Precision Digital PD9000 User guide

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Page 1

PD9000 ConsoliDator+ Multivariable Controller

Instruction Manual

PRECISION DIGITAL CORPORATION

233 South Street • Hopkinton MA 01748 USA Tel (800) 343-1001 • (508) 655-7300

www.predig.com

• NEMA 4X Panel Mount Multivariable Controller

• Convenient Display, Control, & Alarm of Multiple 4-20 mA, Pulse, & Modbus Inputs

• Numeric & Bargraph Color Display (320 x 240 pixels) 5.7" (145 mm)

• Sunlight Readable Display, White Backlight

• Isolated 24 VDC Transmitter Supplies 200 mA / Analog Input: 1,600 mA Max

• 99 Channels, 32 Totalizers, 30 Timers, & 199 Modbus Inputs

• 64 High & Low Alarms, Combine Multiple Alarms Into Logic AND & OR Alarms

• Simulation & Manual Control Modes for Testing and Setup

• Modular Design for Inputs & Outputs Flexibility

• Up to (28) 4-20 mA Isolated Inputs or Pulse Inputs

• Up to (25) 10 Amp Form C Relays (With Eight Analog or Pulse Inputs)

• Up to (25) Isolated 4-20 mA Outputs (With Eight Analog or Pulse Inputs)

• Operating Temperature Range: -25°C to 55°C (-13 to 131°F)

• Pulse, Analog, & Modbus Input Flow Rate / Total / Grand Total Capability

• 50-Point Linearization, Square Root, and Exponent for Open Channel Flow

• Round Horizontal Tank Volume Calculation; Just Enter Diameter & Length

• Open Channel Flow Math Formulas for Weirs & Flumes

• Multi-Pump Alternation Control or On / Off Control with Random Varying Set Point

• Programmable Displays, Function Keys & Digital Inputs

• Math Functions: Sum, Diff, Average, Multiply, Divide, % Efficiency, & More

• Modbus Client (Master) & Snooper / Server with 99 Programmable Outputs

• Direct Modbus PV Inputs – Snooper / Server Mode

• Modbus Spoofer Feature to Replace Servers Removed from Network

• RS-485 Serial Communication with Modbus RTU / ASCII & Ethernet TCP/IP

• USB Data Logger Feature: Up to 8 Log Files with up to 12 Parameters Each

• Input Power Options: 90-264 VAC or 24 VDC

• (20) Screens with up to Eight PVs Each

• ConsoliDator+ Configuration Software

• Type 4X, IP66 Front – Field Enclosures Available

• Auto-Tune PID Control for Multiple Control Loops

• PID Control with Analog, Digital, or Relay Outputs

• Digital Selector Switch (HOA) Function to Route Inputs & Outputs

• 3-Year Warranty

UL & C-UL Listed for Div 2 Hazardous (nonincendive) and Ordinary Location Installations.

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PD9000 ConsoliDator+ Multivariable Controller

Instruction Manual

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.

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.

FREE ConsoliDator+

Configuration Software

The easiest and quickest way to program your ConsoliDator+ multivariable controller is to use the FREE ConsoliDator+ configuration software.

The ConsoliDator+ configuration software is intuitive, and most customers can get their controller programmed as they like without even looking in the manual.

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 adjust the programming after the controller is installed, you can use the front panel soft keys and the instructions in this manual to do so.

ConsoliDator+ configuration software is available for download at https://www.predig.com.

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PD9000 ConsoliDator+ Multivariable Controller

Instruction Manual

Table of Contents

FREE ConsoliDator+ Configuration Software .................................................. 2

Introduction ......................................................................................................... 8

Ordering Information .......................................................................................... 8

Add-On Features ........................................................................................... 10

Input / Output Cards ..................................................................................... 10

Setup & Calibration Services ....................................................................... 10

Enclosures .................................................................................................... 10

Accessories ................................................................................................... 11

Specifications ................................................................................................... 14

General .......................................................................................................... 14

Totalizer ......................................................................................................... 16

Real Time Clock ............................................................................................ 16

Channel & Math Functions ........................................................................... 17

List of Engineering Units ............................................................................. 19

4-20 mA Analog Inputs ................................................................................. 19

Pulse Inputs .................................................................................................. 20

Modbus Inputs - Server ................................................................................ 21

Digital Inputs & Outputs ............................................................................... 21

Relays ............................................................................................................ 21

4-20 mA Transmitter Outputs ...................................................................... 22

Timers ............................................................................................................ 22

Modbus Outputs - Server ............................................................................. 22

Modbus Serial Communications ................................................................. 23

Modbus Client, Snooper & Spoofer ................................................................... 23

Client & Snooper Settings ............................................................................ 23

Spoofer Settings ........................................................................................... 23

Data Logger – USB Drive ............................................................................. 24

How to Enable Add-On Features ................................................................. 24

Sample Data Log File .................................................................................. 24

Ethernet Communications ........................................................................... 24

ConsoliDator+ Software ............................................................................... 25

Compliance Information................................................................................... 25

Hazardous Area Location* ........................................................................... 25

Ordinary Location*........................................................................................ 25

Safety Information ............................................................................................ 26

Installation......................................................................................................... 26

Unpacking ..................................................................................................... 26

Panel Mounting ............................................................................................. 26

Mounting Dimensions .................................................................................. 27

ConsoliDator+ Configuration Software Installation ................................... 28

Connect to ConsoliDator+ Configuration Software ................................... 30

Connections ...................................................................................................... 31

Power Connections ..................................................................................... 32

Isolated Input Signal Connections ............................................................... 32

4-20 mA Analog Input Connections ............................................................. 32

Flow Meter Pulse Input Connections ........................................................... 33

Digital Input Connections............................................................................. 33

Analog Output Connections ......................................................................... 33

Digital Output Connections .......................................................................... 33

Connections to Power Gas Detector ........................................................... 34

Relay Connections ...................................................................................... 35

Switching Inductive Loads ........................................................................... 35

Serial Communication Connections ............................................................ 35

External Keypad Connections ..................................................................... 35

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PD9000 ConsoliDator+ Multivariable Controller

Instruction Manual

Navigating and Editing ..................................................................................... 36

Soft-Keys and Buttons ................................................................................. 36

Setup and Programming .................................................................................. 37

Overview ........................................................................................................ 37

Setup Menu ....................................................................................................... 38

Channel Parameters ................................................................ ..................... 39

Data Entry Keypad ........................................................................................ 40

Setup Channels ............................................................................................. 41

Create New Channel ................................................................................... 42

Bargraph, Background & Text Colors .......................................................... 44

Live Calibration ............................................................................................ 45

Edit Channel ................................................................................................ 45

Delete Channel ............................................................................................ 45

Scale Functions ........................................................................................... 46

2-Point Linear Scaling ................................................................................. 46

Square Root Scaling ................................................................................... 47

Scale Exponent ........................................................................................... 48

Round Horizontal Tank ................................................................................ 48

Open Channel Flow Application .................................................................. 49

Setup Math Functions ................................................................................. 51

PID Control Setup ......................................................................................... 54

Setup Channel 1: PV ................................................................................... 55

Channel 2: Set Point ................................................................................... 55

Channel 3: Power ........................................................................................ 56

Channel 4: PWM Control ............................................................................. 56

PID Control Using Digital Output ................................................................. 57

PID Control Using Analog Output ................................................................ 57

PID Control Screen ..................................................................................... 57

Start / Stop PID with Digital Input ................................................................ 58

Channel 3: PID Control - Power .................................................................. 59

Channel 4: PWM Heating Control ............................................................... 59

PID Control Heating Using Digital Output .................................................... 60

Channel 5: PWM Cooling Control ................................................................ 60

PID Control Cooling Using Digital Output .................................................... 60

PID Control: Heating Using Analog Output.................................................. 61

PID Control: Cooling Using Analog Output .................................................. 61

PID Control Configuration Using the ConsoliDator+ Software ................. 62

Average Function Setup .............................................................................. 62

Configure PID Control Power Channel ........................................................ 63

Configure PWM Control Heating Channel ................................................... 64

Configure PWM Control Cooling Channel ................................................... 64

Configure Set Point Channels ..................................................................... 65

Configure the Switches Function ................................................................. 66

Configure the Digital Outputs ...................................................................... 67

Configure the PID Control Screens ............................................................. 68

PID Control Screens .................................................................................... 70

Open Channel Flow ..................................................................................... 72

Setup Totalizers .......................................................................................... 73

Setup Total with Pulse Input Source ........................................................... 73

Setup Accumulated Total (Triggered) .......................................................... 74

Setup Previous Total ................................................................................... 74

Setup Daily Total ......................................................................................... 74

Setup Grand Total ....................................................................................... 75

Setup Timers ............................................................................................... 76

Setup Alarms ............................................................................................... 77

Logic OR Alarm ........................................................................................... 78

Logic AND Alarm ......................................................................................... 78

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PD9000 ConsoliDator+ Multivariable Controller

Instruction Manual

Logic NOR & NAND Alarms ........................................................................ 78

Day & Time Alarms ..................................................................................... 79

Setup the Switches Function ....................................................................... 80

Setup 2, 3, or 4-Way Switch ........................................................................ 80

Setup a 4-Way Switch ................................................................................. 80

Setup a HOA Switch ..................................................................................... 81

Block Diagram for HOA Switch .................................................................... 81

Configuration for HOA Switch Application Using the Software .................... 82

Setup HOA Switch ....................................................................................... 84

Setup HOA Relay ........................................................................................ 84

Setup HOA Screen ...................................................................................... 85

HOA Screen View ....................................................................................... 85

Setup Inputs .................................................................................................. 86

Setup 4-20 mA Inputs .................................................................................. 86

Setup Pulse Inputs ...................................................................................... 88

Setup Digital Inputs ..................................................................................... 88

Digital Inputs & Data Logger ........................................................................ 90

Modbus Functionality .................................................................................. 91

Setup Modbus Inputs (Server) ..................................................................... 91

Setup Modbus Inputs (Client) ...................................................................... 92

Setup Modbus Inputs (Snooper) .................................................................. 92

Setup All Outputs.......................................................................................... 93

Setup 4-20 mA Outputs ............................................................................... 93

Setup Relay Output ..................................................................................... 94

Setup Digital Output .................................................................................... 96

Setup Modbus Output (Server) .................................................................... 96

Setup Modbus Output (Client) ..................................................................... 97

Setup Modbus Output (Spoofer) .................................................................. 98

Setup Screens ............................................................................................... 99

Screens Settings ......................................................................................... 99

Setup Data Logs ......................................................................................... 101

Setup New Data Log ................................................................................. 101

Setup Log Start / Stop ............................................................................... 102

Setup Log Enable Switch .......................................................................... 102

Setup Log Trigger ...................................................................................... 102

Setup Log Interval & Log Units ................................................................ .. 103

Setup USB Drive ....................................................................................... 103

View Data Logs ........................................................................................... 104

Setup System .............................................................................................. 105

Setup Display ............................................................................................ 105

Setup Colors .............................................................................................. 105

Display Settings ......................................................................................... 105

General Settings ........................................................................................ 106

Add-On Features ....................................................................................... 106

Set Password ............................................................................................ 107

Password Protected Controller .................................................................. 107

Remove Password Protection ................................................................... 107

System Date & Time ................................................................................. 108

System Build ............................................................................................. 108

Modbus Server Settings ............................................................................ 109

Modbus Client Settings.............................................................................. 109

Modbus Snooper Settings ................................ ......................................... 109

Ethernet Settings ....................................................................................... 110

Manually Assigned IP Address .................................................................. 110

Custom Units ................................ ............................................................. 111

Delete Custom Units ................................................................................. 111

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PD9000 ConsoliDator+ Multivariable Controller

Instruction Manual

Ethernet Port Setup - Full .............................................................................. 112

Test Ethernet Communication ................................................................... 114

View Menu ....................................................................................................... 115

View Channel Details .................................................................................. 115

View Associated Parameters ..................................................................... 116

View Alarm Details ...................................................................................... 116

View Totals .................................................................................................. 117

Totals Generated by Non-Rate Inputs ....................................................... 118

View Timers ................................................................................................. 119

View Alarms ................................................................................................ 120

Simulate Alarm Condition .......................................................................... 120

View Inputs .................................................................................................. 121

Simulate mA Input ..................................................................................... 121

View Outputs ............................................................................................... 122

View mA Outputs ....................................................................................... 122

View Relays ............................................................................................... 123

View Alert Messages ................................................................................. 123

View Digital Outputs ................................................................................... 124

View Modbus Outputs ................................................................................ 124

View Screens ............................................................................................... 125

Operation......................................................................................................... 126

Viewing Screens ......................................................................................... 126

Individual Channel View ............................................................................ 126

Low & High Alarm Indication ..................................................................... 126

Multicolor Bargraph Indication ................................................................... 127

Modbus RTU & ASCII Serial Communication ............................................... 128

Modbus Register Tables ............................................................................ 128

PVs Register Numbers & Addresses ........................................................ 130

Modbus Write Protection ........................................................................... 131

Modbus Applications ..................................................................................... 135

Snooper Mode ............................................................................................. 135

Relay Control Using Modbus ..................................................................... 136

Setup Example #1 ..................................................................................... 136

Setup Example #2 ..................................................................................... 136

Troubleshooting Tips ..................................................................................... 137

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PD9000 ConsoliDator+ Multivariable Controller

Instruction Manual

Table of Figures

Figure 1. Front Panel Mount Dimensions ....................................................... 26

Figure 2. Panel Cutout Dimensions ................................................................ 26

Figure 3. Panel Mount Installation .................................................................. 27

Figure 4. Panel Mount Overall Dimension ...................................................... 27

Figure 5. Connection Terminals for a PD9000-6G-4PI-8AI-10AO-10RY-E .... 31

Figure 6. AC Power Connections .................................................................... 32

Figure 7. DC Power Connections .................................................................... 32

Figure 8. Transmitters Powered by ConsoliDator+ Isolated 24 VDC

Power Supply ............................................................................................ 32

Figure 9. Transmitter Powered by External Supply or Self-Powered .......... 32

Figure 10. 3-Wire Transmitters Powered Externally ...................................... 32

Figure 11. Flow Meter Pulse Input Connections ............................................ 33

Figure 12. Digital Input from Switch Closure and Live Signal ..................... 33

Figure 13. Active 4-20 mA Output Powered by Controller ............................ 33

Figure 14. Passive 4-20 mA Output Powered by External Supply ................ 33

Figure 15. Digital Outputs Driving 5 V Solid State Relay .............................. 33

Figure 16. Two Supplies in Parallel Powering 3-Wire Transmitter ............... 34

Figure 17. Powering 4-Wire Gas Detector & Isolated 4-20 mA Output ......... 34

Figure 18. Relay Connections ......................................................................... 35

Figure 19. AC and DC Internal Inductive Loads Protection .......................... 35

Figure 20. Low Voltage DC Loads Protection ................................................ 35

Figure 21. Serial Connections ......................................................................... 35

Figure 22. External Keypad Connections ....................................................... 35

Figure 23. Linear Response Graph ................................................................. 46

Figure 24. Square Root Response Graph ....................................................... 47

Figure 25. Exponent Response Graph ............................................................ 48

Figure 26. Round Horizontal Tank Volume Graph ......................................... 48

Figure 27. Total Relay Sampling Operation.................................................... 49

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PD9000 ConsoliDator+ Multivariable Controller

Instruction Manual

Introduction

The ConsoliDator+ is a multivariable controller that is both easy to use and satisfies a wide variety of process display, alarm, and control applications. It accepts 4-20 mA inputs, flow meter pulse inputs, digital inputs, and Modbus inputs and displays them in both numeric and bargraph format on a large, 5.7" color display. It can be equipped with multiple relays with user-definable actions, 4-20 mA outputs, digital outputs, Modbus RTU & ASCII, Modbus Enron, and Ethernet Modbus TCP/IP protocol communication. Additionally, the controller is equipped with up to 30 timers that can be used to control many processes or events.

Two standard new features have been added to the version 2.300 release:

•

Auto-Tune PID Control

•

Digital Switches (HOA)

The ConsoliDator+ takes full advantage of its color display by allowing the user to customize screen colors for bargraphs, alarm conditions, and input channels.

All this functionality is easily programmed using the free software or via the front panel pushbuttons. Choose the model that best suits your application, from monitoring only to fully loaded controllers with an extensive combination of inputs, outputs, and communication protocols. The standard product offering is listed in the ordering guide and other models are available for special order. The Add-On features expand the functionality of the ConsoliDator+, see the next page for details. The ConsoliDator+ has been Certified by Underwriters Laboratory (UL & C-UL) for use in ordinary locations (electrical safety) and in Div 2 hazardous area locations (nonincendive).

