Precision Digital Corporation ProtEX-MAX PD8-6210 User manual

ProtEX-MAX PD8-6210 Explosion-Proof Batch Controller
Instruction Manual
PRECISION DIGITAL CORPORATION
233 South Street • Hopkinton MA 01748 USA
Tel [phone] • Fax [phone]
www.predig.com
•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: -40 to 60°C (-40 to 140°F)
•FM Approved as Explosion-Proof / Dust-Ignition-Proof / Flame-Proof
•CSA Certified as Explosion-Proof / Dust-Ignition-Proof / Flame-Proof
•ATEX and IECEx Certified as Flame-Proof
•Input Power Options: 85-265 VAC / 90-265 VDC or 12-24 VDC / 12-24 VAC
•Programmable Display, Function Keys & Digital Inputs
•Flanges for Wall or Pipe Mounting
•Explosion-Proof, IP68, NEMA 4X Die-Cast Aluminum Enclosure
•On-Board RS-485 Serial Communications
•Modbus RTU Communication Protocol Standard
•Password Protection
•Four 3/4" NPT Threaded Conduit Openings (Two Plugs Installed)
•3-Year Warranty
MeterView Pro
USB Install

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ProtEX-MAX PD8-6210 Explosion-Proof Analog Input Batch Controller
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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.
See Warranty Information and Terms &
Conditions on www.predig.com for complete
details.
•Read complete instructions prior to installation
and operation of the controller.
•Risk of electric shock or personal injury.
•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.
•Failure to follow installation guidelines could
result in death or serious injury. Make sure only
qualified personnel perform the installation.
•Never remove the controller cover in explosive
environments when the circuit is live.
•Cover must be fully engaged to meet
explosion-proof/dust-ignition-proof/flame-proof
requirements.
WARNING
Cancer and Reproductive Harm - www.P65Warnings.ca.gov
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.
See Warranty Information and Terms & Conditions
on www.predig.com for complete details.
Registered Trademarks
All trademarks mentioned in this document are
the property of their respective owners.
© 2022 Precision Digital Corporation.
All rights reserved.
FREE MeterView Pro
Programming Software
The controller can be powered from the USB connection. When
using the USB connection, DO NOT apply AC or DC power to
the controller.
The easiest and quickest way to program your
ProtEX-MAX batch controller is to use the FREE
MeterView Pro programming software. This software
is loaded into the controller and connects and installs
directly to your PC with a USB cable. We recommend
that the first thing you do after taking the controller out
of the box is connect the ProtEX-MAX to your PC with
the provided USB cable –do not use a different cable.
DO NOT apply AC or DC power to the controller while
your PC is connected to the controller as it will disrupt
the USB connection. You don’t even have to apply an
input signal.
MeterView Pro programming software is intuitive, and
most customers can get their controller programmed
as they like without even looking in the manual.
Watch MeterView Pro Software Video at
www.predig.com/meterviewpro
In addition to programming, the software may be used
to perform many useful tasks:
•Start, Pause, Stop the batch
•Change preset & pre-close settings
•Reset total & grand total
•Test the relays functionality
•Monitor the batch process
•Datalogging using your PC
•Generate & save program files for later use
Once your controller is programmed the way you want
it, you can wire it up for your application per the
instructions in this manual and install it. If you find that
you need to make adjustments to the programming
after the controller is installed, you can use the
programming buttons and the instructions in this
manual to do so.
•When using the USB connection, the controller
should only be connected to a computer when
both devices are in a non-hazardous area.

ProtEX-MAX PD8-6210 Explosion-Proof Analog Input Batch Controller
Instruction Manual
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Table of Contents
Introduction......................................................................................................... 7
Ordering Information.......................................................................................... 7
Key Features....................................................................................................... 9
Specifications................................................................................................... 16
General.......................................................................................................... 16
Batch Controller Rate/Totalizer Display..................................................... 17
Process Inputs ............................................................................................. 18
Relays............................................................................................................ 19
USB Connection........................................................................................... 19
Isolated 4-20 mA Transmitter Output ......................................................... 19
RS-485 Serial Communications .................................................................. 19
Modbus®RTU Serial Communications....................................................... 19
Digital Input (F4)........................................................................................... 20
Digital Inputs & Outputs .............................................................................. 20
MeterView Pro Software .............................................................................. 20
Compliance Information................................................................................... 21
Electromagnetic Compatibility.................................................................... 21
Product Ratings and Approvals.................................................................. 21
EU Declaration of Conformity.......................................................................... 22
Safety Information............................................................................................ 22
Installation......................................................................................................... 22
Unpacking..................................................................................................... 22
Mounting....................................................................................................... 23
Installation Overview ................................................................................... 25
MeterView Pro Software .............................................................................. 25
Transmitter Supply Voltage Selection (P+, P-) .......................................... 26
Connections ................................................................................................. 26
Required & Factory Wired Connection .................................................. 26
PROVUElectronics Module Layout............................................................. 27
USB Connection ........................................................................................ 27
Power Connections.................................................................................... 28
Signal Connections.................................................................................... 29
Relay Connections..................................................................................... 29
Interlock Relay Feature.............................................................................. 29
Switching Inductive Loads.......................................................................... 30
RS-485 Connections.................................................................................. 30
RS-485 Multi-Drop Connection.................................................................. 30
F4 Digital Input Connections...................................................................... 31
4-20 mA Output Connections..................................................................... 31
Analog Output Transmitter Power Supply.................................................. 32
Remote Programming................................................................................ 32
Setup and Programming.................................................................................. 33
Overview....................................................................................................... 33
LED Status Indicators.................................................................................. 33
Programming Buttons ................................................................................. 34
SafeTouch Buttons ...................................................................................... 34
Display Functions and Messages............................................................... 35
Main Menu..................................................................................................... 37
Setting Numeric Values............................................................................... 37
Setting Up the Batch Controller (setup)..................................................... 37
Setting the Input Signal (Input)................................................................. 38
Setting the Totalizer & Batch Control Features (total)............................. 38
Setting the Input Units or Custom Tags (units)........................................ 38
Setting the Decimal Point (dEc pt) ........................................................... 39
Programming the Batch Controller (prog).................................................. 39
Setting the Display Parameter & Intensity (dsplay) .................................. 42
Display Intensity (d-Inty).......................................................................... 42

