 Sanmpl Act 1 OFF Act 1 48

49 Programming Set and Reset Points High alarm indication: program set point above reset point. Low alarm indication: 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. set 1 rly 1 Program Set Point rst 1 rly 1 Program Reset Point Setting Fail-Safe Operation In fail-safe mode of operation, the relay coil is energized when the process variable is within safe limits and the relay coil is de-energized when the alarm condition exists. The fail-safe operation is set independently for each relay. Select on to enable or select off to disable fail-safe operation. Programming Time Delay The On and Off time delays may be programmed for each relay between 0 and 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. 49

50 Relay and Alarm Operation Diagrams The following graphs illustrate the operation of the relays, status LEDs, and ACK button. High Alarm Operation (Set > Reset) Set Input Reset Relay LED de-energized off energized on Automatic (non-latching) Relay LED ACK pressed Automatic or Manual (non-latching) Relay LED ACK pressed Manual (latching) Relay LED ACK pressed Manual only after passing below Reset (latching with clear) 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. 50

51 Low Alarm Operation (Set < Reset) Input Reset Set Relay LED energized on de-energized off Automatic (non-latching) Relay LED ACK pressed Automatic or Manual (non-latching) Relay LED ACK pressed Manual (latching) Relay LED ACK pressed Manual only after passing above Reset (latching with clear) For Manual reset mode, ACK can be pressed anytime to turn "off" relay. For relay to turn back on, signal must go above set point and then go below it. 51

52 High Alarm with Fail-Safe Operation (Set > Reset) Input Set Reset Relay LED energized off de-energized on Automatic (non-latching) Relay LED ACK pressed Automatic or Manual (non-latching) Relay LED ACK pressed Manual (latching) Relay LED ACK pressed Manual only after passing below Reset (latching with clear) Note: Relay coil is energized in non-alarm condition. In case of power failure, relay will go to alarm state. 52

53 Low Alarm with Fail-Safe Operation (Set < Reset) Input Reset Set Relay LED de-energized on energized off Automatic (non-latching) Relay LED ACK pressed Automatic or Manual (non-latching) Relay LED ACK pressed Manual (latching) Relay LED ACK pressed Manual only after passing above Reset (latching with clear) Note: Relay coil is energized in non-alarm condition. In case of power failure, relay will go to alarm state. 53

54 Relay2 Set Relay1 Set Relay1 & Relay2 Reset Pump 1 Pump 2 Relay2 Set Relay1 Set Relay1 Reset Relay2 Reset Pump 1 Pump 2 Relay2 Set Relay1 Set Relay2 Reset Relay1 Reset Pump 1 Pump 2 Input de-energized energized Input de-energized energized Input de-energized energized Pump Alternation Control Operation LEDs indicate the relay status 54

55 Rate Relay Sampling Operation Input Set Reset Sample Time Sample Time Sample Time Relay LED 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 seconds. Total Relay Sampling Operation Total Preset = Sample Time Sample Time Sample Time Relay LED When the total reaches the preset, the relay trips and the sample time starts. After the sample time has elapsed, the relay resets. The cycle repeats every time the preset value is added to the total. 55

56 Time Delay Operation The following graphs show the operation of the time delay function. Set Input Reset Relay <Tdelay <Tdelay >=Tdelay LED* On Time Delay Input Set Reset <Tdelay <Tdelay >=Tdelay Relay LED* Off Time Delay 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 On time delay timer resets and the relay does not change state. The same principle applies to the Off time delay. * Note: If Automatic or Manual (A-nmAn) reset mode is selected, the LED follows the reset point and not the relay state when the relay is acknowledged. 56

57 Relay Operation Details Overview The relay capabilities of the meter expand its usefulness beyond simple indication to provide users with alarm and control functions. These capabilities include front panel alarm status LEDs as well as either 2 or 4 optional internal relays and/or 4 external relays expansion module. Typical applications include high or low temperature, level, pressure or flow alarms, control applications such as simple on/off pump control, and pump alternation control for up to 8 pumps. There are four basic ways the relays can be used: 1. High or Low Alarms with Latching or Non-Latching Relays 2. Simple On/Off Control with 100% Adjustable Deadband 3. Sampling (Based on Time) 4. Pump Alternation Control for up to 8 Pumps Relays Auto Initialization When power is applied to the meter, the front panel LEDs and alarm relays will reflect the state of the input to the meter. The following table indicates how the alarm LEDs and relays will react on power-up based on the set and reset points: Alarm # HI or LO Set Reset Power-Up Relay & Alarm Point Point Reading LED 1 HI Off 2 LO On 3 LO Off 4 HI On Fail-Safe Operation The following table indicates how the relays behave based on the failsafe selection for each relay: Fail-Safe Non-Alarm State Alarm State Selection NO NC NO NC Power Failure Off Open Closed Closed Open Relays go to On Closed Open Open Closed non-alarm state Relays go to alarm state Note: NO = Normally Open, NC = Normally Closed. This refers to the condition of the relay contacts when the power to the meter is off. 57