Ordering Information

General Purpose Panel-Mount Models (UL 508 Certified for US & Canada)

90-264 VAC Models

24 VDC Models

Pulse Inputs

4-20 mA

Inputs

4-20 mA Outputs

Relays

PD9000-6G (Modbus Monitor)

PD9000-7G (Modbus Monitor)

0 0 0

PD9000-6G-4AI

PD9000-7G-4AI

0 4 0

PD9000-6G-4AI-10RY

PD9000-7G-4AI-10RY

0 4 0

PD9000-6G-4AI-5AO-10RY

PD9000-7G-4AI-5AO-10RY

0 4 5

PD9000-6G-4AI-20RY

PD9000-7G-4AI-20RY

0 4 0

PD9000-6G-4AI-5AO-20RY

PD9000-7G-4AI-5AO-20RY

0 4 5

PD9000-6G-8AI

PD9000-7G-8AI

0 8 0

PD9000-6G-8AI-10RY

PD9000-7G-8AI-10RY

0 8 0

PD9000-6G-8AI-10AO-10RY

PD9000-7G-8AI-10AO-10RY

0 8 10

PD9000-6G-8AI-20RY

PD9000-7G-8AI-20RY

0 8 0

PD9000-6G-8AI-25RY

PD9000-7G-8AI-25RY

0 8 0

PD9000-6G-12AI

PD9000-7G-12AI

12 0 0

PD9000-6G-12AI-20RY

PD9000-7G-12AI-20RY

12 0 20

PD9000-6G-12AI-10AO-10RY

PD9000-7G-12AI-10AO-10RY

PD9000-6G-16AI

PD9000-7G-16AI

16 0 0

PD9000-6G-16AI-15RY

PD9000-7G-16AI-15RY

16 0 15

PD9000-6G-16AI-15AO

PD9000-7G-16AI-15AO

PD9000-6G-20AI

PD9000-7G-20AI

20 0 0

PD9000-6G-20AI-10RY

PD9000-7G-20AI-10RY

20 0 10

PD9000-6G-20AI-10AO

PD9000-7G-20AI-10AO

PD9000-6G-24AI

PD9000-7G-24AI

24 0 0

PD9000-6G-24AI-5RY

PD9000-7G-24AI-5RY

24 0 5

PD9000-6G-24AI-5AO

PD9000-7G-24AI-5AO

24 5 0

PD9000-6G-28AI

PD9000-7G-28AI

28 0 0

PD9000-6G-4PI

PD9000-7G-4PI

4 0 0

PD9000-6G-4PI-5AO

PD9000-7G-4PI-5AO

4 0 5

PD9000-6G-4PI-5AO-10RY

PD9000-7G-4PI-5AO-10RY

4 0 5

PD9000-6G-4PI-4AI-5AO

PD9000-7G-4PI-4AI-5AO

4 4 5

PD9000-6G-4PI-4AI-5AO-10R

PD9000-7G-4PI-4AI-5AO-10R

4 4 5

PD9000-6G-4PI-8AI-10AO-10RY

PD9000-7G-4PI-8AI-10AO-10RY

4 8 10

PD9000-6G-8PI

PD9000-7G-8PI

8 0 0

PD9000-6G-8PI-10AO

PD9000-7G-8PI-10AO

8 0 10

PD9000-6G-8PI-10AO-10RY

PD9000-7G-8PI-10AO-10RY

8 0 10

PD9000-6G-8PI-8AI-10AO-5RY

PD9000-7G-8PI-8AI-10AO-5RY

8 8 10

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PD9000 ConsoliDator+ Multivariable Controller

Instruction Manual

Hazardous Area Panel-Mount Models (UL HazLoc Approved)

90-264 VAC Models

24 VDC Models

Pulse Inputs

4-20 mA

Inputs

4-20 mA Outputs

Relays

PD9000-6H (Modbus Monitor)

PD9000-7H (Modbus Monitor)

0 0 0

PD9000-6H-4AI

PD9000-7H-4AI

0 4 0

PD9000-6H-4AI-10RY

PD9000-7H-4AI-10RY

0 4 0

PD9000-6H-4AI-5AO-10RY

PD9000-7H-4AI-5AO-10RY

0 4 5

PD9000-6H-4AI-20RY

PD9000-7H-4AI-20RY

0 4 0

PD9000-6H-4AI-5AO-20RY

PD9000-7H-4AI-5AO-20RY

0 4 5

PD9000-6H-8AI

PD9000-7H-8AI

0 8 0

PD9000-6H-8AI-10RY

PD9000-7H-8AI-10RY

0 8 0

PD9000-6H-8AI-10AO-10RY

PD9000-7H-8AI-10AO-10RY

0 8 10

PD9000-6H-8AI-20RY

PD9000-7H-8AI-20RY

0 8 0

PD9000-6H-8AI-25RY

PD9000-7H-8AI-25RY

0 8 0

PD9000-6H-12AI

PD9000-7H-12AI

12 0 0

PD9000-6H-12AI-20RY

PD9000-7H-12AI-20RY

12 0 20

PD9000-6H-12AI-10AO-10RY

PD9000-7H-12AI-10AO-10RY

PD9000-6H-16AI

PD9000-7H-16AI

16 0 0

PD9000-6H-16AI-15RY

PD9000-7H-16AI-15RY

16 0 15

PD9000-6H-16AI-15AO

PD9000-7H-16AI-15AO

PD9000-6H-20AI

PD9000-7H-20AI

20 0 0

PD9000-6H-20AI-10RY

PD9000-7H-20AI-10RY

20 0 10

PD9000-6H-20AI-10AO

PD9000-7H-20AI-10AO

PD9000-6H-24AI

PD9000-7H-24AI

24 0 0

PD9000-6H-24AI-5RY

PD9000-7H-24AI-5RY

24 0 5

PD9000-6H-24AI-5AO

PD9000-7H-24AI-5AO

24 5 0

PD9000-6H-28AI

PD9000-7H-28AI

28 0 0

PD9000-6H-4PI

PD9000-7H-4PI

4 0 0

PD9000-6H-4PI-5AO

PD9000-7H-4PI-5AO

4 0 5

PD9000-6H-4PI-5AO-10RY

PD9000-7H-4PI-5AO-10RY

4 0 5

PD9000-6H-4PI-4AI-5AO

PD9000-7H-4PI-4AI-5AO

4 4 5

PD9000-6H-4PI-4AI-5AO-10R

PD9000-7H-4PI-4AI-5AO-10R

4 4 5

PD9000-6H-4PI-8AI-10AO-10RY

PD9000-7H-4PI-8AI-10AO-10RY

4 8 10

PD9000-6H-8PI

PD9000-7H-8PI

8 0 0

PD9000-6H-8PI-10AO

PD9000-7H-8PI-10AO

8 0 10

PD9000-6H-8PI-10AO-10RY

PD9000-7H-8PI-10AO-10RY

8 0 10

PD9000-6H-8PI-8AI-10AO-5RY

PD9000-7H-8PI-8AI-10AO-5RY

8 8 10

Key:

6 = 90-264 VAC 7 = 24 VDC G = General Purpose: Electrical Safety Certification

UL & C-UL (E160849) H = Hazardous Area Certification UL & C-UL (E516990)

AI = Analog Input PI = Pulse Input AO = Analog Output RY = Relay E = Ethernet (Add “-E” at the end of the model number) Example: PD9000-6G-4PI-8AI-10AO-10RY-E

Other models are available upon request.

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PD9000 ConsoliDator+ Multivariable Controller

Instruction Manual

Add-On Features

Model

Description

PDK9000-M1

Add-On Feature: ConsoliDator+ Modbus Client/Snooper/Spoofer (Ver. 2.1 & Up)

PDK9000-D1

Add-On Feature: ConsoliDator+ USB Data Logger (Ver. 2.2 & Up)

Note: Add-On features that are ordered with the ConsoliDator+ will be activated at the factory. Add-On features can be ordered for existing ConsoliDator+ units with a firmware version of 2.2 or greater, at any time. The user will receive a key they can enter into the ConsoliDator+ to unlock the Add-On feature. See page 106 for instructions on how to enable the Add-On Features.

• Do not write configuration files created with older versions of the firmware and software to controllers with Add-On features enabled (Ver. 2.1 & up). This can create undesirable results, especially with the function keys F1-F4 and the digital inputs.

• The Auto-Tune PID Control and the Digital Switch functions are standard on versions 2.3 & up.

Input / Output Cards

Model

Description

PDA9000-C4AI

(4) Isolated 4-20 mA Inputs Card for ConsoliDator+

PDA9000-C4PI

(4) Pulse Inputs Card for ConsoliDator+

PDA9000-C5AO

(5) Isolated 4-20 mA Outputs Card for ConsoliDator+

PDA9000-C5RY

(5) Relays Card for ConsoliDator+

Setup & Calibration Services

Part Number

Description

PDN-CALCON+12

ConsoliDator+ Calibration and Certificate for up to 12 Inputs and Outputs

PDN-CALCON+24

ConsoliDator+ Calibration and Certificate for up to 24 Inputs and Outputs

PDN-CALCON+36

ConsoliDator+ Calibration and Certificate for up to 36 Inputs and Outputs

PDN-CALCON+12-DATA

ConsoliDator+ Calibration and Certificate with data for up to 12 Inputs and Outputs

PDN-CALCON+24-DATA

ConsoliDator+ Calibration and Certificate with data for up to 24 Inputs and Outputs

PDN-CALCON+36-DATA

ConsoliDator+ Calibration and Certificate with data for up to 36 Inputs and Outputs

PDN-CSETCON+

Custom Setup for ConsoliDator+

Enclosures

Model

Description

PDA1909

NEMA 4X Plastic Enclosure for One ConsoliDator+ Dimensions: 11.8" x 11.8" x 5.9" (300 mm x 300 mm x 150 mm) (H x W x D)

PDA1939

NEMA 4X Plastic Enclosure for One ConsoliDator+ Dimensions: 17.7" x 13.8" x 7.9" (450 mm x 350 mm x 200 mm) (H x W x D)

PDA2909

NEMA 4 Steel Enclosure for One ConsoliDator+ Dimensions: 12.0" x 12.0" x 6.0" (305 mm x 305 mm x 152 mm) (H x W x D)

PDA2919

NEMA 4 Steel Enclosure for One ConsoliDator+ Dimensions: 14.0" x 12.0" x 8.0" (356 mm x 305 mm x 203 mm) (H x W x D)

PDA2929

NEMA 4 Steel Enclosure for One ConsoliDator+ Dimensions: 16.0" x 14.0" x 10.0" (406 mm x 355 mm x 254 mm) (H x W x D)

PDA3939

NEMA 4X Plastic Enclosure with Clear Cover for One ConsoliDator+ Dimensions: 17.7" x 13.8" x 7.9" (450 mm x 350 mm x 200 mm) (H x W x D)

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PD9000 ConsoliDator+ Multivariable Controller

Instruction Manual

Accessories

Light / Horn Accessories

Model

Description

MOD-LHRB1

Red Light / Horn and Button with Holes Drilled in Enclosure

(1)

MOD-LHGB1

Green Light / Horn and Button with Holes Drilled in Enclosure

(1)

MOD-LHYB1

Yellow Light / Horn and Button with Holes Drilled in Enclosure

(1)

MOD-LHBB1

Blue Light / Horn and Button with Holes Drilled in Enclosure

(1)

MOD-LHWB1

White Light / Horn and Button with Holes Drilled in Enclosure

(1)

MOD-LH5CB1

Light / Horn with User Choice of Red, Green, Yellow, Blue or White Light, Button, and Holes Drilled in Enclosure

(1)

MOD-LH3LCB1-RYG

Light / Horn with Red, Yellow, Green Light Layers, Button, and Holes Drilled in Enclosure

(1)

PDA-LHR

Red Light / Horn

PDA-LHG

Green Light / Horn

PDA-LHY

Yellow Light / Horn

PDA-LHB

Blue Light / Horn

PDA-LHW

White Light / Horn

PDA-LH5C

Light / Horn with User Choice of Red, Green, Yellow, Blue or White Light

PDA-LH3LC-RYG

Light / Horn with Red, Yellow, Green Light Layers

Note:

1. This MOD supplies the Light / Horn and Button. The enclosure comes pre-drilled with holes for Light / Horn and Button and the user performs the installation and wiring. ConsoliDator+ and enclosure are sold separately. The Light / Horn hole is located on the top left corner of the enclosure and the Button is located on the bottom left side of the enclosure.

PDA-BUTTON Momentary Pushbutton

Model

Description

PDA-BUTTON1B

NEMA 4X Black Button

PDA-BUTTON1G

NEMA 4X Green Button

PDA-BUTTON1R

NEMA 4X Red Button

PDA9000SH Sun Hood

Model

Description

PDA9000SH

ConsoliDator+ Sun Hood

PDA2360 Control Stations

Model

Description

PDA2360-E

Emergency Stop Button

PDA2361-A

1 Black Ack Button

PDA2361-Q

1 Black Silence Button

PD9501 Multi-Function Calibrator

Model

Description

PD9501

Multi-Function Calibrator

Page 12

PD9000 ConsoliDator+ Multivariable Controller

Instruction Manual

Signal Splitter & Conditioner Accessories

Model

Description

PD659-1MA-1MA

Signal Isolator with One 4-20 mA Input and One 4-20 mA Output

PD659-1MA-2MA

Signal Splitter with One 4-20 mA Input and Two 4-20 mA Outputs

PD659-1V-1MA

Signal Conditioner with One 0-10 VDC Input and One 4-20 mA Output

PD659-1MA-1V

Signal Conditioner with One 4-20 mA Input and One 0-10 VDC Output

PDA1024-01 Power Supply

Model

Description

PDA1024-01

24 VDC Power Supply for DIN Rail

Split Core AC Current Transducer

Model

Description

PDA6420

Split Core AC Current Transducer. Input: 30/60/120 AAC; Output 4-20 mA

Panel Mount Buzzer and Light

Model

Description

PDA1000

Panel Mount Buzzer and Light

Snubber 0.01μF/470Ω Flexible Leads

Model

Description

PDX6901

Snubber 0.01μF/470Ω Flexible Leads

Low-Cost Signal Generator

Model

Description

PD9502

4-20 mA or 0-10 VDC, Low-Cost Signal Generator

Page 13

PD9000 ConsoliDator+ Multivariable Controller

Instruction Manual

PD9000-ENC ConsoliDator+ NEMA 4X Plastic and NEMA 4 Steel Enclosures

The PD9000-ENC enclosures provide a convenient way to mount the PD9000 ConsoliDator+ to walls and other vertical structures. The enclosures are available in painted steel and plastic and come pre-cut with one cutout to mount the PD9000. The enclosures are available in various sizes, with the larger enclosures capable of housing other pieces of equipment, such as the PDA1024-01 power supply.

Note: The enclosure and ConsoliDator+ are ordered and packaged separately.

Features

● House One ConsoliDator+ PD9000

● Cutout for One ConsoliDator+ Provided

● ConsoliDator+ Mounts in Cover

● ConsoliDator+ Mounts Inside PDA3939 Clear Cover

● Sub-Panels Available

● PDA6909 Pipe Mounting Kit Available

● Light / Horn & Reset Button Available

● UL Listed Plastic Enclosures

● UL Listed, CSA Certified Steel Enclosures

NEMA 4X Plastic Enclosures

PDA1909

Dimensions: 11.8" x 11.8" x 5.9"

(300 mm x 300 mm x 150 mm)

(H x W x D)

PDA1939

Dimensions: 17.7" x 13.8" x 7.9"

(450 mm x 350 mm x 200 mm)

(H x W x D)

PDA3939

Dimensions: 17.7" x 13.8" x 7.9"

(450 mm x 350 mm x 200 mm)

(H x W x D)

NEMA 4 Steel Enclosures

PDA2909

Dimensions: 12.0" x 12.0" x 6.0"

(305 mm x 305 mm x 152 mm)

(H x W x D)

PDA2919

Dimensions: 14.0" x 12.0" x 8.0"

(356 mm x 305 mm x 203 mm)

(H x W x D)

PDA2929

Dimensions: 16.0" x 14.0" x 10.0"

(406 mm x 355 mm x 254 mm)

(H x W x D)

For More Details Download the

PD9000-ENC Data Sheet

Page 14

PD9000 ConsoliDator+ Multivariable Controller

Instruction Manual

Specifications

Except where noted all specifications apply to operation at 25°C (77°F)

General

Display

Color; QVGA (320 x 240 pixels),

5.7" (145 mm) diagonally, white backlight Bargraph: Twenty divisions Numerical: Up to 15 digits (±999,999,999,999,999) Feet & Inches Format: 99,999' 11.9"

Screen Bargraph

Enable/disable: Channels, totals, timers Bargraph scale: 0 – 100%, independent of channel scale. Twenty divisions: 5% each. Screen: Select to show bargraph or not.

Color Selection

65 colors selection Customize bargraph, panel background, and text for normal and alarm conditions.

Decimal Point

0 to 15 decimal places, user selectable

Engineering Units

User selectable units or custom units Time, Distance, Volume, Pressure, Weight, Temperature, Current, Voltage, Percent, Amps, Volts, Counts, Logic, and Custom, Any unit/unit of time or other units. See page 19 for list of units.