ProtEX-MAX PD8-6210 Explosion-Proof Analog Input Batch Controller
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Setting the Relay Operation (relay)........................................................... 43
Relay Assignment (Assign)....................................................................... 44
Setting the Relay Action............................................................................. 45
Setting Batch Control Relays..................................................................... 45
Programming Alarm Set and Reset Points................................................. 45
Setting Fail-Safe Operation........................................................................ 45
Programming Time Delay .......................................................................... 45
Relay Action for Loss of 4-20 mA Input (Loop Break)................................ 45
Automatic Batch Control Operation............................................................ 46
Relay and Alarm Operation Diagrams........................................................ 47
High Alarm Operation (Set > Reset) .............................................................. 47
Low Alarm Operation (Set < Reset)........................................................... 47
High Alarm with Fail-Safe Operation (Set > Reset).................................... 47
Low Alarm with Fail-Safe Operation (Set < Reset)..................................... 47
Time Delay Operation................................................................................ 48
Total Relay Sampling Operation................................................................ 48
Relay Operation Details............................................................................... 49
Overview.................................................................................................... 49
Relays Initialization.................................................................................... 49
Fail-Safe Operation.................................................................................... 49
Front Panel LEDs....................................................................................... 49
Automatic Reset (Auto) ............................................................................. 49
Pump Alternation Control........................................................................... 49
Sample Relay Operation............................................................................ 50
Setting Up the Interlock Relay (Force On) Feature.................................... 50
Scaling the 4-20 mA Analog Output (Aout)................................................ 51
Reset Menu (reset)...................................................................................... 51
Manual Control Menu (Contrl) ................................................................... 51
Setting Up the Password (pass).................................................................. 52
Protecting or Locking the Controller........................................................... 52
Grand Total Reset Password & Non-Resettable Total............................... 52
Making Changes to a Password Protected Controller................................ 52
Disabling Password Protection .................................................................. 52
Controller Operation ........................................................................................ 53
Button Operation.......................................................................................... 53
SafeTouch Buttons ...................................................................................... 53
Default Batch Control Operation................................................................. 53
Batch Control Operation Example.............................................................. 54
Manual Batch Control .................................................................................. 55
Automatic Batch Control............................................................................. 56
Setup with MeterView Pro ........................................................................... 58
Operate with MeterView Pro........................................................................ 58
Advanced Setup & Programming.................................................................... 59
Advanced Features Menu............................................................................ 59
Advanced Features Menu & Display Messages......................................... 59
Function Keys Operation ........................................................................... 60
Digital Inputs Operation ............................................................................. 60
Advanced Setup and Calibration................................................................ 61
Maximum/Minimum Readings.................................................................... 61
Noise Filter (filter) ................................................................................. 61
Noise Filter Bypass (bypass)..................................................................... 61
Rounding Feature (round)......................................................................... 61
Modbus RTU Serial Communications (serial)......................................... 61
Select Menu (SElEct)................................................................................ 62
Programmable Function Keys User Menu (user)...................................... 64
Internal Source Calibration (ICAL)............................................................. 65
Troubleshooting............................................................................................... 66
Diagnostics Menu (diag)........................................................................... 66
Testing the Display LEDs........................................................................... 66
Determining Software Version ................................................................... 66
Reset Controller to Factory Defaults.......................................................... 66
Factory Defaults & User Settings............................................................... 67
Troubleshooting Tips................................................................................... 69

ProtEX-MAX PD8-6210 Explosion-Proof Analog Input Batch Controller
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Table of Figures
Figure 1. Enclosure Dimensions –Front View............................................... 23
Figure 2. Enclosure Dimensions –Side Cross Section View ....................... 23
Figure 3. Transmitter Supply Voltage Selection ............................................ 26
Figure 4. Integrated PROVURequired Connections ....................................... 26
Figure 5. PROVUElectronics Module Layout.................................................. 27
Figure 6. USB Connection ............................................................................... 27
Figure 11. Power Connections........................................................................ 28
Figure 12. Transmitter Powered by Internal Supply...................................... 29
Figure 13. Transmitter Powered by Ext. Supply or Self-Powered................ 29
Figure 14. Voltage Input Connections ............................................................ 29
Figure 15. Relay Connections ......................................................................... 29
Figure 28. Interlock Connection...................................................................... 29
Figure 16. AC and DC Loads Protection......................................................... 30
Figure 17. Low Voltage DC Loads Protection................................................ 30
Figure 15. RS-485 Diagnostic LEDs................................................................ 30
Figure 22. Three-Wire RS-485 Connection..................................................... 30
Figure 23. Digital Input and Output Connections .......................................... 31
Figure 24. F4 Digital Input Connections......................................................... 31
Figure 25. 4-20 mA Output Connections ........................................................ 31
Figure 26. Analog Output Supply Powering Other Devices.......................... 32