58 Front Panel LEDs The LEDs on the front panel provide status indication for the following: LED Status LED Status 1 Alarm 1 5 Alarm 5 2 Alarm 2 6 Alarm 6 3 Alarm 3 7 Alarm 7 4 Alarm 4 8 Alarm 8 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 reaches a set point for a high or low alarm, the corresponding alarm LED will turn on. When the display returns to the reset point the LED will go off. The front panel LEDs respond differently for latching and non-latching relays. For non-latching relays, the LED is always off during normal condition and always on during alarm condition, regardless of the state of the relay (e.g. Relay acknowledged after alarm condition). For latching relays, the alarm LEDs reflect the status of the relays, regardless of the alarm condition. The following tables illustrate how the alarm LEDs function in relation to the relays and the acknowledge button (Default: F3 key assigned to ACK): Latching and Non-Latching Relay Operation The relays can be set up for latching (manual reset) or non-latching (automatic reset) operation. Relay terminology for following tables Terminology Relay Condition On Alarm (Tripped) Off Normal (Reset) Ack Acknowledged The On and Off terminology does not refer to the status of the relay s coil, which depends on the fail-safe mode selected. Warning! In latching relay mode, latched relays will reset (unlatch) when power is cycled. 58

59 Non-Latching Relay (Auto) Automatic reset only Condition LED Relay Normal Off Off Alarm On On Ack (No effect) On On Normal Off Off In this application, the meter is set up for automatic reset (non-latching relay). Acknowledging the alarm while it is still present has no effect on either the LED or the relay. When the alarm finally goes away, the relay automatically resets and the LED also goes off. Non-Latching Relay (A-nman) Automatic + manual reset at any time Condition LED Relay Normal Off Off Alarm On On Normal Off Off Next Alarm On On Ack On Off Normal Off Off In this application, the meter is set up for automatic and manual reset at any time (non-latching relay). The LED and the relay automatically reset when the meter returns to the normal condition. The next time an alarm occurs, the operator acknowledges the alarm manually while the alarm condition still exists. This causes the relay to reset, but the LED stays on until the meter returns to the normal condition. Latching Relay (LatcH) Manual reset any time Condition LED Relay Normal Off Off Alarm On On Ack Off Off 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. 59

60 Latching Relay (Lt-Clr) Manual reset only after alarm condition has cleared Condition LED Relay Normal Off Off Alarm On On Ack (No effect) On On Normal On On Ack Off Off In this application, the meter is set up for manual reset only after the signal passes the reset point (alarm condition has cleared). Acknowledging the alarm while it is still present has no effect on either the LED or the relay. When the alarm is acknowledged after it returns to the normal state, the LED and the relay go off. Notice that the LED remains on, even after the meter returns to the normal condition. This is because, for latching relays, the alarm LED reflects the status of the relay, regardless of the alarm condition. Acknowledging Relays There are two ways to acknowledge relays programmed for manual reset: Via the programmable front panel function keys F1-F3 (Default: F3 assigned to ACK) Remotely via a normally open pushbutton wired across one of the digital inputs and the +5 V terminals on the digital I/O modules. When the ACK button or the assigned digital input is closed, all relays programmed for manual reset are acknowledged. PDA1044 Digital I/O Module I1 I2 I3 I4 O1 O2 O3 O4 G DI 1-4 ACK DO 1-4 GND Figure 18: Acknowledge Relays w/function Key or Digital Input 60

61 Pump Alternation Control Applications (Altern) For pump control applications where two or more similar pumps are used to control the level of a tank or a well, it is desirable to have all the pumps operate alternately. This prevents excessive wear and overheating of one pump over the lack of use of the other pumps. Up to 8 relays can be set up to alternate every time an on/off pump cycle is completed. The set points and reset points can be programmed, so that the first pump on is the first pump off. Scaling the 4-20 ma Analog Output (Aout) The 4-20 ma analog output can be scaled to provide a 4-20 ma signal for any display range selected. No equipment is needed to scale the analog output; simply program the display values to the corresponding ma output signal. The Analog Output menu is used to program the 4-20 ma output based on display values. Aout setup dis 1 Aout dis 2 Aout dis dis 2 Out 1 Aout Out 2 Aout Out Out 2 For instructions on how to program numeric values see Setting Numeric Values, page