Feet & Inches Units

Data entry format: Decimal (e.g. 50.58 feet) Display format: 50' 6.96"

Units Conversion

Units’ conversion is supported for channels, totals, timers, and any function using those parameters. Channel scaling must be in the intended base units (e.g. Gallons/min)

Boot-Up Time

Less than 10 seconds All inputs and outputs

Display Update Rate

User selectable: 0.1 to 0.5 sec (10 updates/sec to 2 updates/sec)

Programming Method

Front panel buttons, external buttons, or ConsoliDator+ Software

Number of Alarms

Up to 64 high or low, Logic AND & OR Automatic (non-latching) or latching On & Off time delays Can be assigned to one or more relays.

Note: Alarms are independent from relays.

Alarm Types

Single Source: One input Multi-Source: Two or more inputs Interval: Enter time interval and On Time Day & Time: Select day of the week & time Alarm OR: Any active input alarm triggers

the OR alarm

Alarm AND: All alarms must be active to

trigger the AND alarm

Alarm Ack & Reset

Automatic only (Non-latching) Automatic and manual Manual only (Latching) Manual with Ack only after alarm is cleared (Latching with Clear)

Alarm Indication

1. Bargraph, panel, and text can be set up to change color on alarm

2. Enable internal buzzer

3. Assign external relay to drive a horn

Internal Buzzer

60 dBA @ 24 inches (61 cm) Enable/disable in System – General menu Associated with alarm Horn setting

External Horn (Sold Separately)

Assign any relay to the Horn function to activate an external horn when alarm condition is detected.

Live Channel Calibration

Live calibration of channels is independent of the input calibration used for scaling.

Input & Output Cards

Max Number of I/O Cards: 7 Analog Inputs: 4/card Pulse Inputs: 4/card Analog Outputs: 5/card Relays: 5/card

Number of Screens

Up to 20 screens with 1 to 8 PVs or items per screen Enable or disable screen title, channel #, and bargraph Automatic or manual scanning Scan time: 1 to >1000 sec, independent for each screen F1-F4 keys are assigned per screen

Function Keys

User programmable (See defaults below) F1 = Previous  F2 = Next → F3 = Scan/Stop F4 = Ack

Number of Channels

Up to 99 channels Input Source: 4-20 mA, Pulse, Digital, Modbus, another Channel, Total, Timer, Alarm, Date & Time, mA Output, Relay Output, Digital Output, or Modbus Output

Channel Functions

There is an extensive number of functions that can be applied to the inputs, see Channel & Math Functions on page 17.

Number of PID Control Channels

Up to (8) PID control loops can be set up with (8) analog inputs and (8) analog outputs. Note: (2) analog input cards and (2) analog output cards are used. The (3) remaining slots can be used for relays.

Programmable Switches

Up to (32) programmable digital switches can be used to route any input, output, or process variable.

Password

Programmable password restricts modification of programmed settings. View and Setup menus are password protected, function keys and digital inputs are not protected.

Simulation Mode

Inputs, channels, totals, timers, and alarms can be simulated from the View menu or from a function key. Simulation mode is not saved on power down. Alert! message is provided for simulated items.

Manual Control

Analog outputs and relays can be controlled manually from the View menu or from a function key. Manual control mode is not saved on power down. Alert! message is provided for outputs in manual control. Note: If it is necessary to turn relays off and maintain the condition through power cycle, configure the relays to Always Off.

Non-Volatile Memory

Settings stored for a minimum of 10 years.

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PD9000 ConsoliDator+ Multivariable Controller

Instruction Manual

AC Powered Models (-6)

Three-terminal connector (L, N, GND) 90-264 VAC, 47 to 63 Hz, 60 W max

DC Powered Models (-7)

Two-terminal connector (G, 24V) 24 VDC ±10%, 60 W max Means of Protection: Class 2 (Reinforced) Overvoltage Category: Class II

Fuse

Units are protected internally with autoresettable fuse AC: 1.25 A max DC: 3.7 A max

External Fuse

Recommended external fuse slow-blow 120 VAC: 2.0 A 240 VAC: 1.0 A 24 VDC: 4 A

Isolation & Grounding

1500 V Analog inputs/outputs-to-power line

500 V Analog input-to-input, input-to-output, analog output-to-output All analog inputs and analog outputs are isolated from each other.

Environmental

Operating temperature range:

-25 to 55°C (-13 to 131°F)* Storage temperature range:

-40 to 60°C (-40 to 140°F) Relative humidity: 0 to 90% non-condensing

Front Sealing

Type 4X, IP66

Pollution Degree

Maximum Altitude

2000 m (6,562 feet)

Internal Fan

Automatic temperature-controlled fan turns on if the inside temperature reaches 50°C and increases the speed as the temperature rises to 60°C.

Internal Heater

Automatic temperature-controlled heater located behind the LCD turns on at 0°C, delivering the minimum power. If the temperature drops below -10°C, the heater delivers its maximum power.

Connections

Removable screw terminal blocks Inputs/Outputs: 12 to 24 AWG wire Digital I/O: 16 to 30 AWG RS-485: 12 to 24 AWG wire RJ45 Ethernet connection USB ports: Micro-USB used for programming; cable included. Data Log Drive: Type A, used with Data Logger Add-On feature.

Tightening Torque

Screw terminal connectors: Analog I/O & Relays: 0.5 Nm (4.5 lb-in) Digital I/O terminals: 0.23 Nm (2 lb-in)

Enclosure

Enclosure Body: Thermoplastic Polyester Color: Gray Display Window: Clear Polycarbonate, GE LEXAN HP12W Front Panel Keys: Silicone rubber

Mounting

Panel-mounting frame and twelve screws (provided) Cutout: 10.0" x 10.0" ±0.05" (254 mm x 254 mm ±1.3 mm) (H x W)

Panel thickness: 0.07" – 0.35" (1.8 mm – 8.9 mm) Clearance behind panel: 6" (152 mm)

Overall Dimensions

10.85" x 10.85" x 4.87" (276 mm x 276 mm x 124 mm) (H x W x D)

Weight

Ex: PD9000-XY-4PI-8AI-10AO-10RY

7.4 lb (3.4 kg) approx.

Field Enclosure

This device is an open-type controller and is required to be installed in a suitable enclosure that can only be accessed with

the use of a tool or key. Panel mounting fasteners shall be tightened to a torque value of 0.8 Nm (7 lb-in).

Warranty

3 years parts and labor. See Warranty Information and Terms & Conditions on

www.predig.com for complete details.

Page 16

PD9000 ConsoliDator+ Multivariable Controller

Instruction Manual

Totalizer

Number of Totalizers

Up to 32 totalizers 15 digits with comma separator

Totalizer Inputs

Calculates total based on selected rate channel, pulse input, digital input, or triggered event for non-rate channels. Total is stored in non-volatile memory if power is lost.

Maximum Total

18 digits 999,999,999,999,999,999

Rate Channel Input

4-20 mA input, Pulse input, Modbus input

Rate & Total Decimal Point

Independent and user selectable from 0 to 15 places

Totalizer Reset

Via front panel keys or digital inputs

Non-Resettable Total

Total can be set up to be non-resettable to prevent unintentional reset. This can be changed in the Setup Totals menu.

Total Units Conversion

Input: Rate channel Total units can be different than rate units. Use the custom units to convert to any unit (e.g. Gallons to Billion gallons BGAL: Factor = 0.000000001)

Pulse Input K-Factor

K-Factor = pulses/units of measure Calculates total directly from pulse input,

Modbus input, channel, total, or Modbus output. Create rate channel by entering K-Factor, units and time base in sec, min, hr, or day. Decimals: 0 to 15

Count Down

Total can set up to count down from a predetermined value entered by the user.

Preset Value

Enter the preset value to count up or down. Reset total sets total to the preset value; to reset to zero uncheck the Preset box.

Roll-Over

Enter the value for total to roll-over to 0 Example: Roll-Over = 1,000,000 Total goes to 0 after 1 million

Negative Total

Allow total value to count below 0 for bi-directional flow based on rate channel

Total Bargraph

Bargraph can be scaled to represent the expected maximum total

Function Keys

Screen Setup: Assign F1-F4 to Reset Total, Enter Total, Add To, or Remove From Total

Previous Total

This is the total prior to the last reset. Multiple previous totals can be set up by selecting a previous total as the input to a new total. The date & time is captured with the previous total.

Daily Total

This is the total for the day, starting at midnight. Daily total can be the input for previous totals to keep a record of a few days. The date is captured with the previous total.

Grand Total

Uses another total as the input and it is setup as non-resettable

Non-Rate Total

This total takes the input from a non-rate channel, a trigger causes the total to increment, or decrement based on the settings selected (e.g. Input from weight scale added when digital input is triggered).

Real Time Clock

Date Format

Month, day, year (e.g. July 16, 2020)

Time Format

24 hour; 00: Midnight hh:mm:ss

Battery

3V, P/N: CR2032 included Battery replacement only with a Panasonic CR2032 Lithium Metal 3V coin cell battery.

Display Date & Time

Displayed on the top line of Setup and View menus, including day of the week.

Screens

Date & Time can be added to any screen.

Channels

Date & Time can be the input to a channel. Display Format: yyyy/mm/dd hh:mm:ss

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PD9000 ConsoliDator+ Multivariable Controller

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Channel & Math Functions

Scale Functions

K-Factor

Converts number of pulses to volume or other units

Scale Factor

Apply multiplier to a channel

Scale Linear 2-Pt

Scale a channel

Scale Multi-Point*

Multi-point scaling of a channel

Scale Square Root

Apply square root to a channel – Differential Pressure from two channels

Scale Exponent

Apply exponent for weirs and flumes open channel flow calculation

Round Horizontal Tank

Calculate volume in round horizontal tank with flat ends

Units Conversion

Convert base units to any units

Percent (Bargraph)

% bargraph of any: 4-20 mA input, channel, total, timer, or mA output

Text (Percent)

Text displayed based on the % input value

Math Functions

Constant

Assign fixed value

Summation

Add two or more channels

Difference

Subtract any two channels

Abs Difference

Difference always positive

Absolute Value

Convert channel value to positive

Average

Find the average of channels

Weighted Average

Assign % weight to two or more channels

Multiply

Multiply two channels

Divide

Divide two channels

Exponent

Set the base and the exponent; both can be constants or variables

Logarithm

Set the base and the value; both can be constants or variables

Modulo

Set constants or variables for A mod B

Trigonometry

Sine, cosine, tangent, arc sine, arc cosine, arc tangent. Select the input and angle

% Efficiency

Calculate input to output efficiency ((A-B)/A)*100%

Open Channel Flow Functions

Parshall Flumes

Q = K H^n Enter constant, head

variable, exponent, and units

V-Notch Weirs

Q = K H^2.5 Enter constant, head variable, and units

Cipolletti Weirs

Q = K L H^1.5 Enter constant, crest

length, head variable, and units

Rectangular Weirs w/o Contractions

Q = K L H^1.5 Enter constant, crest length, head variable, and units

Rectangular Weirs with Contractions

Q = K (L-0.2H) H^1.5 Enter constant, crest length, head variable, and units

Note: Enter K value for Q = cuFt/sec; select any flow rate units to be displayed or used as input to a totalizer.

*Scale Multi-Point: There is no minimum input span

requirement; it is up to the user to make sure the input values are correct.

Page 18

PD9000 ConsoliDator+ Multivariable Controller

Instruction Manual

Additional Functions

Compare

Greatest

Greatest value in a group of channels

Least

Smallest value in a group of channels

Middle of 3

Outputs the middle value of three inputs

Measure

Tare

Calculate net value when Tare function is applied via function key

Maximum

Maximum value reached by the process

Minimum

Minimum value reached by the process

Duration

Keep track of time a condition has been present (e.g. high alarm active)

Rate of Change

Calculates how fast a process is changing /sec, /min, /hr, /day

Filter

Window Average

Enter time to calculate the average

IIR (First Order)

Infinite Impulse Response (slow)

Cutoff

PV = 0 below cutoff Flip Side: 0 above (-)

Limits

Sets PV upper & lower limits.

Round

Round (to nearest) Floor (always down) Ceiling (always up) Less (toward zero) More (away from zero)

Hysteresis

Resists a directional change using a time delay, filters change in the trending direction

Delay

Enter the number of seconds to delay the output

Pulse Filter

Use to filter discrete inputs, set minimum and maximum on/off time in seconds

Control

Sampler

Trigger relay sample and select sampling time (e.g. Turn relay on for 30 sec every time total increases by 1,000 Gallons)

On-Off Control

Set on & off control based on PV

On-Off Control with Random Varying On/Off

Select Randomizer, enter on/off points +/random variation

Select A or B

Switch between 2 inputs

Select 1,2,3…

Select 1 from 3 or more inputs, it works as a selector switch

Schedule

Daily or weekly event The available actions depend on the

configuration of the inputs and outputs.

Capture

Set a trigger event to capture a value in real time

PID Control

Set up channel for PID control

PWM Control

Set up channel for pulse width modulation control to be used with PID control loop

Switch Position

Set up channel to read the digital switch position (0, 1, 2, 3)

Relays

Cycle Count

Number of relay cycles since reset

Runtime

Relay runtime (ON) hh:mm:ss

Modbus

Time Since Read

Time since a Modbus client device read a register

Time Since Write

Time since a Modbus client wrote to a register

Page 19

PD9000 ConsoliDator+ Multivariable Controller

Instruction Manual

List of Engineering Units

Time

seconds, minutes, hours, days & /sec, /min, /hr, /day

Distance (Height)

cm, m, Inch, Feet, Ft-In, Yard, km, miles, custom

Volume

Gallons, GAL, L, IGAL, M3, BBL, BUSH, cuYD, cuFt, cuIn, LiBBL, BBBL, HECtL, quarts, pints, fl oz, mL, DT, M/T, MGAL, custom

Pressure

psi, Pa, bar, hPa, kPa, MPa, GPa, inH2O, cmH2O, inHg, mmHg, atm, kg/cm2, kg/m2, mbar, Mbar, Torr, mTorr, custom

Weight

grams, Oz, Lb, lb, g, kg, ounces, tons, tonnes, custom

Temperature

C, F, K, Ra

Percent

%, PCT, Percent, custom

Amps

mA, Amps, custom

Volts

V, mV, Volts, custom

Counts

Pulses, Cycles, Counts, custom

Logic

ON, OFF, OPEN, CLOSED, YES, NO, START, RUNNING, STOP, STOPPED, PUMP ON, PUMP OFF, OK, OKAY, ERROR, WARNING, custom

Custom

Enter unit’s name, type, base unit, and factor.

4-20 mA Analog Inputs

Number of Inputs

(4) Analog inputs/card (28) Analog inputs max, no other I/O

Typical Input

4-20 mA

Input Range

0-24 mA

Accuracy

±0.03% of full scale 1 count

4-20 mA Display Value

Up to six recommended ±999,999 More digits can be used, but the stability

will be affected. Increase the filter value and lower the display update rate or use rounding to get a more stable reading.

Number of PID Control Loops

(8) PID control loops can be set up with (8) analog outputs connected to SCRs. Note: (4) digital outputs can be used to control SSR (Solid State Relays).

Transmitter Power Supply

Isolated 24 VDC @ 200 mA/input Max current: 1,600 mA (All inputs) (8) Analog Input @ 200 mA max (28) Analog Input @ 20 mA max Available on AC or DC powered units

Temperature Drift

Better than 20 ppm/C from -40 to 60°C ambient

Filter

Window average: None, 0.5, 1, 2, 4, 8 sec IIR (Infinite Impulse Response): 16, 32 sec Glitch Filter: Discards a single sample caused by high frequency noise

Filter Bypass

0 to 100 % of full scale Filter is ignored, if the signal change is greater than bypass value

Channel Input Scale Function

Scale Linear 2-Point, Scale Multi-Point (2 to 50 points)* Scale Square Root Scale Exponent (Open Channel Flow) Scale Factor Round Horizontal Tank (Volume) Units Conversion (mA Input Reading) Percent Bargraph Text (Percent)

Channel Input Live Calibration

Each channel can be calibrated using live calibration signal from a sensor or a calibrator.

Input Protection

Each 4-20 mA input is protected by an auto-resettable fuse, 30 VDC max. The fuse resets automatically after the fault condition is removed.

Input Impedance

125  typical, including auto-resettable fuse

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.

Isolation

1500 V: Input-to-power line 500 V: Input-to-input, input-to-output All analog inputs and analog outputs are isolated from each other.