ProtEX-MAX PD8-6210 Explosion-Proof Analog Input Batch Controller
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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 die-cast aluminum, field-mountable,
NEMA 4X/IP68 rated enclosure 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.
Ordering Information
85-265 VAC Models
Model
Standard Features
PD8-6210-6H7
4 relays, 4-20 mA output,
5 Digital Inputs, 4 Digital Outputs,
RS-485 Communications
12-24 VDC Models
Model
Standard Features
PD8-6210-7H7
4 relays, 4-20 mA output,
5 Digital Inputs, 4 Digital Outputs,
RS-485 Communications
Accessories
Model
Description
PDA0001
3/4" M-NPT to F-M20 Reducer
PDA0002
3/4" M-NPT to 1/2" F-NPT Reducer
PDAPLUG75
3/4" Metal Conduit/Stopping Plug
PDA-SSTAG
Custom Stainless Steel Tag (see
website for convenient ordering form)
PDA6848
2" U-Bolt Kit Zinc Plated Steel
PDA6848-SS
2" U-Bolt Kit Stainless Steel
PDA7485-I
RS-232 to RS-485 isolated converter
PDA8485-I
USB to RS-485 isolated converter
SafeTouch Buttons
To make it possible to program and operate the
ProtEX-MAX in a hazardous area, the programming
buttons that are located behind the glass window can
be operated without removing the cover by using the
SafeTouch through-glass buttons. The operator puts
their finger on the glass over the button and the
button is actuated.
To learn more about SafeTouch buttons,
see this video:
predig.com/videos/Safetouch_Buttons

ProtEX-MAX PD8-6210 Explosion-Proof Analog Input Batch Controller
Instruction Manual
8
Helpful Videos
There are several videos that will help you get a
better understating of the features and functionality of
the ProtEX-MAX products. Since the ProtEX-MAX
meters have the same general features and
functionality of the ProVu meters, appropriate videos
for the ProVu controller are also included.
PROVUBatch Controllers
These provide simple batch control with features like
preclose relays and automatic overrun correction.
https://www.predig.com/videos/KN6Y6R0I1OE
PROVUFunction Keys Tutorial
Learn how the PROVU’s function keys increase the
utility of the PROVU.
https://www.predig.com/videos/WMBYKlavW-Q
Connect a PROVUto a PC Using
MeterView Pro
Learn how easy it is to use MeterView Pro software.
https://www.predig.com/videos/PC_Connect
MeterView Pro USB Programming
Software
Learn how easy it is to program a PROVUPD6000
process meter.
https://www.predig.com/videos/MVPro_SW
ProtEX-MAX Explosion-Proof Family
The ProtEX-MAX Series has been designed to offer
the functions and features of any ProVu in a great
looking explosion-proof housing.
https://www.predig.com/videos/ProtEXMAX_Overview
4-20 mA Connections
This Tech Tips video shows how to make connections
to power the transmitter with the ProVu’s
(ProtEX-MAX’s) 24 VDC power supply.
predig.com/videos/4-20_mA_Connections

ProtEX-MAX PD8-6210 Explosion-Proof Analog Input Batch Controller
Instruction Manual
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Key Features
Connections for PD8-6210-6H7 & PD8-6210-7H7
The Only Explosion-Proof Batch Controller You Will Ever Need
The ProtEX-MAXPD8-6210 explosion-proof batch
controllers are specifically designed for displaying
flow rate and total from flowmeters with analog
outputs.
The first thing you notice about the PD8-6210 is its
modern looking, rugged, die-cast aluminum housing
with convenient mounting flanges. Housed inside this
enclosure is a dual-line, 6-digit display that is usually
setup to show the current batch quantity and the
batch preset on the two lines. START, BATCH, and
STOP buttons (which can be operated remotely or
without removing the cover) come setup by default for
batch control operation. The START button starts the
batch. The BATCH button shows the preset value.
The STOP button pauses or stops the batch.
The PD8-6210 is approved as a complete product by
FM and CSA and also carries ATEX and IECEx
certification. One of the more convenient features of
the PD8-6210 is its through-glass SafeTouch buttons
which allow the controller to be operated without
removing its cover. Just put your finger on the glass
over the button to actuate it. The PD8-6210 can also
provide 5, 10, or 24 VDC to power the flowmeter.
A ProtEX-MAX batch controller can be programmed
for a wide variety of applications. Setup is easy for
single or multi-stage batching. Automatic overrun
correction keeps the batch size accurate, even over
time. The PD8-6210 can display the number of
batches that have been run and the total amount of
product that has been batched. These features and
capabilities can easily be programmed without
removing the cover using SafeTouch buttons in a
hazardous area or with free MeterView Pro PC-based
software in a safe area.