62 Setting Up the Password (pass) The Password menu is used for programming three levels of security to prevent unauthorized changes to the programmed parameter settings and to program the non-resettable totalizer. Pass 1: Allows use of the F1 F3 function keys Pass 2: Allows use of the F1 F3 function keys and changing the set/reset points Pass 3: Restricts all programming and F1 F3 keys and Digital Inputs Total: Prevents 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 34. Pass 1 Pass Pass Pass 1 Locd Pass 1 Pass 2 Pass Run Mode Pass 3 Pass Total Pass Gtotal Pass Record the password for future reference. If appropriate, it may be recorded in the space provided. Model: Serial Number: Password 1: Password 2: Password 3: Total GTotal 62

63 Total Reset Password & Non-Resettable Total The total and the grand total can be password-protected to prevent unauthorized total resets. The grand total can be programmed as a non-resettable total by entering the password ! Caution! Once the Grand Total has been programmed as nonresettable the feature cannot be disabled. 63

64 Making Changes to a Password Protected Meter If the meter is password protected, the meter 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 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 new password is entered. Run Mode Pulse Locd Locd Enter Password unloc Locd reset Pass Enter Password unloc Pass 1 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 Run Mode. To try again, press Enter while the Locked message is displayed. Did you forget the password? The password may be disabled by entering a master password. If you are authorized to make changes, enter the master password to unlock the meter. 64

65 Advanced Features Menu To simplify the setup process, functions not needed for most applications are located in the Advanced Features menu. Press and hold the Menu button for three seconds to access the advanced features of the meter. Run Mode Pulse Press & hold Menu for 3 sec to access Advanced features GAtE Filter serial Select diag Copy user 65

66 Advanced Features Menu & Display Messages The following table shows the functions and messages of the Advanced Features menu in the order they appear in the menu. Display Parameter Action/Setting filter Filter Set the Contact De-bounce filter value serial Serial Set serial communication parameters addres Address Set meter address baud Baud rate Select baud rate Tr dly Transmit delay Set transmit delay for serial communication SelEct Select Enter the Select menu (function, cutoff, out) Functn Math Function Select linear, square root, programmable exponent, or round horizontal tank function Linear Linear Set meter for linear function and select number of linearization points No PtS Number of points Set meter for 2 to 32-point linearization Square Square root Set meter for square root extraction Prog E Programmable Set meter for programmable exponent and exponent enter exponent value rht Round horizontal tank Set meter for round horizontal tank volume calculation diamr Diameter Enter the tank s diameter in inches Length Length Enter the tank s length in inches CutofF Cutoff Set low-flow cutoff AoutPr Analog output Program analog output parameters programming Source Source Select source for the 4-20 ma output O-rang Overrange Program ma output for display overrange u-rang Underrange Program ma output for display underrange Break Loop Break Set relay condition if loop break detected Force Force Force analog output value for loop break Ignore Ignore Ignore loop break condition nmax Maximum Program maximum ma output allowed 66

67 Display Parameter Action/Setting nmin Minimum Program minimum ma output allowed Calib Calibrate Calibrate 4-20 ma output (internal reference source used for scaling the output) 4 nma 4 ma output Enter ma output value read by milliamp meter with at least ma resolution 20 nma 20 ma output Enter ma output value read by milliamp meter with at least ma resolution user User I/O Assign function keys and digital I/O F1 F1 function key Assign F1 function key F2 F2 function key Assign F2 function key F3 F3 function key Assign F3 function key LL I 1 LL O 1 Logic level input 1 Logic level output 1 Assign logic level input 1 8, if expansion modules are connected Assign logic level output 1 8, if expansion modules are connected Copy Copy Enter copy function send Send Send meter settings to another meter done Done Copy function completed Diag Diagnostics Display parameter settings Input Input Input selection Functn Function Function selected SCALE Scale Scaling parameter Cutoff Cutoff Cutoff value Dsplay Display Display assignments RELAY Relays Relay settings Aout Analog output Analog output scaling Aoutpr Analog output Analog output programming programming SEriaL Serial Serial communication settings LED t LED test Test all LEDs Info Information Display software and S/N information 67

68 Serial Communications (serial) The meter is equipped with serial communications capability as a standard feature using PDC Serial Communication Protocol. To communicate with a computer or other data terminal equipment, an RS-232 or RS-422/485 adapter option is required; see Ordering Information on page 7 for details. Warning! Do not connect any equipment other than Precision Digital s expansion modules, cables, or meters to the RJ45 M-LINK connector. Otherwise damage will occur to the equipment and the meter. Note: More detailed instructions are provided with each optional serial communications adapter. serial Address Serial baud Serial tr dly Serial When using more than one meter in a multi-drop mode, each meter must be provided with its own unique address. The address may be programmed from 1 to 247. The transmit delay may be set between 0 and 199 ms. The PD6300 can also be connected to another PD6300 allowing the user to copy all the settings from one meter to another, using the Copy function. 68