Normal Mode Rejection

100 dB at 50/60 Hz

Common Mode Rejection

90 dB at 50/60 Hz

Page 20

PD9000 ConsoliDator+ Multivariable Controller

Instruction Manual

Pulse Inputs

Number Of Inputs

(4) Pulse inputs/card (28) Pulse inputs max, no other I/O

Input Type

Active Square Wave, NPN, PNP, Reed Switch, Coil (Magnetic Pickup) Normal threshold: 1.2 V (0.8 to 3.0 V) High threshold: 2.5 V (2.0 V to 6.0 V) Coil threshold: 20 mV (Low) or 100 mV (High)

Signal Level

Active Square Wave: 0 to 30 V max Typical: 0 to 5 V Coil: 20 mVp-p to 30 Vp-p (Magnetic Pickup)

Input Impedance

Active, NPN, Reed: 10 kΩ pull-up to 5 V PNP: 10 kΩ pull-down to (S-) Coil: >2 kΩ (20 mV sensitivity), >10 kΩ (100 mV sensitivity)

Isolation

Pulse inputs are not isolated, (S-) terminal is connected to system GND

Input Protection

±36 V, non-isolated

Frequency Response & Signal Level

Active Square Wave 5 V: 0 to 100 kHz Coil (Magnetic Pickup): 0 to 50 kHz Frequency – Signal level (Coil: 20 mV) 20 mVp-p – 100 Hz 100 mVp-p – 10 kHz Frequency – Signal level (Coil: 100 mV) 100 mVp-p – 90 Hz 500 mVp-p – 5 kHz 20 Vp-p – 50 kHz

Minimum Frequency

250 µHz with High Gate = 4,000 sec

Low Gate

1 to 99 sec

High Gate

2 to 4,000 sec (Must be higher than low gate)

Low Speed

100 Hz maximum Used for contact debouncing

Pulse Counter

8,388,607 maximum, used for troubleshooting purposes only

Accuracy

±1 count for K-Factor > 1 or 30 ppm

K-Factor

Programmable pulses/unit of measure with up to 14 decimal resolution

Scale Pulse Input

Scale Linear 2-Point Scale Multi-Point Scaling*: 2 to 50 points Scale Factor Units Conversion

Live Calibration

Pulse input channel can be calibrated using live calibration signal from a sensor.

*Scale Multi-Point: There is no minimum input span

requirement; it is up to the user to make sure the input values are correct.

Page 21

PD9000 ConsoliDator+ Multivariable Controller

Instruction Manual

Modbus Inputs - Server

Availability

Standard feature

Number of Inputs

199 Modbus RTU or ASCII

Scale Modbus Input

Modbus input can be used as the input for creating channels and totals, the same way the 4-20 mA inputs are used.

Data Type

Bit-Logic Signed/Unsigned:

16 (Short), 32 (Long), 64 (Long-Long)

Float 32, Float 64 (Double)

Decimal Point

User selectable

Comm Break & Timeout

Specify what value to hold when a communication break occurs and how long to wait for new data before reporting a break condition.

Input Action

Specify what should happen when new data is written to the input register (e.g. Add to Total 1, Log Entry – All Logs).

Digital Inputs & Outputs

Digital Inputs

5 Inputs, non-isolated, 30 VDC max Standard feature on all ConsoliDator+ models Low: 0 to 1.2 V High: 2.8 to 30.0 V Internal pull-up: 5 kΩ to 5 V Max pulse frequency: 1 kHz @ 5 Vp-p +5 V terminal: Internal pull-up 100 Ω Note: Pulse inputs can be used as digital inputs

Digital Input Types

Normally open switch: External excitation not required (Current: 1 mA) Open collector: 4.1 V open circuit voltage Logic level: 0 to 30 V

Assignment & Operation

Active Low or Active High Functions: Remote front panel button, total functions, timer control, alarm functions, screen navigation, horn functions, reset relay information. Digital inputs can be used as input source for channels, totals, and alarms.

Digital Outputs

4 Outputs Standard feature on all ConsoliDator+ models Low: 0 V (no load), 1.5 V max @ 10 mA sink (External pull-up) High: 5.0 V (no load), 3.5 V @ 10 mA load Maximum current: 30 mA Output impedance: 100 Ω Output protection: 150 mA auto-resettable fuse Max frequency: 5 Hz

Digital Output Assignment

Digital outputs require logic units as the input. Input sources: Digital input, Modbus input, channel, alarm, horn, always on, or always off

Input / Output Protection

±36 V, non-isolated

Relays

Number of Relays

(5) Relays/card (30) Relays max with (4) analog or (4) pulse inputs, no other I/O

Rating

SPDT (Form C) Resistive load: Rated 10A @ 120/240 VAC or 8A @ 30 VDC Inductive load: NO contacts: 5A, 1/3 HP, 120 VAC; 30,000 cycles NC contacts: 1/8 HP, 120 VAC; 50,000 cycles Minimum load: 100 mA @ 5 VDC

Maximum Current per Relay & Number of Relays

11 relays or more: 5A @ 120/240 VAC or 30 VDC. Limited due to heat dissipation inside the enclosure.

Isolation

1500 VAC, 50/60 Hz for 1 min between coil and contacts

Deadband

0-100% of full scale, user selectable

Electrical Noise Suppression

TVS diodes & snubbers on all contacts. Recommended additional external snubber: 0.01 µF/470 , 250 VAC (Order: PDX6901)

Assignment & Operation

Any relay can be assigned to any alarm, channel, total, timer, digital input, Modbus input, pump alternation, horn, always on, or always off. Multiple relays can be assigned to the same alarm or channel. All relays are programmed independently.

High & Low Alarm: Defined by set and reset points in the Alarm menu

High or Low Alarm: Assign relay to any alarm or channel for on/off relay control Note: Automatic reset only for channel

Multi-Source High or Low Alarm: Assign relay to multi-source alarm to indicate common high or low condition.

Pulse Action: Set any relay for pulsing on/off timed relay control. Programmable pulse width (on/off time) and on/off delay.

Sampling: Relay must be assigned to channel setup for Sampler function with user-defined total increment and sampling time.

Pump Alternation: Any relay can set up to alternate with any relay in the group. Multiple alternation groups can set up.

Acknowledge

Front panel Ack key or digital input acknowledges individual or all alarms; relays associated with acknowledged alarm are turned off.

Alarm Relay

Assign any relay to be driven by any alarm; acknowledging the alarm turns off the relay (non-fail-safe mode).

Time Delay

Programmable on/off delays,

0.0 to 999.9 sec Independent for each relay.

Auto Initialization

When power is applied to the controller, relays will reflect the state of the input to the controller.

Fail-Safe 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.

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4-20 mA Transmitter Outputs

Number of Analog Outputs

(5) Analog outputs/card (35) Analog outputs max with no other I/O cards (Seven I/O slots)

Output Range

4.00 to 20.00 mA, nominal

Calibration

Factory calibrated for 4-20 mA

Scaling Range

Any process range Reverse scaling allowed

Assignment & Operation

Assign to any analog or pulse input, digital input, Modbus input, channel, total, timer, alarm, or fixed value (none). Note: Multiple 4-20 mA outputs can be assigned to the same input.

Accuracy

±0.03% F.S. 0.005 mA

Temperature Drift

20 ppm/C from -40 to 60C ambient. (Output & Input drifts are separate)

Output Loop Power

Output Loop Resistance

Powered by controller: 10 to 600  External 12 VDC: 10 to 200  External 24 VDC: 10 to 600  External 32 VDC: 10 to 1000 

Isolation

1500 V: Output-to-power line 500 V: Output-to-output, output-to-input All analog inputs and analog outputs are isolated from each other.

Timers

Number of Timers

Up to 30

Time Format

hh:mm:ss with 0 decimals selected Seconds with 1 or more decimals

Automatic Actions

Power Up: Timer action on power up Error: Action when an error is detected Reset: Event causes the timer to reset Start: Event triggers the timer to start Stop: Event causes the timer to stop

Start / Stop Reset

The function keys and digital inputs can be used to start, stop, and reset the timers, regardless of the automatic actions selected.

Assignment & Operation

Timers can be triggered, stop, and reset, by rising or falling signals from 4-20 mA input, pulse, digital, Modbus input, channel, total, other timers, alarm, mA output, relay, or Modbus output.

Count Down Timer

Select count down and enter starting time

Timer Alarm

Timer can be used to trigger alarms

Bargraph

Select bargraph during setup and scale the bargraph for 0 – 100% target time

Timer Control

Access timer control via the View Timer menu or assign a function key to timer control in the Screens menu

Timer & Relay

Timer can be assigned to drive relays based on selected set and reset points.

Modbus Outputs - Server

Availability

Standard feature

Data Type

Bit-Logic Signed/Unsigned: 16 (Short), 32 (Long),

64 (Long-Long)

Float 32, Float 64 (Double)

The register numbers are automatically generated based on the Modbus output number and the output’s data type. Bit – Logic: 04101 – 04199 Signed/Unsigned 16: 44101 – 44199 Signed/Unsigned 32: 44201 – 44398 Signed/Unsigned 64: 45001 – 45396 Float 32: 44401 - 44598 Float 64: 44601 - 44996

Engineering Units

Select the engineering units for the process variable assigned to the output

Decimal Point

User selectable. For short and long integers this is a multiplier applied to the input value, but it is not displayed on the server’s screen. The Modbus client uses this setting to read the correct value from the server. Example: Ch 1 value = 4,379.26 MB Output Data Type: Signed 32 Decimals = 0 → Output = 4,379 Decimals = 3 → Output = 4,379,260

Output Action

Specify what should happen when the output register is read by the client (e.g. Start timer 1, Log Entry – All Logs).

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Modbus Serial Communications

Compatibility

RS-485 (EIA-485)

Protocols

Modbus RTU or Modbus ASCII Modbus Enron is supported by the Client and the Spoofer modes.

Device Address

1 to 247 (Server)

Transmit Delay

0 to 999 ms

Receive Timeout

1 to 9 seconds

Baud Rate

1,200 to 115,200 bps

Data

8 bit (1 start bit, 1 stop bit)

Parity

Even, Odd, None with 1 stop bit, or None with 2 stop bits

Modbus Inputs

199 for all modes

Modbus Outputs

99 for all modes. The outputs can be grouped together to be sent as blocks of registers.

These Modbus outputs are in addition to the outputs listed in the Modbus Register Tables, see page 128.

Communication Break

Reports a break condition after the response timeout has elapsed. The break condition can be: Zero, a default value, or the text Break.

The Client goes into break condition after the server device fails to respond and the timeout has elapsed.

The Snooper and Server modes go into break condition after no new data is received within the response timeout window.

Alarms can be programmed to go on, off, or stay as is when a break condition is detected. The analog outputs can set up to generate a fixed mA current when a break condition is detected.

Modbus Client, Snooper & Spoofer

Add-On Feature PDK9000-M1

Client, Snooper & Spoofer The Modbus Client is an option in the

ConsoliDator+. It can be purchased at the time the order is placed or it can be purchased and enabled at any time.

The Modbus Snooper & Spoofer features are part of the Client Add-On feature.

Modes

Client: Requests data from servers and

writes data to servers. Snooper: Listens to the RS-485

network communications and reads the selected registers.

Spoofer: A channel is configured to pretend being a device that has been removed from the network. The device ID and register number is used.

Client & Snooper Settings

Availability

Order Add-On Feature model PDK9000-M1 at any time.

Number of Output PVs

99 process variables can be written by the Client mode to Modbus servers. Modbus server inputs and outputs are available over the Ethernet port, in Client mode also.

Server ID

Enter the server ID or address containing the process variables to be read or written by the Client or read by the Snooper.

Function Code

Select which Modbus function code to use for reading the server device or for writing to a server by the ConsoliDator+ Client.

0-65,533 (Base 0) Reg. No. 30001-39999, 40001-49999 Reg. No. 300001-365534 or 400001-465534 Specifies which register(s) to read from the server device.

Data Type

Select the data format used by the server device. Bit – Logic (Coil) Signed/Unsigned: 16 (Short, 2 byte)

32 (Long, 4 byte) 64 (Long Long, 8 byte)

Float 32 (4 byte), Float 64 (Double, 8 byte)

Byte Order

ABCD, CDAB, BADC, or DCBA (big-endian, swapped, or little-endian)

Client Poll Time

1.0 to 999.9 sec. Time between read commands.

Server Response Timeout

99:59:59 hrs.: Time allowed for the server to respond before the Modbus client generates a communication break condition. The timeout should be greater than the poll time. Server/Snooper mode: Time the Modbus input will wait for new data before going into a break condition. If the timeout is disabled, the last value will remain until a new value is received.

Spoofer Settings

Availability

Order Add-On Feature model PDK9000-M1 at any time.

Number of Output PVs

99 process variables can be replaced by the ConsoliDator+ Spoofer feature.

Number of Input PVs

199 process variables can be written by a client to the Spoofer inputs replacing other Modbus servers.

Server ID

Enter the server ID or address being replaced by the ConsoliDator+ Spoofer.

Function Code

Select the Modbus function code used by the server device.

Enter the address 0-65,533 (Base 0) for the process variable of the replaced server.

Data Type

Select the data format used by the server.

Byte Order

Select the byte order ABCD, CDAB, BADC, or DCBA (big-endian, swapped, or little-endian)

Engineering Units

Select the engineering units for the process variable.

Decimals

Enter the number of decimals required.

Output Action

Select an action to be performed by the controller, when the Spoofer output is read by a Modbus client or leave as None.

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Data Logger – USB Drive

USB Data Logger Add-On Feature PDK9000-D1

The Data Logger is an option in the ConsoliDator+. It can be purchased at the time the order is placed or it can be purchased and enabled at any time. The Data Logger feature is available on ConsoliDator+ units with a firmware version 2.2 or greater.

Storage Device

External USB flash drive Format: FAT32 (32 GB maximum) Recommended drive: SanDisk 32GB maximum.

Number of Data Logs

8, maximum

Number of Variables / Log

12, maximum

Number of Log Variables

96 variables, maximum (8 logs x 12 variables / log)

Number of Log Records

The number of records depends on the flash drive size. Examples for 32 GB:

1) 4 logs with 8 variables each 1 min rate: ~160,000,000 records Log time: 60 years

2) 8 logs with 12 variables each 1 min rate: ~70,000,000 records Log time: 16 years

Log File Type

csv (comma separated value)

Maximum Log File Size

100 MB A new file is automatically created when the log file exceeds 100 MB.

Stop when Full

This should be selected if the oldest logged data is more important than logging new data. If Stop when Full is not selected, the oldest block of data will be deleted to make room for new data.

Remove Device

Use the Remove Device button, in the System – USB Drive, to safely remove

the USB drive and prevent data corruption.

Alert! Message

An Alert! message is displayed in place of the Menu key if the USB drive is removed.

Start / Stop

Selecting this feature enables the Start / Stop function key in the View – Data Logs menu. The Start / Stop function

can be activated using the digital inputs, F1-F4 function keys in the Setup – Screens menu, Channel control schedule, Modbus inputs, and Modbus outputs.

Log Enable Switch

The Enable Switch setting can be used to control the log process using digital inputs, Modbus inputs, Channel control, alarms, or relay outputs. Logs are recorded only if the Enable Switch input is in the active (on) condition.

Log Trigger

The Log Trigger setting is used to log data on a specific event; a log can be triggered using digital inputs, Modbus inputs, Channel control, alarms, relays.

Manual Log

The user can record a log entry at any time by using the F4 key in the View – Logs menu or by assigning a function key in the Setup – Screens menu.

Log Interval

00:00:01 to 23:59:59 hrs:min:sec

How to Enable Add-On Features

To enable the Data Logger features, see Add-On Features on page 106.

• The USB Data Logger functions are available only if the Add-On feature has been enabled in the System – General Settings, see Add-On Features on page 106.

Sample Data Log File

Ethernet Communications

Device

Lantronix Xport-05

Protocol

Modbus TCP/IP (Default) Modbus UDP/IP Modbus RTU Over TCP/IP Modbus RTU Over UDP/IP

Port Settings (Do Not Change)

Protocol: RS-232 Baud Rate: 9600 Data Bits: 8 Flow Control: None Parity: None, Stop Bits: 1

Network Stack

IPv4

Ethernet Mac/Phy

10/100 Mbps

Additional Specifications

Refer to the Lantronix webpage at https://www.lantronix.com/products/xport.

Ethernet Port Configuration

Use the System menu for basic Ethernet configuration or download the Lantronix Device Installer software to fully configure the Ethernet port at

https://www.lantronix.com/products/xport. See page 112 Ethernet Port Setup for

instructions.

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PD9000 ConsoliDator+ Multivariable Controller

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ConsoliDator+ Software

System Requirements

Windows® 7, 10

Compatibility

The software and firmware versions must be matched.

• Do not write configuration files created using older versions of the firmware and software to controllers with Add-On features enabled (Ver. 2.1 & up). This can create undesirable results, especially with the function keys F1-F4.

Connection

Standard USB A to Micro-USB type B (cable included).

Configuration

Configure inputs and outputs, channels, totals, timers, alarms, etc.

Configure bargraph and panel colors for normal operation, and colors for alarm indication. Save controller settings file on PC for programming other controllers or to restore settings.

Compliance Information

Hazardous Area Location*

UL & C-UL Listed

For Hazardous Location Installations (US and Canada) Class I Division 2 Groups A, B, C, and D Class II Division 2 Groups F and G Class III Temperature Code: T4A

UL File Number

E516990

Front Panel

UL Type 4X, NEMA 4X, IP66; Panel gasket provided

Low Voltage Directive

CSA-C22.2 No. 61010-1 and CSA-C22.2 No. 61010-2-201 UL 61010-1 and UL 61010-2-201 Safety Requirements for Electrical Equipment for Measurement, Control, and Laboratory Use

• Explosion Hazard - Batteries must only be changed in an area known to be non-hazardous.