ProtEX-MAX PD8-6210 Explosion-Proof Analog Input Batch Controller
Instruction Manual
10
Easy Programming Methods
The ProtEX-MAX can be programmed in a hazardous
area with the through-glass SafeTouch buttons
without removing the cover, in a safe area with the
front panel push buttons with the cover removed, or in
a safe area with free, PC-based MeterView Pro
software. MeterView Pro is resident on the
ProtEX-MAX and is accessed by a provided USB
cable, so it is by far the easiest way to program the
ProtEX-MAX. The ProtEX-MAX can be calibrated
either by applying a known signal or scaled by
entering a desired value with the front panel buttons
or MeterView Pro software. Most customers will use
the scaling method because it is simpler and does not
require a calibrated signal source. Selecting the input
to be current or voltage is done with the front panel
buttons or MeterView Pro software. Once programming
is completed it can be locked with a password.
The ProtEX-MAX comes preloaded with free
MeterView Pro programming software that connects
and installs directly to your PC with a standard USB
cable, also provided free with each instrument. This
eliminates the need to insert CDs, install drivers, or
download software from the internet. When you
connect your ProtEX-MAX to your PC, MeterView Pro
is downloaded to your PC, the software automatically
selects the model you are programming, and you’re
ready to start programming immediately. Further
simplifying the programming process, the
ProtEX-MAX can be powered from the USB port, so
no need to apply external power while programming
your controller. In addition to programming, the
software will also allow you to monitor, and datalog a
ProtEX-MAX using your PC. You can also generate
and save programming files for later use.
Advanced Display Features
Display What You Want
The most common setup for these batch controllers is
to display the batch total on the main display and batch
preset on the second display. This allows the user to
monitor the batch as it progresses and compare it to
the total batch size. Other possible setups include
displaying the batch total and flow rate, batch total
and batch count, and batch total and grand total.
Batch Total & Preset Batch Total & Rate
Batch Total Batch Total
& Batch Count & Grand Total
Easy to Use
The user-friendly dual-line display makes the PROVU
easy to set up & program. No jumpers to set for input
selection. All setup & programming are done via the
front panel.
Input Setup Display Setup
Totalizer Overflow Displays Total to 9 Digits
These flow rate/totalizers can display up to nine digits of
total flow with the total overflow feature. In the diagram
below, the flow totalizer is displaying 532,831,470 by
toggling between a display of “oF 532” and “831470”.
Notice the (T with arrow ▲ symbol) is lit up indicating
the display is in overflow mode.
Super-Bright Display
The ProtEX-MAX comes standard with a super-bright
display, with LEDs that are visible even in direct sunlight.
The display also has up to eight levels of adjustable
intensity for optimum visibility in any lighting condition.
Rounding for Even Steadier Display
The rounding feature is used to give the user a
steadier display with fluctuating signals. It causes the
display to round to the nearest value according to the
rounding value selected (1, 2, 5, 10, 20, 50, or 100).
For example, with a rounding value of 10, and an
input of 12346, the display would indicate 12350.

ProtEX-MAX PD8-6210 Explosion-Proof Analog Input Batch Controller
Instruction Manual
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Batch Controller Capabilities
A ProtEX-MAX batch controller can be programmed
for a wide variety of single or multi-stage batching
applications and set up to run in either manual or
automatic operation. Batch size can be displayed on
the controller and is easily programmed and changed
if needed. The controller can even display the number
of batches that have been run. Automatic overrun
correction keeps the batch size accurate, even over
time and with system wear. The controller can display
the rate with a time base of seconds, minutes, hours
or days. The user can program a conversion factor,
configure a non-resettable grand total, and configure
password protection.
Manual or Automatic Batch Control
Batches may be started manually with the START
front panel button, or with a remote digital input
trigger. Batches may also be programmed to start
automatically after a 0 to 999.9 second delay after the
end of the last completed batch. A manually stopped
batch will only restart after the START button is
pressed or digital input triggered.
Automatic Overrun Correction
The ProtEX-MAX batch controller will correct for batch
overrun or shortages automatically. By tracking the
amount the batch was off by, the controller will
automatically adjust the batch by modifying the batch
relay deactivation time.
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. Each additional stage batching relay has
an individually programmable preclose amount.
Single Stage Batch Control
Multi-Stage Batch Control
Quick Preset Changes
The front panel BATCH key is configured by default to
access the preset menu. The preset may be changed
quickly and easily between batches without the need
to enter setup menus.
Non-Resettable Grand Total
The user can set up the grand total to be non-resettable
by entering a specific password. Once this is done,
the grand total can never be reset.
Total Conversion Factor
The user can enter a conversion factor that allows the
controller to display total in different units than the
rate. For instance, an operator could measure flow
rate in gallons per minute and grand total in millions of
gallons.
Grand Total & Rate Alarms
The ProtEX-MAX’s four internal relays can be set up
to alarm when the grand total reaches a user-defined
set point or when the rate is above or below a certain
value. Rate alarms are only activated when the
batching process is running. A variety of reset modes
are available and the user can also program time
delays and fail-safe operation.
F4 Digital Input
The digital input can be used for a variety of functions
such as starting or stopping a batch, resetting the total,
or resetting an alarm relay. This is ideal for installations
where the controller is inaccessible behind a cover, or
where an additional function key is needed for
customized operation.
Remote Operation of Controller
There are four digital inputs that can be programmed
to mimic the MENU, START, BATCH, and STOP
buttons that could be controlled by a control station*
suitable for location in a hazardous area.
* Control station must be approved for hazardous
locations