69 Select Menu (SElEct) The Select menu is used to select the math function applied to the input (linear), low-flow cutoff, and analog output programming. The multi-point linearization is part of the linear function selection. select Functn Select Cutoff Select AoutPr Select Linear Functn Program cutoff value Source AoutPr Square Functn O-rang AoutPr Prog E Functn Underrange Max Min rht Functn Calib AoutPr Math Function Selection (Functn) The Function menu is used to select the math function applied to the input: linear, where the multi-point linearization is part of the linear function selection. Meters are set up at the factory for linear function with 2-point linearization. The linear function provides a display that is linear with respect to the input signal. 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 under the linear function. The multi-point linearization can be used to linearize the display for non-linear signals. Linear Functn no Pts Linear Program Number of Points scale Select 69

70 Square Root Linearization (Square) Note: Although this option may appear in the menu the functionality is not available in the PD6300 series products. Programmable Exponent Linearization (Prog E) Note: Although this option may appear in the menu the functionality is not available in the PD6300 series products. Round Horizontal Tank Linearization (rht) Note: Although this option may appear in the menu the functionality is not available in the PD6300 series products.! Caution! Attempting to program any of the three functions noted above may affect any multi-point linearization previously programmed. 70

71 Low-Flow Cutoff (CutofF) The low-flow cutoff feature allows the meter to be programmed so that the often-unsteady output from a differential pressure transmitter, at low flow rates, always displays zero on the meter. The cutoff value may be programmed from 0 to The meter will display zero below the cutoff value. Programming the cutoff value to zero disables the cutoff feature. Analog Output Programming (AoutPr) The Analog Output Programming menu is used to program the behavior of the 4-20 ma output. The following parameters and functions are programmed in this menu: 1. Source: Source for generating the 4-20 ma output (e.g. PV) 2. Overrange: Analog output value with display in overrange condition 3. Underrange: Analog output value with display in underrange condition 4. Max: Maximum analog output value allowed regardless of input 5. Min: Minimum analog output value allowed regardless of input 6. Calibrate: Calibrate the internal 4-20 ma source reference used to scale the 4-20 ma output Analog Output Source The source for generating the 4-20 ma output may be assigned to the rate/process variable, total, grand total, maximum or minimum value reached by the rate/process, or one of the set points. Source AoutPr rate Source total Source gtotal Source Set Points 1-8 nmin Source nmax Source Analog Output Calibration To perform the analog output calibration it s 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. 71

72 Programmable Function Keys User Menu (user) The User menu allows the user to assign the front panel function keys F1, F2, F3 and up to eight digital inputs to access most of the menus or to activate functions immediately (e.g. Reset max & min). Up to eight digital outputs can be assigned to a number of actions and functions executed by the meter (e.g. Alarms, relay acknowledgement, etc.). user F1 user F2 user F3 user LL O 8 user LL O 1 user LL I 8 user LL I 1 user Function Keys & Digital I/O Available Settings Display Description Display Description AcH Acknowledge relays Big Hi Max on big display Reset Reset menu Big Lo Min on big display Rst t Reset total Big HL Max/min big display Rst Gt Reset grand total Little Little display menu Rst Hi Reset max Lit Hi Max on little display Rst Lo Reset min Lit Lo Min on little display Rst HL Reset max & min Lit HL Max/min little display relay Relay menu disabl Disable function key Set 1 Set point 1-8 nmenu Menu button Rly d Disable relay Right Right arrow button Rly E Enable relay up Up arrow button O Hold Relay output hold Enter Enter button Dsplay Display menu Alnm 1 Alarm 1 8 Big Big display menu 72

73 Meter Copy Function (Copy) The Copy function is used to copy (or clone) all the settings from one meter to other meters requiring exactly the same setup and programming (i.e. type of input, scaling, decimal point, filter, gate, etc.). Warning! Only the PDA1200 meter copy cable must be used for meter-to-meter interfacing. The PDA1200 is a special eight-conductor flat cable with two wires swapped. Using standard CAT5 or other cable will cause damage to both meters. PDA1200 Meter Copy Cable Figure 19: Meter Copy Connection Copy Function Requirements To successfully copy settings from one meter to another, both meters must have: 1. Same software version 2. Same baud rate setting See Determining Software Version, page 77 for instructions. 73