• Explosion Hazard - Do NOT Connect or Disconnect Equipment unless power has been switched off or the area is known to be non-hazardous.

*Hazardous Area Location approvals apply to all PD9000

(H) models. See ordering information.

Ordinary Location*

UL & C-UL Listed

USA and Canada UL 508 Industrial Control Equipment

UL File Number

E160849

Front Panel

UL Type 4X, NEMA 4X, IP66; Panel gasket provided

Low Voltage Directive

CSA-C22.2 No. 61010-1 and CSA-C22.2 No. 61010-2-201 UL 61010-1 and UL 61010-2-201 Safety Requirements for Electrical Equipment for Measurement, Control, and Laboratory Use

*Ordinary Location approvals apply to all PD9000

(G) models. See ordering information.

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Safety Information

• Read complete instructions prior to installation and operation of the controller.

• Risk of electric shock.

• Hazardous voltages exist within enclosure.

• Installation and service should be performed only

by trained service personnel.

Installation

Unpacking

Remove the instrument from its box. Inspect the packaging and contents for damage. Report any damages to the carrier. If any part is missing or the controller malfunctions, please contact your supplier or the factory for assistance.

Panel Mounting

• Prepare panel cutout per the dimensions provided

• Locate the panel mounting bracket and screws

• Inspect the controller to assure the gasket is

securely in place

• Insert controller in the panel cutout, the latches on the top and bottom should hold it in place

• Insert the panel mounting bracket from the back of the panel, observe the orientation of the piece marked TOP

• Install the 12 screws provided to a torque value

of 0.8 Nm (7 lb-in)

Figure 1. Front Panel Mount Dimensions

Figure 2. Panel Cutout Dimensions

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PD9000 ConsoliDator+ Multivariable Controller

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Figure 3. Panel Mount Installation

Mounting Dimensions

Figure 4. Panel Mount Overall Dimension

Panel

Panel Mounting Bracket

Notes:

1. Panel cutout: 10.0" x 10.0" ±0.05" (254 mm x 254 mm ±1.3 mm), see Figure 2.

2. Panel thickness: 0.07" – 0.35" (1.8 mm – 8.9 mm)

3. Clearance: Allow 6" (152 mm) behind panel

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PD9000 ConsoliDator+ Multivariable Controller

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ConsoliDator+ Configuration Software Installation

We recommend the following sequence for getting the controller into service:

1. Download the latest version of the Consolidator+ configuration software from our website predig.com/software.

2. Extract the contents of the ConsoliDatorPlus2XXX_Installer.zip file into a folder on your computer.

3. Double-click on the executable file ConsoliDatorPlus2XXX_Installer.exe and follow the on-screen instructions.

4. This message is displayed. Click on Next to start the setup process.

5. Follow the onscreen instructions to install the required .NET Runtime version, if not installed in your computer.

6. This message is displayed, click Next to continue.

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PD9000 ConsoliDator+ Multivariable Controller

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7. Read and accept the End-User License Agreement and click Next to proceed.

8. Select the folder where you want to install the ConsoliDator+ software and click Next.

9. After selecting the installation folder, click Install to continue.

10. The User Account Control message is displayed. Click Yes to proceed with the installation of the ConsoliDator+ software. Follow the onscreen instructions.

11. After the software installation is complete, click the Finish button.

12. A ConsoliDator+ icon is placed on your desktop.

You are now ready to start using the software to configure your ConsoliDator+ controller.

The easiest and quickest way to program your ConsoliDator+ is to use the FREE ConsoliDator+ configuration software available for download at

predig.com/software.

The ConsoliDator+ configuration software is intuitive, and most customers can get their controller programmed as they like without even looking in the manual.

• Only one controller can be connected at a time. Attaching multiple controllers will cause a conflict with the controller software.

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PD9000 ConsoliDator+ Multivariable Controller

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Connect to ConsoliDator+ Configuration Software

1. Connect one end of the provided USB cable to the controller and the other end to the computer.

2. Double-click on the ConsoliDator icon

3. The application will start displaying the System menu and the connection status.

4. Click on Read, at the top of the screen, to read the configuration of the connected controller. After a read, the channels settings overview is displayed.

5. You can now begin to configure the ConsoliDator+ for your application, either by editing the existing settings or by starting fresh creating a new configuration.

6. Click on Write to send the new configuration to the connected controller.

7. Click on File to save files, open existing files, or to create a new configuration even without a controller connected.

8. The Advanced Settings menu allows changing

the target firmware version and add-on features. These settings are set automatically to match your ConsoliDator when the controller is read.

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Connections

The back panel is labeled with the I/O boards that were installed at the factory. The removable connectors are labeled with the connection signal for each terminal. The following diagram shows what the back of the model PD9000-6G-4PI-8AI-10AO-10RY-E looks like. This model is powered from 90-264 VAC, it accepts (4) pulse and (8) analog inputs and has (10) 4-20 mA outputs and (10) relays. (5) digital inputs, (4) digital outputs, RS-485 serial capability and USB connections are standard on all ConsoliDator+ models. Ethernet is an option.

If all Input / Output slots are used exclusively for one function, the ConsoliDator+ can accept up to (28) isolated 4-20 mA inputs, (28) pulse inputs, (25) isolated 4-20 mA outputs, or (25) relays.

If used as a Modbus Client, Snooper, or Server only: It can have (35) 4-20 mA outputs, 30 relays, or (20) 4-20 mA outputs and (15) relays.

Units are powered from AC or DC according to the power option ordered (AC: -6 or DC: -7).

Figure 5. Connection Terminals for a PD9000-6G-4PI-8AI-10AO-10RY-E

Notes:

1. Each 4-20 mA input has its own isolated 24 VDC power supply to power the transmitter.

2. Each 4-20 mA output has its own isolated 24 VDC power supply to power the output loop.

3. Each relay is Form C and rated at 10 A.

4. Input / output connections are made to removable screw connectors.

5. Every ConsoliDator+ has five digital inputs (additional digital inputs can be obtained by using the Pulse Inputs).

6. Every ConsoliDator+ has four digital outputs.

7. Every ConsoliDator+ has RS-485 with Modbus.

8. Powered from AC or DC, depending on the ordered power option.

9. The Data Log Drive is used for the Data Logger Add-On feature.

10. Ethernet with Modbus TCP is an option.

11. The micro USB is used for programming the ConsoliDator+ with Free Software.

• 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 controller and ensure personnel safety.

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Power Connections

Power connections are made to a three-terminal connector for AC (-6) models and to a two-terminal connector for DC (-7) models.

90-264 VAC Power

• Use three-terminal power connector as shown in Figure 7.

• Unit is protected internally with 1.25 A auto- resettable fuse. 2 A max, slow blow, 250 V min, UL Recognized external fuse recommended.

Figure 6. AC Power Connections

24 VDC Power ± 10%

• Use two-terminal power connector as shown in Figure 7.

• Unit is protected internally with 3.7 A auto- resettable fuse. 4 A max, slow blow, 50 V min, UL Recognized external fuse recommended.

Figure 7. DC Power Connections

Isolated Input Signal Connections

Isolated input signal connections are made to removable screw terminal connectors, which are labeled individually on the back panel of the controller. The back panel shows the type of input card installed in each slot (The top slot is #1 and the bottom is #7). Individual inputs are referenced as PI-1 to PI-4 for pulse inputs and AI-1 to AI-4, AI-5 to AI-8, etc for analog inputs.

4-20 mA Analog Input Connections

Analog 4-20 Input connections are made to screw terminal connectors (two inputs per connector). The following figures show examples for typical applications. Each of the 4-20 mA inputs can be connected in any of the modes shown below.

mA- mA+ 24V

Pwr+

3-Wire 4-20 mA

Transmitter

Analog Input

mA- mA+ 24V

2-Wire 4-20 mA

Transmitter

Analog Input

Signal

Pwr+

Figure 8. Transmitters Powered by ConsoliDator+

Isolated 24 VDC Power Supply

mA- mA+ 24V

- + -+

External

Power

Supply

2-Wire

4-20 mA

Transmitter

Analog Input

mA- mA+ 24V

- +

2-Wire 4-20 mA

Self-Powered

Transmitter

Analog Input

Figure 9. Transmitter Powered by External Supply

or Self-Powered

mA- mA+ 24V

3-Wire 4-20 mA

Transmitter

Analog Input

External

Power Supply

Signal +

Power +

Signal -

Figure 10. 3-Wire Transmitters Powered Externally

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Flow Meter Pulse Input Connections

Flow Meter Pulse Inputs are wired to four-terminal connectors (two inputs per connector). A square waveform is used in the illustration, but the pulse input can read many types of signals within the specified voltage and frequency ranges.

S- S+

Pulse Input

Signal Source

Figure 11. Flow Meter Pulse Input Connections

Digital Input Connections

Inputs are wired between terminals 1-5 of the digital input connector and the G terminal of the 2-position connector above the digital inputs. Normally open switch contacts can be used as shown in Figure 12. The diagram also shows a Digital Input using an NPN open collector transistor output from a live signal. Logic LO or switch closure appearing across the terminals is interpreted as ON. When using an open collector transistor, a logic HI at the base (marked “B” in Figure 12) will be interpreted as ON. The 2-position connector has a +5 V terminal that can be used to provide excitation to some sensors requiring more than the pull-up provided on each digital input terminal.

Digital Inputs

+5V

1 2

3 4

Switch

Contact

Live

Signal

Figure 12. Digital Input from Switch Closure

and Live Signal

Analog Output Connections

The following figures show examples for isolated 4-20 mA transmitter output connections. Terminal connectors are labeled individually. The analog outputs are isolated from each other and from the inputs. They are powered internally to provide an active 4-20 mA output loop. The outputs can be powered externally by connecting the positive voltage to the Ex+ terminal.

Figure 13. Active 4-20 mA Output Powered by Controller

Figure 14. Passive 4-20 mA Output Powered

by External Supply

Note: Analog inputs and outputs are isolated from

each other.

Digital Output Connections

The digital outputs can be used to drive digital inputs, alarm annunciators, or other devices such as solidstate relays that can be driven with low voltage signals.

Figure 15. Digital Outputs Driving 5 V Solid State Relay

Digital Outputs

1 2

3 4

Alarm

Annunciator

Load

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PD9000 ConsoliDator+ Multivariable Controller

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Connections to Power Gas Detector

Some sensors requiring more than 200 mA of excitation current can be powered by the ConsoliDator+ by connecting two or more power supplies in parallel as shown in the following diagrams.

Figure 16. Two Supplies in Parallel Powering

3-Wire Transmitter

Figure 17. Powering 4-Wire Gas Detector

& Isolated 4-20 mA Output

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PD9000 ConsoliDator+ Multivariable Controller

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Relay Connections

Relay connections are made to three-terminal connectors labeled individually. There are five relays per card.

C NC NO

Relay Output

Figure 18. Relay Connections

Switching Inductive Loads

The ConsoliDator+ has internal circuitry to protect the relays from inductive loads, however, the use of external 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.

Note: Because of the built-in RC network, there is the potential for leakage current when driving low power devices such as LEDs or piezoelectric alarms. It is recommended to use external relays to drive the low power devices or request a modification to the relay card from the factory.

Figure 19. AC and DC Internal Inductive Loads

Protection

For additional external protection choose R and C as follows:

R: 0.5 to 1  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 instrument's relay screw terminals. An RC network may also be installed across the load. Experiment for best results.

C NC NO

L O A D

Figure 20. 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: PDX6901.

Serial Communication Connections

The RS-485 port for serial communication (using Modbus protocol) has three terminals labeled D+, D-, and G. It is strongly recommended to use three-wire shielded cable and to always connect the ground terminal to the other equipment’s ground to avoid differential voltage between the systems. Distances up to 4000 feet can be reached with RS-485. Up to 32 Modbus devices can be connected to a single RS-485 bus.

Figure 21. Serial Connections

Ethernet Option

The Ethernet port is available on the RJ45 connector. This allows the ConsoliDator+ to connect to a local area network.

The Ethernet port option is configured using the System menu. See page 24 for specifications, page 110 for setup using the ConsoliDator+ software, and page 112 for complete Ethernet Port Setup.

External Keypad Connections

Normally open pushbuttons can be wired to the digital inputs connector for use when the front panel of the controller is not accessible. The external keys can be assigned to replicate the Menu and F1-F4 function keys.

Digital Inputs

+5V

1 2

3 4

External Keypad

Figure 22. External Keypad Connections

L O A D

Internal Protection

MOV MOV

4.7nF 4.7nF

ConsoliDator+

RS-485 Port

D+ DG

120 ohm

B+ AG

120 ohm

Last Modbus

Device

Terminating Resistor Terminating Resistor

Use diode with a reverse breakdown voltage two to three times the circuit voltage and forward current at least as large as the load current.

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PD9000 ConsoliDator+ Multivariable Controller

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Navigating and Editing

The device displays various screens throughout programming and operation. Functions are programmed within their respective menu screens and in many cases are accompanied by user prompts.

Soft-Keys and Buttons

The unit is equipped with five buttons located below the display. The function of each button corresponds to its soft-key, which appears at the bottom of the screen. Buttons assume different functions, which change according to the screen in view.

Screen Navigation

Menu Navigation

Selections are highlighted with green background for illustration purposes. The keys below are used to navigate through menus and edit settings. Other special keys appear throughout the programming process.

Note: This is not a touch-screen display; the pushbuttons must be used to activate the soft-key

Key

Action

PID Tuner #

View and edit PID tuning parameters

Auto Tune #

Start auto tuning process

Start

Start (turn on) PID process

Stop

Stop (turn off) PID process

Abort

Abort auto tuning process

Key

Action

Enter menu

Right-key →

Step into menu/setting

Left-key ←

Exit/go back

Down-key ↓

Next screen/channel/setting

Up-key ↑

Previous screen/channel/setting

Stop

Stop automatic scan

Scan

Scan screens automatically

Ack

Acknowledge alarms/relays

Reset

Reset total/max/min

Setup

Enter the Setup menu

Edit

Modify selection

Enter

Execute keypad entry

Accept setting change

Save

Save all settings in view

Cancel

Discard changes

Delete

Delete channel/item

New

Create new channel/alarm

←|

Move cursor left

|→

Move cursor right

X→

Delete to the right

←X

Delete to the left

Access additional settings or actions

Alert! .

Flashing red: View new alarm alerts Steady red: Alarm alerts, already viewed

Alert! .

Amber: View manually controlled outputs, simulated parameters, and warning about USB Drive not installed

Timer Ctrl

View menu: Allows controlling the timer

Start Log #

View menu: Press to start the log

Stop Log #

View menu: Press to stop the log

Log # Entry

View menu: Press to capture a log record

Remove USB

The Screens F4 key is assigned to the Remove USB function, by default, on units with data logger feature enabled. Press to safely remove the USB drive.

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PD9000 ConsoliDator+ Multivariable Controller

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Setup and Programming

There is no need to recalibrate the instrument when first received from the factory. Use the Scale function to set up the input channels to display your process in engineering units.

The device is factory calibrated prior to shipment, for all input types and 4-20 mA outputs. The calibration equipment is certified to NIST standards.

Overview

Setup and programming are done through the front panel buttons or with the ConsoliDator+ Software. After power and signal connections have been completed and verified, apply power to the instrument.

Inputs, outputs, channels, and relays are configured individually. It is recommended that all inputs be configured before channels, outputs, and relays are programmed.

Shown below are typical screens for tank level applications. Actual screens will vary according to the selected configuration. Screens can be edited, deleted, or added to fit the application.

For information on soft-keys and button functions, see Soft-Keys and Buttons on page 36.

Typical screen view displaying 4 channels and 4 bargraphs representing the values of each channel.

Typical screen view displaying 8 channels and 8 bargraphs representing the values of each channel.

Press the Menu key to begin setup and programming

The View screen allows a user to view all the settings and values for Channels, Totals, Timers, etc. To program the instrument, press the Setup key.

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PD9000 ConsoliDator+ Multivariable Controller

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Setup Menu

The Setup menu is the starting point during the programming process for setting up Channels, Totals, Timers, Alarms, Inputs, Outputs, Screens, and System settings. The number of channels shown on this screen is determined by the number of channels previously configured. More channels can be added to the list, by selecting New in the Setup Channels menu.

Press Right Arrow key to step into channels.

Press New key to create a new channel. Go to page 42 for details.