ProtEX-MAX PD8-6210 Explosion-Proof Analog Input Batch Controller
Instruction Manual
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Physical Features
The ProtEX-MAX is designed for ease-of-use in safe
and hazardous applications. The ProtEX-MAX is
housed in a rugged NEMA 4X explosion-proof
enclosure, can operate over a wide temperature
range, includes removable screw terminal connectors,
has worldwide approvals for use in hazardous areas,
and features through-glass buttons for easy controller
operation without the need to remove the cover.
All of these features are backed by a 3-year warranty.
Super-Bright LED Display
The ProtEX-MAX features a dual-line 6-digit display
with super-bright LEDs, our brightest ever. These
allow the display to be read in any lighting condition,
even in direct sunlight.
SafeTouch Through-Glass Buttons
The ProtEX-MAX is equipped with four sensors that
operate as through-glass buttons so that it can be
programmed and operated without removing the
cover (and exposing the electronics) in a hazardous
area. These buttons can be disabled for security by
selecting the DISABLE setting on the NO-CONTACT
BUTTONS switch located on the back of the
electronics module, inside the enclosure.
Rugged, Heavy-Duty Enclosure
The ProtEX-MAX is housed in a rugged NEMA 4X, 7,
& 9, IP68 die-cast aluminum enclosure, designed to
withstand harsh environments in safe and hazardous
areas across a wide temperature range.
Wide Viewing Angle
Customers can’t always look at the display from
straight on, so the window and display module have
been optimized to provide a wide viewing angle of
approximately ± 40°; nearly twice that of the
competition.
Built-In Mounting Flanges
The ProtEX-MAX is equipped with four slotted flanges
for wall mounting or NPS 1½" to 2½" or DN 40 to
65 mm pipe mounting.
Flexible Mounting & Wiring
The ProtEX-MAX features four ¾" NPT threaded
conduit openings so that wiring can be routed to the
most convenient conduit connection(s). Two ¾" NPT
metal conduit plugs with 12 mm hex key fitting come
installed.

ProtEX-MAX PD8-6210 Explosion-Proof Analog Input Batch Controller
Instruction Manual
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Rotatable Display
The ProtEX-MAX rotatable display, along with four
available conduit connections, provide for numerous
installation options. The display can be rotated in 90°
increments. Rotate it 90° for horizontal mounting.
Vertical Mounting Horizontal Mounting
Perfect & Secure Fit Every Time
The internal cast rails ensure the ProtEX-MAX
assembles together perfectly, quickly and securely;
and everything lines up for optimal viewing every
time. There are no standoffs to worry about breaking
or getting out of alignment. Two spring-loaded,
self-retaining, thumbscrews make the assembly a
snap, while pressing the display as close to the glass
as possible to improve wide angle viewing.
Stainless Steel Tags
PDA-SSTAG is a laser etched stainless steel tag
accessory for any of your Precision Digital controllers.
The tag features custom text for equipment
identification, instruction, or whatever else is needed
in your facility. Each tag comes with a stainless steel
wire and lead seal for easy mounting wherever you
need it.
Removable Screw Terminals
Industrial applications require screw terminal
connections for easy field wiring and the ProtEX-MAX
goes one step further in convenience by making them
removable also.
USB Port MeterView Pro
Hazardous Area Approvals
The ProtEX-MAX's approvals allow it to be used in
hazardous areas around the world. These include: FM
Approved as Explosion-Proof / Dust-Ignition-Proof /
Flame-Proof, CSA Certified as Explosion-Proof /
Dust-Ignition-Proof, and ATEX and IECEx Certified as
Flame-Proof.
Wide Operating Temperature Range
The ProtEX-MAX can operate from -40 to 60°C
(-40 to 140°F) meaning it can be installed in a wide
variety of indoor and outdoor industrial applications.
And over this range, the ProtEX-MAX will drift no
more than 0.005% of calibrated span/°C max from
0 to 65°C ambient and 0.01% of calibrated span/°C
max from -40 to 0°C ambient.
USB cable conveniently
plugs into side of
ProtEX-MAX controller

ProtEX-MAX PD8-6210 Explosion-Proof Analog Input Batch Controller
Instruction Manual
14
Transmitter Power Supplies
Controller Powers Transmitter
One of the most useful standard features of the
PD8-6210 is its built-in isolated, 24 V @ 25 mA power
supply to power the transmitter. This feature saves
money by eliminating an external power supply and
also simplifies wiring by reducing the number of
devices in the loop. It can be configured for 5, 10, or
24 V (default) by means of a simple internal jumper.
This power supply is even available on controllers that
are powered from DC power (24 V @ 25 mA). To use
an external power supply instead of the internal power
supply, simply make connections to different terminals
on the ProtEX-MAX.
The following diagram illustrates how to wire the
ProtEX-MAX so it will power the transmitter:
Controller Powers 4-20 mA Output
Not only can the ProtEX-MAX power the 4-20 mA
input signal, but an additional power supply of
24 V @ 25 mA is provided with the 4-20 mA output
option to power the 4-20 mA output.
Fuse Prevents Current Overload
Another very useful aspect of the ProtEX-MAX is that
the current input is protected against current overload
by a resettable fuse. The fuse limits the current to a
safe level when it detects a fault condition, and
automatically resets itself when the fault condition is
removed.