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PD9000 ConsoliDator+ Multivariable Controller

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Channel Parameters

1. Channel tag: Editable

2. Auto-generated channel #: Use to reorder channels

3. Function*: This is the function applied to the input source

➢ Scale

• Scale Factor

• Scale Linear 2-Pt

• Scale Multi-Point

• Scale Square

Root

• Scale Exponent

• Round Horz Tank*

• Units Conversion

• Percent

(Bargraph)

• Text (Percent)

➢ Math

• Constant

• Summation

• Difference

• Absolute

Difference

• Absolute Value

• Average

• Weighted Average

• Multiply

• Divide

• Exponent

• Logarithm

• Modulo

• Trigonometry

• % Efficiency

➢ Open Channel Flow

• Parshall Flumes

• V-Notch Weirs

• Cipolletti Weirs

• Rectangular Weirs

w/o Contractions

• Rectangular Weirs

with Contractions

➢ Compare

• Greatest

• Least

• Middle of 3

➢ Measure

• Tare

• Maximum

• Minimum

• Duration

• Rate of Change

➢ Filter

• Window Average

• IIR (First Order)

• Cutoff

• Limits

• Round

• Hysteresis

• Delay

• Pulse Filter

See Channel & Math Functions on page 17

for details.

➢ Control

• Sampler

• On-Off Control

w/Randomizer

• Select A or B

• Select 1,2,3

• Schedule

• Capture

• PID Control

• PWM Control

• Switch Position

➢ Relays

• Cycle Count

• Runtime

➢ Modbus

• Time Since Read

• Time Since Write

➢ Other

• None (Reserved)

4. Input: Source for the channel (PV)

• mA Input (4-20

mA)

• Pulse Input

• Digital Input

• Modbus Input

• Channel

• Total

• Timer

• Alarm

• mA Output

• Relay Output

• Digital Output

• Modbus Output

5. Units: Engineering units / time or none

• None

• Time

• Distance (Height)

• Volume

• Pressure

• Weight

• Temperature

• Percent

• Amps

• Volts

• Counts

• Logic

• Custom

6. Decimals: Number of decimals for the PV

7. Input scale: Enter input and output values

8. Cutoff: PV goes to zero below the cutoff value

9. Soft keys: These change based on the screen in place

10. Bargraph scale: Set the 0 and 100% values

11. Display bargraph: Display on the screen

12. Colors: Select the bargraph & panel colors

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PD9000 ConsoliDator+ Multivariable Controller

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Data Entry Keypad

The system provides a soft keypad for entering values and tags; it contains numbers, alpha characters, and symbols.

Press Edit key to start editing the channel configuration.

The green background indicates the field to be edited. Press Edit key again to change the channel’s tag, this

opens the data entry keypad.

Use the Down Arrow key to navigate to the keypad. Use the |→ and | keys to move the cursor and use the X→ key to delete characters. To enter characters in the selected text field, use the arrow keys to navigate through the popup keypad.

To change the character set, navigate to the three dots and press the key indicating the next set of characters.

To enter symbols, press the three dots and select the desired symbol.

When done typing the characters in the selected field, press the Enter key.

To enter numbers, select the numeric keypad, move the cursor to the insertion point and enter the number using the soft keys.

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PD9000 ConsoliDator+ Multivariable Controller

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Press Enter to accept the changes.

Press the Save key to save the changes. The bargraph is automatically adjusted to reflect the scale entered.

The bargraph scaling can be changed without affecting the input scaling.

Setup Channels

The Setup Channels menu is used to configure each channel, enter a tag, select the input source, scale the input, and program other settings that will determine the channel’s processing capabilities.

• Use the Arrow keys to navigate through the existing channels

• Press the New key to create a new channel

• Press the Right Arrow key to step into the

channel setup

• Press the Edit key to make changes to a particular channel

• Press the Delete key to delete a channel

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PD9000 ConsoliDator+ Multivariable Controller

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Create New Channel

To create a new channel press the New key.

Press the Edit key to edit the channel tag and other settings. Press the Up and Down arrow keys to select setting to be edited.

Select the function to be applied to the input and press the Ok key.

Select the input source for the channel.

Note: The inputs shown depend on the installed hardware and the configuration.

Select the engineering units, decimal point, enter scale points and press the Ok key.

Select number of decimals, scale the input, enter the cutoff value, select colors for bargraph and text,

confirm the bargraph’s scale, and press Save.

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PD9000 ConsoliDator+ Multivariable Controller

Instruction Manual

Feet & Inches Engineering Units

The Feet & Inches (Ft-In) units are entered in feet, inches, and decimal of an inch. The number of decimals selected correspond to the inches portion of the value.

The View and Screens show the feet value followed by the feet symbol, followed by the inches with decimals followed by the inch symbol (e.g. 48' 0.0").

The mA output from a level sensor can be displayed as level in feet & inches using one channel and as volume using a second channel.

Screen with Feet & Inches Units

The screen to the right shows the level and volume of two tanks; the level is displayed in feet & inches and the volume in gallons.

According to the dimensions of the tank used in this example, the maximum height is 48 feet and the maximum volume is 630,000 gallons. The tank diameter is 48 feet.

Because of the large signal amplification, the volume can fluctuate significantly while filling on emptying the tank. You can use the Rounding function to obtain a more stable reading (e.g. Round to nearest 50).

To create a channel with rounding function: Go to Setup > Channel > Function > Filter > Round,

and enter the desired rounding value.

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PD9000 ConsoliDator+ Multivariable Controller

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Bargraph, Background & Text Colors

To select a channel color pattern, navigate to the Colors setting and press the Colors key.

Select a color pattern or press the Edit key to make

changes to the colors’ tag, text, background, and

bargraph.

Use the arrow keys to navigate the settings and press Edit to make changes.

Press Edit to change text color, this applies to the channel tag, units, and value.

Select the desired color and press Ok. Navigate to the other settings and make the necessary changes.

Press Save to save the color changes. Press Select to apply the color pattern to the channel. The Manage button is used to move or delete colors.

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PD9000 ConsoliDator+ Multivariable Controller

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Live Calibration

The Live Calibration feature is used to calibrate a channel by applying a live calibration signal.

1. From the Setup menu, navigate to the channel to be calibrated.

2. Go to Input 1 entry box

3. Apply Input 1 signal from sensor or calibrator

4. Press & hold the Edit key and press the Live key a few time until a stable reading is displayed.

5. Release the Edit key; the input 1 value has been captured.

6. Repeat the steps above for the additional inputs to be calibrated.

7. Adjust the output values according to the calibrated inputs.

8. Press Save.

Edit Channel

To edit a channel press the Edit key and navigate to the setting you want to change, press Edit again and make the changes required.

After making all the changes, press the Save key.

Delete Channel

To delete a channel, press the Delete key and follow the instructions.

Press the Ok key to delete the channel or the Cancel key to cancel delete action.

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PD9000 ConsoliDator+ Multivariable Controller

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Scale Functions

Channels can be configured using various functions to fit a particular application.

• K-Factor

• Scale Factor

• Scale Linear 2-Point

• Scale Multi-Point

• Scale Square Root

• Scale Exponent

• Round Horizontal Tank

• Units Conversion

• Percent (Bargraph)

• Text (Percent)

2-Point Linear Scaling

Linear mode refers to basic 2-point scaling of a 4-20 mA signal in engineering units. The graph in

Figure 23 shows the display

response based on example scaling parameters. For this mode select [Scale Linear 2-Pt] from Function options, then enter your scaling parameters.

Process

Scaling Parameters

Input (mA)

Output

(%)

mA Input:

4.000

Low Value:

0.00

4.00

0.00

mA Input:

20.000

High Value:

100.00

5.00

6.25

6.00

12.50

7.00

18.75

8.00

25.00

9.00

31.25

10.00

37.50

11.00

43.75

12.00

50.00

13.00

56.25

14.00

62.50

15.00

68.75

16.00

75.00

17.00

81.25

18.00

87.50

19.00

93.75

20.00

100.00

Figure 23. Linear Response Graph

0.00

20.00

40.00

60.00

80.00

100.00

4.00 8.00 12.00 16.00 20.00

Output (%)

mA Input

Linear Response

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Square Root Scaling

Square root mode refers to 2-point scaling with square root extraction typically used to linearize the signal from a differential pressure transmitter and display the flow rate in engineering units. The graph in

Figure 24 shows the display

response based on example scaling parameters. For this mode select [Scale Square Root] from Function options.

The square root mode supports low-flow cutoff which can be used to suppress readings below a programmed value. Below the cutoff value, the controller will

display “0”.

Process

Scaling Parameters

Input (mA)

Display

(%)

mA Input:

4.000

Low Value:

0.00

4.00

0.00

mA Input:

20.000

High Value:

100.00

5.00

25.00

6.00

35.36

7.00

43.30

8.00

50.00

9.00

55.90

10.00

61.24

11.00

66.14

12.00

70.71

13.00

75.00

14.00

79.06

15.00

82.92

16.00

86.60

17.00

90.14

18.00

93.54

19.00

96.82

20.00

100.00

Figure 24. Square Root Response Graph

0.00

20.00

40.00

60.00

80.00

100.00

4.00 8.00 12.00 16.00 20.00

Output (%)

mA Input

Square Root Response

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Scale Exponent

Exponent mode refers to 2-point scaling with programmable exponent, typically used in openchannel flow applications using weirs and flumes to linearize the signal from a level transmitter and display the flow rate in engineering units. The graph in Figure 25 shows the display response based on example parameters and exponent of “1.5”. For this mode select [Scale Exponent] from Function options.

The exponent mode supports lowflow cutoff which can be used to suppress readings below a programmed value. Below the cutoff value, the controller will display “0”.

Process

Scaling Parameters

Exponent

Input (mA)

Output

(%)

mA Input:

4.000

Low Value:

0.00

1.500

4.00

0.00

mA Input:

20.000

High Value:

100.00

5.00

1.56

6.00

4.42

7.00

8.12

8.00

12.50

9.00

17.47

10.00

22.96

11.00

28.94

12.00

35.36

13.00

42.19

14.00

49.41

15.00

57.00

16.00

64.95

17.00

73.24

18.00

81.85

19.00

90.77

20.00

100.00

Figure 25. Exponent Response Graph

Round Horizontal Tank

The Round Horizontal Tank (RHT) function calculates the volume of round tank with flat ends, based on the diameter and length dimensions of the tank.

The input source for the channel calculating the volume must be a level channel with units of distance (height). The RHT function linearizes the signal from a level transmitter and displays the volume in engineering units. The graph in

Figure 26 shows the display

response based on tank example: Diameter = 48.00 inches

Length = 120.00 inches For this mode select [Round Horz

Tank] from Function options.

Process

Parameters

Tank Dimensions

Input

(Inch)

Output

(US GAL)

Level Input 1:

0.00

Low Value:

0.00

Diameter: 48.0 Inch

Length: 120.0 Inch

0.00

Level Input 2:

48.00

High Value:

940.03

6.00

67.82

12.00

183.78

24.00

470.01

30.00

618.05

36.00

756.25

42.00

872.21

48.00

940.03

Figure 26. Round Horizontal Tank Volume Graph

0.00

20.00

40.00

60.00

80.00

100.00

4.00 8.00 12.00 16.00 20.00

Output (%)

mA Input

Exponent Response

0.0

100.0

200.0

300.0

400.0

500.0

600.0

700.0

800.0

900.0

1000.0

0.0 10.0 20.0 30.0 40.0 50.0

Volume US GAL

Input (Inches)

RHT Response

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Open Channel Flow Application

The ConsoliDator+, in combination with a level transmitter, makes for a practical way to measure and display open channel flow rate and total in most weirs and flumes and take periodic samples. There are two ways the user can program the ConsoliDator+ for open channel flow applications:

Programmable Exponent: In this method, all the user needs to do is enter the exponent for the weir or flume into the ConsoliDator+ and the controller automatically raises the input signal to that power. For instance, to display open channel flow rate and total from a 3-inch Parshall flume and take a one pint sample every 100,000 gallons, the user would program the ConsoliDator+ as shown in the upper table on the right.

Specific Weir or Flume Function: In this method, the user selects one of the following functions to be applied to the input from a menu in the ConsoliDator+: Parshall Flumes, V-Notch Weirs, Cipolletti Weirs, Rectangular Weirs with or without Contractions. The second table on the right shows the parameters the user then enters.

In addition, a total can set up as non-resettable, and a relay can be programmed to take a sample at user-defined intervals.

Programmable Exponent for Open Channel Flow

Function

Desire

Programming

Open Channel Flow

3" Parshall flume

Use Scale Exponent function Set Exponent to 1.547

Flow Rate 1

Millions of Gallons per Day (MGD)

Set 4 mA: 0 Set 20 mA: 3.508 Custom unit: MG; Time base: day Flow rate units: MG/day

Total 1

Millions of Gallons

Input: Flow Rate 1 Select unit = MG

Sampling Channel 2

Take a 1 pint sample every 100,000 gallons

Input: Total 1 Function: Sampler Sample Interval: 0.1 MG Sample Time: 10 sec

Sampling Relay 1

Turn valve on to take a sample

Input: Channel 2 (On / Off) Use a timer to count the time needed to take the sample

Total 2 Non-Resettable

Program controller so total 2 can never be reset

Input: Flow Rate 1 Set total 2 as non-resettable total

Screen

Display flow rate, totals, and relay status

Set a screen to display rate, total 1, total 2, and relay status.

Specific Weir or Flume Function for Open Channel Flow

Function

Desire

Programming

Open Channel Flow

3" Parshall flume

Create Channel 1 to measure head height 4 mA = 0 feet 20 mA = 3.000 feet

Flow Rate 1

Millions of Gallons per Day (MGD)

Create Channel 2 for flow rate Use Flow – Parshall Flumes function Constant K = 0.992 Head = Channel 1 head height Custom unit: MG; Time base: day

Total 1

Millions of Gallons

Input: Flow Rate 1 Select unit = MG

Sampling Channel 2

Take a 1 pint sample every 100,000 gallons

Input: Total 1 Function: Sampler Sample Interval: 0.1 MG Sample Time: 10 sec

Sampling Relay 1

Turn valve on to take a sample

Input: Channel 2 (On / Off) Use a timer to count the time needed to take the sample

Total 2 Non-Resettable

Program controller so total 2 can never be reset

Input: Flow Rate 1 Set total 2 as non-resettable total

Screen

Display flow rate, totals, and relay status

Set a screen to display rate, total 1, total 2, and relay status.

Figure 27. Total Relay Sampling Operation

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PD9000 ConsoliDator+ Multivariable Controller

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Scale Multi-Point

The Scale Multi-Point function is used to linearize the signal from sensors with non-linear output or sensors used to measure volume in odd-shape vessels, where a 2-point scale cannot be used to get accurate readings. Another application for multi-point scaling is in open channel flow using weirs and flumes with flow equations not covered by the functions provided in the controller.

• Create a channel

• Function: Scale Multi-Point

• Input: Select the input sensor

• Units: Select engineering units

• Decimals: Number of decimals to display

• Scale: Insert the input and output values

• Cutoff: Select and enter the cutoff value

The controller can be configured with up to 50 linearization points. The use of the ConsoliDator+ software is highly recommended for entering the linearization points.

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PD9000 ConsoliDator+ Multivariable Controller

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Setup Math Functions

There are many math functions that can be applied to any channel, which allows the execution of simple or complex math functions. Math channels can be the source for other math channels, totalizers, alarms, and analog outputs.

List of Math Functions

1. Constant

2. Summation

3. Difference

4. Absolute Difference

5. Absolute Value

6. Average*

7. Weighted Average

8. Multiply

9. Divide

10. Exponent

11. Logarithm

12. Modulo

13. Trigonometry

14. % Efficiency

*Average can be used for applications requiring redundant

sensors by selecting the Exclude Fail Input feature. The two 4-20 mA inputs must be set to break below a failed level value.

Application Example: % Efficiency

Description: Calculate the VOC Destruction Efficiency in a Thermal Oxidizer

Thermal Oxidizer Efficiency = (Inlet VOC – Outlet VOC) / Inlet VOC 4-20mA output = 0-100% efficient Efficiency = ((Ch1 – Ch2)/Ch1)*100 Ch1 = Inlet VOC Ch2 = Outlet VOC AO-1 Source = Ch 20. VOC %Efficiency AO-1 Scale: 4-20 mA = 0-100% efficiency VOC: Volatile Organic Components

Select math function for % Efficiency and press Ok.

Enter the input sources for the math function, select the

units and number of decimals, and press Ok and Save

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Additional Functions

Scale

K-Factor Scale Factor Scale Linear 2-Pt Scale Multi-Point* Scale Square Root Scale Exponent Round Horz Tank Units Conversion Percent (Bargraph) Text (Percent)

Open Channel Flow

Parshall Flumes V-Notch Weirs Cipolletti Weirs Rectangular Weirs with End Contractions Rectangular Weirs w/o End Contractions

Compare

Greatest Least Middle of 3

Measure

Tare Maximum Minimum Duration Rate of Change

Filter

Window Average IIR (First Order) Cutoff Limits Round Hysteresis Delay Pulse Filter

Control

Sampler On-Off Control Select (A or B) Select 1,2,3… Schedule Capture PID Control PWM Control Switch Position

Relays

Cycle Count Runtime

Modbus

Time Since Read Time Since Write

*Scale Multi-Point: There is no minimum input span

requirement; it is up to the user to make sure the input values are correct.