ProtEX-MAX PD8-6210 Explosion-Proof Analog Input Batch Controller
Instruction Manual
15
Useful Tools
PD9501 Multi-Function Calibrator
This PD9501 Multi-Function Calibrator has a variety
of signal measurement and output functions, including
voltage, current, thermocouple, and RTD.
PD9502 Low-Cost Signal Generator
The PD9502 is a low-cost, compact, simple to use
4-20 mA or 0-10 VDC signal generator. It can easily
be set for 0-20 mA, 4-20 mA, 0-10 V or 2-10 V ranges.
Signal adjustment is made with a one-turn knob. A
15-27 VDC wall plug is provided with the instrument.
Optional USB power bank is available.

ProtEX-MAX PD8-6210 Explosion-Proof Analog Input Batch Controller
Instruction Manual
16
Specifications
Except where noted all specifications apply to
operation at +25°C.
General
Display
Display Line 1: 0.60" (15 mm) high,
red LEDs
Display Line 2: 0.46" (12 mm) high,
red LEDs
6 digits each (-99999 to 999999),
with lead zero blanking
Display
Intensity
Eight user selectable intensity levels.
Default is six.
Display
Update Rate
5/second (200 ms)
LED Status
Indicators
See LED Status Indicators on page 33 for
details
Overrange
Display flashes 999999
Underrange
Display flashes -99999
Default
Display
Assignment
Line 1 displays batch total. Line 2 displays
batch preset, and can be switched to show
grand total, or batch count with the STOP
key.
Custom
Display
Assignment
Display lines 1 and 2 may be assigned to
rate, total, grand total, batch count, preset,
set points, units (second 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.
Programming
Methods
Four SafeTouch through-glass buttons
when cover is installed. Mechanical buttons
can be used with the cover removed. Free
PC-based USB MeterView Pro
programming software.
Noise Filter
Programmable from 2 to 199
(0 will disable filter)
Filter Bypass
Programmable from 0.1 to 99.9% of
calibrated span
Recalibration
All ranges are calibrated at the factory.
Recalibration is recommended at least
every 12 months.
Max/Min
Display
Max/min readings reached by the process
are stored until reset by the user or until
power to the controller is cycled.
Rounding
Select 1, 2, 5, 10, 20, 50, or 100
(e.g. rounding = 10, value = 123.45,
display = 123.50)
Password
Three programmable passwords restrict
modification of programmed settings and
two prevent resetting the totals.
Pass 1: Allows use of function keys and
digital inputs
Pass 2: Allows use of function keys, digital
inputs and editing set/reset points
Pass 3: Restricts all programming, function
keys, and digital inputs.
Total Password: Prevents resetting the total
manually
Gtotal Password: Prevents resetting the
grand total manually
Non-Volatile
Memory
Total and Grand Total values, and all
programmed settings are stored in non-
volatile memory for a minimum of ten years
if power is lost.
Power
Options
85-265VAC50/60Hz;90-265VDC,20Wmax;
12-24 VDC, 12-24 VAC, 15 W max.
Powered over USB for configuration only.
Fuse
Required external fuse: UL Recognized,
5 A max, slow blow; up to 6 controllers may
share one 5 A fuse
Normal Mode
Rejection
Greater than 60 dB at 50/60 Hz
Isolation
4 kV input/output-to-power line
500 V input-to-output or 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 = -40 to 60°C
T5 Class operating temperature range
Ta = -40 to 65°C
Storage temperature range:
-40 to 85°C (-40 to 185°F)
Relative humidity:
0 to 90% non-condensing
Max Power
Dissipation
Maximum powerdissipation limited to 15.1W
Connections
Power, signal, relays, mA out: Removable
screw terminal blocks accept 12 to 22
AWG wire.
RS-485: Removable screw terminal block
accepts 16 to 30 AWG wire.
Digital I/O: Removable screw terminal
blocks accept 16 to 30 AWG wire.
Enclosure
Explosion-proof die-cast aluminum with
glass window, corrosion resistant epoxy
coating, color: blue
NEMA 4X, 7, & 9, IP68
Default conduit connections: Four ¾" NPT
threaded conduit openings and two ¾" NPT
metal conduit plugs with 12 mm hex key
fitting installed. Additional conduit opening
configurations may be available; verify
quantity and sizes on specific device
labeling during installation.

ProtEX-MAX PD8-6210 Explosion-Proof Analog Input Batch Controller
Instruction Manual
17
Mounting
Wall Mounting:
Four (4) mounting holes provided for
mounting controller to wall. See Wall
Mounting Instructions on page 23 for
additional details.
Pipe Mounting:
Optional pipe mounting kit (PDA6848)
allows for pipe mounting. Sold separately.
See Pipe Mounting Instructions on page 24
for additional details.
Tightening
Torque
Power, signal, relays, mA out terminals:
5 lb-in (0.56 Nm)
Digital I/O and RS-485:
2.2 lb-in (0.25 Nm)
Overall
Dimensions
6.42" x 7.97" x 8.47" (W x H x D)
(163 mm x 202 mm x 215 mm)
Weight
16.0 lbs (7.26 kg)
Warranty
3 years parts & labor. See Warranty
Information and Terms & Conditions on
www.predig.com for complete details.
Batch Controller Rate/Totalizer
Display
Rate Display
Indication
-99999 to 999999, lead zero blanking.
“R” LED illuminates while displaying rate.
Batch Total &
Grand Total
Display
0 to 999,999; automatic lead zero blanking.
“T” LED is illuminated while displaying batch
total. “GT” LEDs are illuminated while
displaying grand total. Up to 999,999 for
batch total/preset. Up to 999,999,999 with
grand total-overflow feature. “oF” 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, d.dddd, d.ddd, d.dd, d.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.
Time Base
Second, minute, hour, or day
Batch Control
Mode
Automatic or manual batch control
Manual
Batch
The operator must press the START button
every time a new batch is started.
Press STOP to pause the batch and either
press START to resume or STOP to stop
the incomplete batch.
Automatic
Batch
Once the START button is pressed, the
batches will run automatically until the
STOP button is pressed twice. The time
delay between batches is entered during
the setup.
Batch Time
Delay
Programmable up to 999.9 seconds
This is the time delay between batches for
automatic batch control. Allow sufficient
time to put in place an empty container.
Batch Preset
The F2 key is assigned to the preset.
The preset value is the total volume to be
batched in each cycle.
Batch
Pre-Close
The pre-close value is equal to the volume
amount before reaching the preset value
(batch size).
Single or
Multi-Stage
Single Stage: Only relay 1 is used
Multi-Stage: Two or more relays are used
to control the batch with more precision;
this is done using multiple presets or using
the pre-close feature.
Multiple
Presets
Each relay de-energizes at its own preset
value.
Remote
Operation
Start / Stop / Batch Size buttons may be
operated remotely using a hazardous
area-approved control station
Start
The F1 key is assigned to START batch.
Press START to start a new batch in
manual mode or a set of batches in
automatic mode.
Pause / Stop
The F3 key is assigned to PAUSE / STOP.
Press F3 once to pause and press it again
to stop the batch process.

ProtEX-MAX PD8-6210 Explosion-Proof Analog Input Batch Controller
Instruction Manual
18
Automatic
Overrun
Correction
Adjusts the closing of the batch control
relays to compensate for inaccuracies from
batch to batch. The overrun correction
feature is capable of compensating for
inaccuracies of up to 1% of the
programmed preset value.
To achieve an accurate batch, the flow rate
must be slowed down, such that the total
most-right digit increments at a rate of less
than 10 counts/second. The use of a
dual-stage batch control is recommended.
Count Up or
Count Down
Batch total and grand total can set to count
up or count down, independently.
Start / Stop
Batch
The F4 digital input is assigned to start &
stop the batch, it is located on the input
signal connector.
An external push-button can be connected
between terminal F4 and COM. Press the
button once to start the batch and press it
again to stop the batch.
High or Low
Flow Alarm
The user may program any alarm for high
or low trip point. The alarm detection is
active only while the batch is running.
Unused alarm LEDs and relays may be
disabled (turned off).
Grand
Totalizer
Rollover
Grand totalizer rolls over when display
exceeds 999,999,999. Relay status reflects
display.
Grand Total
Overflow
The grand total can display up to
999,999,999 using the overflow feature.
After the value exceeds 999,999 a 3-digit
value with the prefix “oF” toggles every 10
seconds. The overflow feature can be
disabled by setting a grand total alarm that
automatically resets the grand total when
999,999 is reached.
Grand Total
Alarms
Up to three, 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. Relay 1 should
always be assigned to batch.
Programmable
Delay on
Release
0.1 and 999.9 seconds; applied to the first
relay assigned to total or grand total.
If the controller is programmed to reset total
to zero automatically when the preset is
reached, then a delay will occur before the
total is reset.
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
Grand total passwords 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”.
•Once the Grand Total has been programmed as
“non-resettable” the feature CANNOT be disabled.
Process Inputs
Inputs
Field selectable: 0-20, 4-20 mA
10 V (0-5, 1-5, 0-10 V)
Modbus PV (Slave)
Isolated
Transmitter
Power Supply
Terminals P+ & P-: 24 VDC 10%
All models selectable for 24, 10, or 5 VDC
supply (internal jumper J4)
All models transmitter supply
rated @ 25 mA max
Refer to Figure 3. Transmitter Supply
Voltage Selection on page 26 and
Figure 19. 4-20 mA Output Connections on
page 31
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
Input Signal
Conditioning
Linear, square root, or programmable
exponent
Multi-Point
Linearization
2 to 32 points
Programmable
Exponent
User selectable from 1.0001 to 2.9999 for
open channel flow
Low-Flow
Cutoff
0.1 to 999,999 (0 disables cutoff function).
Point below at which the display always
shows zero.
Decimal Point
Up to five decimal places or none:
d.ddddd, d.dddd, d.ddd, d.dd, d.d, or dddddd
Calibration
Range
Input Range
Minimum Span
Input 1 & Input 2
4-20 mA
0.15 mA
10 V
0.10 V
An error message will appear if the input 1
and input 2 signals are too close together.
Input
Impedance
Voltage ranges: greater than 500 k
Current ranges: 50 - 100 (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
The controller does not interfere with
existing HART communications; it displays
the 4-20 mA primary variable and it allows
the HART communications to pass through
without interruption. The controller is not
affected if a HART communicator is
connected to the loop. The controller does
not display secondary HART variables.