Random Varying On-Off Control

The On-Off Control with the Randomizer function is used to prevent grease buildup in tank level control applications.

The controller randomly varies the On and Off points within the user-selected range.

• Create a channel

• Function: On-Off Control

• Input: Level or volume channel

• Enter On / Off points

• Enter the allowed +/- deviations

After creating the On-Of Control with Randomizer channel, assign this channel as the input for the relay controlling the pump.

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Control – Select 1,2,3 …

The Select 1,2,3 control function is used as a selector switch to select from 3 or more sources to be the output for the channel.

The input for the Select function must be capable of providing the values corresponding to the selection indexes (i.e. 0, 1, 2, 3, etc.).

• First create a channel to generate the switching points values (0, 1, 2, 3, etc.)

• Create a channel to switch the inputs

• Function: Select 1,2,3…

• Input: Channel with multi-point scaling or

Modbus input.

• Selection: Insert the parameters to selected for the channel output.

After creating the multi-point channel, assign this channel as the input for the channel with the Select 1,2,3 function.

Select 1,2,3 Function Operation

1. Input AI-1 @ 4 mA Selector Switch channel 5 = 0 Channel 6. Switched Output displays Tank 1

2. Input AI-1 @ 8 mA Selector Switch channel 5 = 1 Channel 6. Switched Output displays Tank 2

3. Input AI-1 @ 12 mA Selector Switch channel 5 = 2 Channel 6. Switched Output displays Tank 3

4. Input AI-1 @ 20 mA Selector Switch channel 5 = 3 Channel 6. Switched Output displays Tank 4

The input for the Select 1,2,3 function can be a Modbus input value received from a Modbus Client.

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PID Control Setup

The ConsoliDator+ can be set up with up to 8 control loops; the following steps show an example of the PID setup process.

1. Channel 1: PV Configure a channel with the 4-20 mA input provided by the transmitter measuring the process.

2. Channel 2: Set Point This is the target setpoint for the process, which can be adjusted using the function keys.

3. Channel 3: Power Configure the initial PID Control parameters. These determine the power provided to Pulse Width Modulation (PWM) channel.

• Bidirectional (Heating & Cooling)

• Not Reverse (Heating)

• Reverse (Cooling)

4. Channel 4: PWM Control Configure the PWM Control channel to take the input from the Power channel and provide the control signal to the output controlling the load.

5. PID Control Output Select the output from the ConsoliDator+ that is intended to control the device driving the load.

• Digital Output: Connected to Solid State Relay

• Analog Output: Connected to a power

controller with 4-20 mA control signal.

• Relay Output: Connected to a low power

control relay.

6. PID Control Screen Configure the PID Control screen to show:

• PV

• Set Point

• Power (%)

• Assign function keys

F1: PID Tuner (Manual) F2: Auto Tune F3: Set Point 1 F4: Next Screen

The following screens show the process for setting up a PID control application for heating. The values shown are for illustration only.

PID Controller: Block Diagram for Heating

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PD9000 ConsoliDator+ Multivariable Controller

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Setup Channel 1: PV

The first step is to set up the channel for the PV. In this example an RTD temperature transmitter is used.

Channel 2: Set Point

Channel 2 is set up with a constant that will be used to change the set point using a function key and the target set point can be displayed in the PID Control screen.

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PD9000 ConsoliDator+ Multivariable Controller

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Channel 3: Power

Channel 3 is set up with the PID Control function.

The input for the PID control is the value reported by the PV channel.

The Set point uses the constant set up in channel 2.

• Start/Stop: If selected, a function key or digital input can be used to start & stop the PID control.

• Bidirectional: This is used for heating & cooling.

• Reverse: Select for cooling only.

• Hysteresis: This is used for switching between

heating & cooling outputs.

• Tuning Parameters: These values determine how fast the target set point is reached and how much overshoot occurs. It is best to run the Auto Tune function and then make any adjustments, if necessary.

Note: Auto Tune and Manual tune functions are assigned to function keys in the Screens menu.

Channel 4: PWM Control

Channel 4 is set up as the Pulse Width Modulation (PWM) control channels. This channel provides the signal to the actual hardware outputs:

1) Digital output or

2) Relay

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PID Control Using Digital Output

In this example, digital output 1 (DO-1) takes the input from the PWM channel (4. PWM Heat); DO-1 drives a low voltage Solid State Relay (SSR 1). The SSR 1 in turn drives the load or a larger relay.

PID Control Using Analog Output

In this example the signal from the PID Control channel (3. Power) is used to control a 4-20 mA analog output (AO-1). The analog output is connected to a power controller, which in turn drives the load.

PID Control Screen

Finally set up the PID screen to display the PV, Set Point, and the % Power being delivered to the load. The function keys can be assigned the following functions:

• F1: Manual PID Tuner

• F2: Auto Tune PID

• F3: Set Point

• F4: Navigate to the next screen

Additional screens can be used to display other parameters:

• Analog inputs

• Set point channels

• PWM status

• PID Start/Stop function key

• Analog outputs

The Switches function can be used to change the target set point using a function key or a digital input.

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Start / Stop PID with Digital Input

A digital input or a function key can be used to start/stop the PID control process.

PID Control Adjustments

Issue

Try This

There is too much overshoot

1) Increase the Proportional band (Pb)

2) Increase the Derivative (D) setting

The process is too slow to reach the target

1) Decrease the Proportional band (Pb)

2) Increase the Integral (I) setting

Note: The PID controller response time is 1 second.

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PID Controller: Block Diagram for Heating & Cooling Using SSR

Channel 3: PID Control - Power

The input for the PID control is the value reported by the PV channel 1.

The Set point uses the constant set up in channel 2.

• Start/Stop: If selected, a function key can be used to start & stop the PID control.

• Bidirectional: Select this for heating & cooling.

• Reverse: Do not select (This is for cooling only).

• Hysteresis: This is used for switching between

heating & cooling outputs.

Note: Auto Tune and Manual tune functions are assigned to function keys in the Screens menu.

Channel 4: PWM Heating Control

Channel 4 is set up as the Pulse Width Modulation (4. PWM Heat) heating control channel. This channel provides the signal to the actual hardware outputs:

1) Digital output or

2) Relay

Notes:

1) Do not select Reverse (used for cooling only).

2) The units must be ON/OFF or other logic units. Custom units can be set up.

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PID Control Heating Using Digital Output

In this example, digital output 1 (DO-1) takes the input from the PWM channel (4. PWM Heat); DO-1 drives a low voltage Solid State Relay (SSR 1). The SSR 1 in turn drives the heating element or a larger relay.

Channel 5: PWM Cooling Control

Channel 5 is set up as the Pulse Width Modulation (PWM) cooling control channel. This channel provides the signal to the actual hardware outputs:

1) Digital output or

2) Relay

Notes:

1) Select Reverse for cooling.

2) The units must be ON/OFF or other logic units.

Custom units can be set up.

PID Control Cooling Using Digital Output

In this example, digital output 2 (DO-2) takes the input from the PWM channel (5. PWM Cool); DO-2 drives a low voltage Solid State Relay (SSR 2). The SSR 2 in turn drives the compressor or a larger relay.

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PID Controller: Block Diagram for Heating & Cooling Using Analog Outputs

Notes:

1) The Switches function can be used to manually switch between primary and backup sensors, using a function key or digital input.

2) The Average function can be used to continuously average two sensors and to ignore a failed sensor, while continue to use the good sensor.

3) If the primary sensor fails, the system can be configured to switch to the backup sensor automatically by setting an alarm to monitor the primary sensor and using the Switch function to get the PV from the backup sensor.

PID Control: Heating Using Analog Output

In this example the signal from the PID Control channel (3. Power) is used to control a 4-20 mA analog output (AO-1. Heating Control). The analog output is connected to a power controller, which in turn drives the heating element.

Note that channel (3. Power) is scaled to output 4-20 mA for 0 to 100% power.

PID Control: Cooling Using Analog Output

In this example the signal from the PID Control channel (3. Power) is used to control a 4-20 mA analog output (AO-2. Cooling Control). The analog output is connected to a power controller, which in turn drives the compressor.

Note that channel (3. Power) is scaled to output 4-20 mA for 0 to -100% power.

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PID Control Configuration Using the ConsoliDator+ Software

The easiest way to configure the ConsoliDator+ PID Controller is using the software. Most of the functions are set up using the Channels menu. The following images illustrate how to configure the controller using the following advanced user functions:

• Average function for two sensors

• Pulse Width Modulation (PWM) for SSR control

• Heating & Cooling PWM set up

• Switch function to quickly change target set point

• Switch function to select which RTD is used

Average Function Setup

1) Set up channel 1 to process the signal from RTD1.

2) Set up channel 2 to process the signal from RTD2.

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3) Set up channel 3 to average channels 1 and 2.

Configure PID Control Power Channel

The PID Control channel determines how the power is delivered to the output devices. The PID Control channel can be used as the input to the PWM channels for heating & cooling or as the input to the 4-20 mA analog outputs connected to power controllers.

• The set point value is selected using the Switch function, the setup for the set points and how to switch them is shown below.

Note: The set points and Switch function must be set up before setting up this channel, otherwise use a constant as the set point to begin.

• Select Start / Stop to manually control the PID process.

• Select Bidirectional for heating & cooling applications.

• The tuning parameters are automatically updated after

running the Auto Tune PID function using the function keys.

• Manual tuning can be done using the function keys.

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Configure PWM Control Heating Channel

The PID Control power channel is used as the input for the PWM heating channel. Do NOT select Reverse for heating applications. This channel is used as the input to the digital output (DO-1), which in turn drives a Solid State Relay (SSR1) providing power to the heating element.

• The units must be ON/OFF or other logic units.

Configure PWM Control Cooling Channel

The PID Control power channel is used as the input for the PWM cooling channel. Reverse must be selected for cooling applications. This channel is used as the input to the digital output (DO-2), which in turn drives a Solid State Relay (SSR2) providing power to the compressor.

• The units must be ON/OFF or other logic units.

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Configure Set Point Channels

Set points 1 – 4 are configured the same way.

• Display Tag: Description

• Function: Math > Constant

• Units: Select according to the PV being used

• Decimals: Select number of decimals

• Value: Enter initial value, this can be changed with

function keys

• Color Scheme: Select colors to display set point

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Configure the Switches Function

Switch 1 tag: Active SP A four-way switch is used to select four set points, previously configured using constants and the input to channels.

A function key is set up in the Screen menu to select SP1 through SP4. Additional actions can be selected when the switch moves through the various positions.

The Switches function can be used to manually switch the active sensor. A function key can be assigned to control which sensor is used. In this setup, the internal horn sounds every time the sensors are switched.

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Configure the Digital Outputs

The digital outputs are controlled by the PWM channels and are connected to the SSRs. DO-1 is used to drive SSR1, which provides power to the heating element.

DO-2 is used to drive SSR2, which provides power to the compressor.

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Configure the PID Control Screens

The screens are configured according to the application. There are three values needed for monitoring the PID control process.

• PV

• Set Point

• % Power

The function keys can be assigned as desired.

• F1: Manual Tune

• F2: Auto Tune

• F3: Active Set Point controlled with Sw1

• F4: Next Screen

This screen is used to display the set point configured using channels 7 – 10.

The function keys are assigned as follows:

• F1: Start / Stop the PID control process

• F2: Quick access to changed SP1

• F3: Quick access to changed SP2

• F4: Next Screen

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This screen is used to display the PV and the status of the PWM channels.

The function keys are assigned as follows:

• F1: Quick access to changed SP3

• F2: Quick access to changed SP4

• F3: Switch between RTD1 and RTD2 sensors

• F4: Next Screen

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PID Control Screens

This is the main PID Control screen after power up. The Power channel displays the message STOPPED. The next screen has the function key to start the PID control.

• PV AVG: 23.3°C

• Active Set Point: 0.0°C

• % Power: STOPPED

Press the F4 key to go to the next screen and start the PID control process.

The function keys can be assigned as desired.

• F1: Manual Tune

• F2: Auto Tune

• F3: Next Set Point switched with Sw1

• F4: Next Screen

This is the Set Points screen.

• SP1: 0.0°C

• SP2: 10.0°C

• SP3: 65.0°C

• SP3: 85.0°C

Press the F4 key to go to the next screen and access the function keys for changing SP3 (Set 9) and (Set 10).

The function keys are assigned as follows:

• F1: Start – Press to start the PID control

• F2: Set 7 – Press to change SP1

• F3: Set 8 – Press to change SP2

• F4: Next Screen

Press the F4 key twice to go to the main PID Control screen.

This is the main PID Control screen after pressing the Start key.

The Power channel outputs -100% indicating that is driving the compressor at full power.

• PV AVG: 23.3°C

• Active Set Point: 0.0°C

• % Power: -100.00%

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This is the PWM H&C screen, it shows the PV and the status of the heating and cooling channels.

• Power % negative: PWM Cooling

• Power % positive: PWM Heating

• Power % 0.00: Heating & Cooling are OFF

The Power channel outputs -100% indicating that is driving the compressor at full power.

• F1: Set 9 – Press to change SP3

• F2: Set 10 – Press to change SP4

• F3: RTD2 – Press to switch to RTD 2 sensor

• F4: Next Screen

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Open Channel Flow

The built-in math formulas in the ConsoliDator+ makes the setup of open channel flow applications an easy task. All you need to know is the type of device being used and the formula for calculating the flow rate using the head height.

The first thing to do is to create a channel for measuring the head height of the weir or flume. This example shows the setup for a 3" Parshall Flume with a maximum head height of 3 feet.

Scale the 4-20 mA input

Select the type of weir or flume installed

Enter the constant K (for Q = cuFt/sec), the channel used for measuring the head height and the specified exponent. Select the flow rate units. The Controller calculates the flow rate in the specified engineering units. The units can be changed at any time without making any other changes.

Setup Totalizer Based on Flow Rate

Setup Screen to Monitor Open Channel Flow

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Setup Totalizers

The totalizers are setup the same way as the channels. The rate from an analog or pulse input channel is integrated over the specified time unit to generate an accumulated total that can be configured to count up or count down. Each total can be configured as “non-

resettable”*, which means the total reset functions are

not available for it. The pulse inputs can be either integrated from a rate

channel or they can be directly totalized based on the pulse count and K-Factor value; this is the most accurate method because every pulse is counted.

*Note: The non-resettable function can be disabled by the user

at any time, after unlocking a password-protected controller.

Setup Total with Rate Source

Select the rate input channel for the total and press Ok.

Select total units, count up or down, enter preset and roll-over values, and select non-resettable if required.

After pressing Save, press Yes to reset the total to the preset value.

Setup Total with Pulse Input Source

Pulse inputs can be totalized directly without the need to create a rate channel.

Select the units and enter the K-Factor provided by the flow meter manufacturer.

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Setup Accumulated Total (Triggered)

Selecting a total as the input for a new total enables the Mode menu: Totalizer, Previous Total, Daily Total, and Grand Total selections.

The Totalizer mode can be used to add the input total to the new total, when a trigger is activated. The trigger can be a digital input, a Modbus input, or any event selected.

Setup Previous Total

The previous total is saved just before the input total is reset. The date & time when the total was reset is saved.

Multiple previous totals can be saved by using a previous total as the input for a new total. Link previous totals to maintain a history of total resets.

Setup Daily Total

The daily total is automatically reset every day at midnight.

The daily total can be the input to a previous total to saved the previous day total. Link previous daily totals to maintain a history of daily totals.

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Setup Grand Total

The grand total takes the input from another total and it is not affected by resets of the input total. It is normally set up as non-resettable.

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Setup Timers

Up to 30 timers can set up to control and monitor various processes. The timers can be triggered by any input or output, such as an analog input rising above a certain threshold or a digital input going from low to high.

Additional Inputs to control the timer:

● mA Input

● Pulse Input

● Relay Output

● Digital Output

● Modbus Output

Timer Automatic Actions

The automatic timer actions are:

Power Up: Timer action on power up Error: Timer action when an error is detected Reset: Event that causes the timer to reset Start: Event that triggers the timer to start Stop: Event that causes the timer to stop

Timer Function Keys & Digital Inputs

The function keys and digital inputs can be used to start, stop, and reset the timers, regardless of the automatic actions selected.

Time Format

The time format is hh:mm:ss with 0 decimals selected. If decimal is other than 0, the time is displayed in seconds with the number of decimals selected.

Count Down Timer

Select count down and enter the starting time count.

Timer Bargraph

The bargraph scaling follows the time format selected based on decimal point.

Timer Colors

Select the colors for normal and alarm conditions.

Timer Alarms

Alarms can set up to trigger on timer values, counting up or down. Go to the Alarms menu and select a timer as the source for the alarm.

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Setup Alarms

The system is capable of handling up to 64 alarms; they can be driven by a single channel, multiple channels, digital inputs, time interval, or a combination of other alarms into logic AND & logic OR alarms. Set and reset point values determine if it is a high or low alarm and the dead band. Alarms can set up as latching or non-latching (automatic) with on and off time delays.