ProtEX-MAX PD8-6210 Explosion-Proof Analog Input Batch Controller
Instruction Manual
19
Relays
Rating
4 SPDT (Form C) internal 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; see Switching Inductive Loads on
page 30 for details.
Relay
Assignment
Relays may be assigned to batch control
total, sampling, rate, or grand total alarms.
Pre-Close
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
Flow Alarm
User may program any alarm for high or
low trip point. The alarm detection is active
only while the batch is running. Unused
alarm LEDs and relays may be disabled
(turn off).
Relay
Operation
•Manual or automatic batch control
•Automatic (non-latching)1 and/or manual
alarm reset (acknowledge)
•Latching (requires manual
acknowledge) with or without clear
•Pump alternation control (N/A to batch)
•Sampling (based on set point and time)
•Off (disable unused relays and enable
Interlock feature)
•Manual on/off control mode
Relay Reset
(Acknowledge)
User selectable via programming buttons,
F4 digital input, external contact closure on
digital inputs, automatically via user
selectable preset value and time delay, or
through serial communications.
Alarm 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.
Alarm Auto
Initialization
When power is applied to the controller,
relays will reflect the state of the input to
the controller.1
1. Alarms are active only when the batch is running.
USB Connection
Function
Programming only
Compatibility
USB 2.0 Standard, Compliant
Connector
Type
Micro-B receptacle
Cable
USB A Male to Micro-B Cable
Driver
Microsoft®Windows®XP/Vista/7/8/10
Power
USB port provides power to the controller
for configuration only.
DO NOT apply AC or DC power to the
controller while the USB port is in use.
Isolated 4-20 mA Transmitter
Output
Output
Source
Rate/process, total, grand total, max, min,
set points 1-4, Modbus register, or manual
control mode
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 Out
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%. Used to
power the 4-20 mA output.
All models rated @ 25 mA max.
External Loop
Power Supply
35 VDC maximum
Output Loop
Resistance
Power supply
Minimum
Maximum
24 VDC
10 
700 
35 VDC
(external)
100 
1200 
RS-485 Serial Communications
Compatibility
EIA-485
Connectors
Removable screw terminal connector
Max Distance
3,937' (1,200 m) max
Status
Indication
Separate LEDs for Power (METER LINK),
Transmit (TX), and Receive (RX)
Modbus®RTU Serial
Communications
Slave Id
1 –247 (Controller address)
Baud Rate
300 –19,200 bps
Transmit
Time Delay
Programmable between 0 and 199 ms
Data
8 bit (1 start bit, 1 or 2 stop bits)
Parity
Even, Odd, or None with 1 or 2 stop bits
Byte-To-Byte
Timeout
0.01 –2.54 second
Turn Around
Delay
Less than 2 ms (fixed)
Note: Refer to the ProtEX-MAX Modbus Register Tables
located at www.predig.com for details.

ProtEX-MAX PD8-6210 Explosion-Proof Analog Input Batch Controller
Instruction Manual
20
Digital Input (F4)
Function
Start/Stop batch, remote operation of
front-panel buttons, acknowledge/reset
relays, reset max/min values. See Function
Keys & Digital I/O Available Settings on
page 64 for a complete list of capabilities.
Contacts
3.3 VDC on contact. Connect normally
open contacts across F4 to COM.
Logic Levels
Logic High: 3 to 5 VDC
Logic Low: 0 to 1.25 VDC
Digital Inputs & Outputs
Function
Terminals provided for remote operation of
all four programming / operation buttons.
Other uses include acknowledge/reset
relays and reset max/min values. See
Function Keys & Digital I/O Available
Settings on page 64 for a complete list of
capabilities.
Channels
4 digital inputs & 4 digital outputs
Digital Input
Logic High
3 to 5 VDC
Digital Input
Logic Low
0 to 1.25 VDC
Digital Output
Logic High
3.1 to 3.3 VDC
Digital Output
Logic Low
0 to 0.4 VDC
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 push buttons
across +5 V & DI 1-4.
•DO NOT use +5 V terminal to power external
devices.
MeterView Pro Software
Availability
Download directly from controller or from
www.predig.com/download_software
System
Requirements
Microsoft®Windows®XP/Vista/7/8/10
Communications
USB 2.0 (for programming only)
(USB A Male to Micro-B Cable)
RS-485 to USB converter
(programming, monitoring, batch
control, and data logging)
Configuration
Configure controllers one at a time
Power
USB port provides power to the
controller for configuration only.
DO NOT apply AC or DC power to the
controller while the USB port is in use.
Batch Control
Use MeterView Pro to control the
batch, change the preset, reset totals,
and test the relays.
Data Logging
Use MeterView Pro for data logging of
the batch process.