1. Tag: 15-character user-defined

2. Type: Select alarm type

• Single Source

• Multi-Source

• Time Interval

• Alarms OR

• Alarm AND

• Day & Time

3. Input: This will depend on type selected Type: Single or Multi-Source

• Digital

• Modbus

• Channel

• Total

• Timer

Type: Alarms AND & OR Inputs: Other alarms

4. Colors: Normal and alarm conditions

5. Sound Horn: Internal buzzer and relay

6. Alert!: Display alert message on Menu key

7. Automatic: Resets when PV crosses the reset point

8. Ack Anytime (Latching): Ack alarm anytime

9. Break: Alarm status when sensor/comm. break is detected (e.g. Input < 0.01 mA)

• Alarm On

• Alarm Off

• Stay (Maintain the state before the break)

10. On/Off Delays

Multi-Source Alarm This alarm type behaves as a logic OR; if any of the sources crosses the set point, the alarm goes on. If the first source is digital (logic), only sources with digital value (on = 1, off = 0) are available for selection. If the first source is a PV channel or timer, digital inputs can be added as source.

Automatic reset and Ack anytime Relay assigned to Horn activates on alarm condition

Automatic only: Alarm resets automatically at the reset point

Latching: Acknowledge only after the alarm condition has cleared Manual Ack (Latching): Select Ack Anytime only

Latching & Non-Latching Alarms

Reset (Ack)

Ack

Anytime

Automatic

Auto & Manual

Auto Only

0 X Manual Only

Manual Only After Cleared

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Logic OR Alarm

The inputs for the logic OR alarm are any existing alarms, regardless of the source or type.

Any active alarm in the group triggers the OR alarm. The OR alarm can be used as a summary alarm.

Logic AND Alarm

The inputs for the logic AND alarm are any existing alarm, regardless of the source or type.

All alarms in the group must be active to trigger the AND alarm.

Logic NOR & NAND Alarms

To create a NOR alarm, select an existing OR alarm and apply the Not function available during Setup – Edit.

The same applies to the NAND alarm. Any input alarm can be inversed (Not) to create a specialized alarm logic.

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Day & Time Alarms

The Day & Time alarm uses the system clock. You can choose to alarm every day, weekdays, or any day of the week at a selected time.

Choose how long the alarm should stay on and if manual acknowledge is allowed.

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Setup the Switches Function

The Setup Switches screen is used to create and configure the digital switches.

Press on the New key to create a new switch.

Setup 2, 3, or 4-Way Switch

The Switches function can be used to switch all types of inputs and outputs.

This screen shows the 4-20 mA outputs of two temperature sensors being switched with the digital switch Sw1.

• The output from Sw1 is used as the input for channel 1 to obtain the temperature reading from the RTD sensors.

• Assign a function key (F1-F4) or a digital input to control the digital switch Sw1 to route the signal into channel 1.

• The Position Action can be used to activate many user functions (e.g. Turn relays on/off, Horn Test, Modbus Input, etc).

Setup a 4-Way Switch

This screen shows the setup of a 4-Way switch connecting the signal from four RTD transmitters.

• Every time the function key, controlling the switch, is pressed the switch advances to the next position.

• Relays have been assigned to turn on at different positions and to go to automatic mode at position number 4.

If no actions are needed, simply ignore these fields, and leave them as Do Nothing.

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Setup a HOA Switch

This screen shows the setup of a HOA switch to control a pump used to fill a tank based on the tank level. After setting up the tank level and on/off control channels, set up 3 channels to provide the input to the HOA switch.

• Channel 1: Tank Level

• Channel 2: Automatic On/Off Control

HOA Switch Channels

• Channel 2: Automatic

• Channel 3: Manual

• Channel 4: Off

These channels are used to display the settings in the screens for monitoring the process.

HOA Switch Actions

• Position 1: Turn relay 1 On

• Position 2: Turn relay 1 Off

• Position 3: Automatic control

Select this feature to save the last setting on power down and start in the last position on power up.

Block Diagram for HOA Switch

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Configuration for HOA Switch Application Using the Software

Channel 1: Tank Level

Channel 2: Automatic On / Off Control

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Channel 3: Manual Control

Channel 4: Off Control

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Setup HOA Switch

Setup HOA Relay

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Setup HOA Screen

HOA Screen View

This screen shows the following:

1) Tank level in gallons

2) Alert! message indicating the pump has been turned off manually

3) HOA switch is the Off position

4) Pump 1 relay shows the runtime and number of cycles.

5) Press F4 key (AUTO) to switch to automatic control.

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Setup Inputs

The Setup Inputs screen is used to configure the hardware inputs, assigning a user-defined tag, and setting the filter values.

Setup 4-20 mA Inputs

This screen gives you a quick view of the mA inputs connected, the slot # and position, and the actual mA input value.

Press the Right Arrow key to set up the selected input.

The top line, for each input, shows the slot # and input location (2b = slot #2, second input from the left). It also shows the actual current input.

The next line shows the input type and # (AI-2) with the default tag, which can be changed at any time.

• Filter*: Select window average time or IIR time.

• Filter Bypass: If the signal change is greater than

the bypass value, the reading jumps to the actual value. The bypass value is in % of full scale.

• Glitch Filter: Eliminates short duration noise spikes.

• Break Below: Set the mA value at which a break is reported to the system.

• Disable Input Channel: This turns off the power to the input, but the settings are saved for future use. This should only be used to save power on unused inputs.

*Need more filtering? If you need a more stable reading, select IIR 16 sec or IIR 32 sec setting. IIR: Infinite Impulse Response

• The Filter selection depends on the stability of the

input and the desired stability of the display. The larger the selected filter setting, the slower the display response is.

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Filter Settings

Most of the applications should work fine with the default filter setting.

There are two types of filters available:

• Window Average: This filter is based on time; samples are averaged within the selected time window; older samples are discarded to make room for new samples.

• IIR (Infinite Impulse Response): This filter is a first order type, and it is equivalent to an analog RC filter. The time constant of the filter is roughly

what defines the “delay” for the filter to reach its

steady state. An IIR filter has a feedback loop from the output which distinguishes it from an FIR (Finite Impulse Response) filter, which uses only the input signal.

How to Decide what Filter to Use

The selection of the filter setting has many factors that need consideration; the user should weight the pros and cons of increasing or decreasing the filter setting.

Do you need a steadier reading?

Increase the filter setting

Do you need a faster response?

Reduce the filter setting

Do you need the fastest response possible?

Set the filter to None

In most of the cases, you need to find the balance between a steady reading and the response time.

• The Filter Bypass setting is an excellent feature used to achieve a fast response for larger changes in the input signal and a steadier reading for small changes, below the bypass value.

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Setup Pulse Inputs

The top line, for each input, shows the slot # and input location (1a = slot #1, first input from the left). It also shows the actual frequency, state of the input, and the number of pulses received since power up, to a maximum of 8,388,607. The counter rolls over to 0.

The next line shows the input type and # (PI-1) with the default tag, which can be changed at any time.

• Type: Select the pulse input type.

• Low Gate: this is the time window used to

calculate and update the rate.

• High Gate: This is the time window used to calculate slow rates before the rate goes to zero.

• Low Speed: This setting is used as a de-bounce filter for contact closure or switch inputs.

Threshold: Is the voltage level at which a transition from high to low is

detected. For example, the “Active

1.2V Thrshld” setting will detect a

square wave signal when it falls below 1.2 V.

Setup Digital Inputs

The digital inputs can be assigned to perform various user functions, such as trigger alarm, acknowledge alarms, reset total, etc.

Pulse inputs can be used as digital inputs by setting them up according to the type of input they are intended to accept. For example, to accept a contact closure the pulse input must be set up for Reed Switch type input.

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Digital Input Functions

A digital input can be used to execute one of the listed functions and at the same time, it can be used to trigger an alarm or to totalize (count) how many times the function has been executed (e.g. Reset Total).

The available functions depend on the I/O cards installed, the Add-On features enabled, and the controller’s configuration.

List of Digital Input Functions

• None: Use digital input (DI) to trigger an

alarm or timer

• Button: Digital input behaves as a front panel

button

• Channel: Tare, Reset Tare, Reset Max,

Reset Min

• Total: Access total functions (Reset, Add To,

…)

• Timer: Access timer functions (Start, Stop,

…)

• Alarm: Access functions (Ack, Reset, Set

Points)

• Screens: Next, Previous, Stop/Scan, Go To,

View, …

• Data Log: Log Entry, Start / Stop, Remove

USB, New File

• Simulate: Pulse input, mA input, Modbus

input, Channel, Total, Timer, Alarm

• Horn: Silence, Snooze, Test

• mA Output: Manual, Hold (Manual),

Automatic, Manual / Auto, Hold / Auto

• Relay: Reset info, Force On, Force Off,

Manual On, Manual Off, Hold (Manual), Automatic

Note: The elements to be acted upon must be created before trying to set up the digital input; otherwise it is not available in the list of functions to execute. For example, to assign the digital input to tare a channel, a Tare Channel must be created first.

Alarm Reset: The alarm condition is cleared, allowing the

alarm to trigger again based on input.

Acknowledge: The input must cross the reset point to trigger

new alarm after it has been acknowledged.

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Digital Inputs & Data Logger

If the Data Logger feature is enabled, a digital input can be used to start/stop, capture a log entry at any time, safely remove USB, start a new log file.

• The Data Logger functions are available only if the Add-On feature has been enabled in the System – General Settings, see Add-On Features on page

106. Refer to page 101 for Setup Data Logs.

Choose to capture all the data logs or choose any log.

Choose to start / stop all data logs or choose any log.

Safely Remove USB

Start a New Log File

Digital inputs can be used to safely remove the USB drive in case the funtion keys are not available.

Digital inputs can be used to start a new log file.

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Modbus Functionality

The ConsoliDator+ supports Modbus RTU, Modbus ASCII, Enron Modbus, and Ethernet Modbus TCP/IP.

The Server mode is a standard ConsoliDator+ feature; it responds to requests and accepts writes from a Modbus client.

The Client mode can request process variables from server devices; the input variables can be scaled, combined with other variables using math functions, and they can be written to other server devices using the Modbus output functions.

The Snooper mode can listen and read the process variables being transmitted on the RS-485 bus without causing any disruptions to the network.

The Spoofer Modbus output is used to replace Modbus devices that have been removed from the network; there is no need to make changes to the Modbus client’s configuration.

Setup Modbus Inputs (Server)

The Modbus Server mode is a standard ConsoliDator+ feature. The controller can accept up to 199 Modbus inputs sent by a Modbus Client. The inputs can be used as the source for channels, math functions, alarms, relay control, etc.

• Enter Modbus Input tag

• Type: Select the data type

The register number is displayed to the right

• Decimals: Number of decimals

• Units: Select units or enter custom unit

• Break: Value or condition for comm. break

• Timeout: Select timeout to detect break

• Input Action: Select action when new value is

received (e.g. Add to Total 1 the value written)

Data Types

Bit – Logic (Coil) Signed/Unsigned 16 (Short), 32 (Long), 64 (Long Long) Float 32, Float 64 (Double)

• A controller configured as a Modbus Client can accept Modbus inputs as a Server via the Ethernet Modbus TCP/IP connection.

• The Modbus TCP/IP connection does not use a Server ID.

• The Modbus Client does not have a Modbus network ID because only one client is allowed on a Modbus network.

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Setup Modbus Inputs (Client)

The Modbus Client mode is an option in the ConsoliDator+. It can be purchased at the time the order is placed or it can be purchased and enabled at any time.

The controller can request up to 199 Modbus values, as inputs from other Modbus devices. The inputs can be used as the source for channels, math functions, alarms, relay control, etc.

• Enter Modbus Input tag

• Mode: Select Client

• Server ID: Enter the device ID to read from

• Address: Enter the register address to be read, the

• Enron: Click on Enron to use Modbus Enron protocol

• Type: Select the data type

• Byte Order: Select the byte order for the data

• Units: Select units or enter custom unit

• Decimals: Number of decimals

• Break: Value or condition for comm. break

• Poll Time: Enter the time interval to poll the

requested data, it is important to allow enough time to get all the data with each poll.

• Timeout: Select timeout to detect break if new data is not received after the poll.

• Input Action: Select action when new value is

received (e.g. Add to Total 1 the value written)

Note: Make sure to set up the controller as a Modbus Client and configure the serial communication settings before trying to set up the Modbus Client inputs. See Modbus Client Settings, page 109 for details.

Data Types

Bit – Logic (Coil) Signed/Unsigned 16 (Short), 32 (Long), 64 (Long Long) Float 32, Float 64 (Double)

Setup Modbus Inputs (Snooper)

The Modbus Snooper mode is part of the Modbus Client Add-On Features option in the ConsoliDator+. It can be

purchased at the time the order is placed or it can be purchased and enabled at any time.

The controller can read up to 199 Modbus values, as inputs from other Modbus devices being polled by a Modbus Client. The inputs can be used as the source for channels, math functions, alarms, relay control, etc.

• Enter Modbus Input tag

• Mode: Select Snooper

• Server ID: Enter the device ID to read from

• Address: Enter the register address to be read, the

• Enron: Click on Enron to use Modbus Enron protocol

• Type: Select the data type

• Byte Order: Select the byte order for the data

• Units: Select units or enter custom unit

• Decimals: Number of decimals

• Break: Value or condition for comm. break

• Timeout: Select timeout to detect break if new data

is not received within the specified time window.

• Input Action: Select action when new value is received (e.g. None, if not action is required)

Note: Make sure to set up the controller as a Modbus Server/Snooper and configure the serial communication settings before trying to set up the Modbus Snooper inputs. See Modbus Snooper Settings, page 109 for details.

Data Types

Bit – Logic (Coil) Signed/Unsigned 16 (Short) 32 (Long), 64 (Long Long) Float 32, Float 64 (Double)

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Setup All Outputs

The Setup Outputs screen is used to configure the hardware outputs, assigning a user-defined tag, scaling the mA outputs, associating relays with alarms, configuring the digital outputs, and assigning the Modbus outputs.

• mA Output: Configure analog outputs

• Relay Output: Configure relay outputs

• Digital Output: Configure digital outputs

• Modbus Output: Configure Modbus outputs

Setup 4-20 mA Outputs

The mA output can be assigned to any analog input, channel, alarm, or digital input. It can be scaled to any input and output value.

The top line indicates the slot # and position of the analog output (4a = slot #4, first position from the left). It also displays the actual mA output.

• AO-1: Analog output 1

• Input: Select source for the mA output

• Scale: Enter input and output values

• Break: mA output when sensor or

communications break is detected

• Minimum: The minimum output allowed

• Maximum: The maximum output allowed

• Slew Rate: Rate of change in mA/sec

• Underrange: mA value when the PV goes below

the low range value by more than 1%.

• Overrange: mA value when the PV goes above the high range value by more than 1%.

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Setup Relay Output

The relays can be driven by alarms, digital inputs, Modbus inputs, channels, totals, and timers. If the input source is a channel, set and reset points must be entered. These are the available settings depending on the source selected.

• Input: Select the source to drive the relay

• Set & Reset: Enter values to turn on & off the relay

for Channel, Total, or Timer Input

• Pulse Output: Pulse relay on/off when set is active

• Break*: The relay state when break is detected

• Fail-Safe: Relay energized under normal conditions

• Relay Status & Runtime: hh:mm:ss

Function: Select Other to set relay to always

on, always off, drive a relay-horn, or to alternate with another relay.

The F4 key can be used to momentarily turn on/off the relays. To manually control the relays, go to the View Menu to set the relay to be permanently on or off.

Select the input source to drive the relay and enter the required parameters according to the input.

Relay Assigned to Alarm

Relay Assigned to Channel

The relay runtime & cycle count can be reset (cleared) from the relay setup screen.

*Note: Break needs to be set in the analog input menu.

Relays not assigned to alarms are used for automatic on/off control based on set & reset point; they cannot be acknowledged.

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Pump Alternation Relays

To set up a group of relays for pump alternation control, follow these steps.

1. Select the primary alternating relay

2. Select the input for alternation (e.g. Ch 1)

3. Enable alternation

4. Enable alternate on time and enter time

5. Enter the On & Off alternation points according to the number of relays to alternate

6. Select relay condition when input break is detected*

7. Select fail-safe, if desired (Reverses the relay contacts state: NO closes and NC opens)

8. Enter the On & Off time delays

9. After saving the primary relay configuration, navigate to the next relay and configure it to alternate with the primary relay

Alternation Input Sources

Most level control applications use channels as the input. The channel is setup to read the signal from a level transmitter and display the level either in height or volume units. The continuous level monitoring allows for selecting multiple alternation points.

If the input is other than a channel, the alternation is limited to only one pump on at one time. A level switch could be connected to a digital input and the digital input will alternate the pumps for each on/off cycle.

Set (On) & Reset (Off) Points

Up to eight alternation points can be entered to alternate eight relays per group. The On & Off points determine if pumps are on when the level rises or when it falls.

On & Off Time Delays

To prevent turning pumps off and on at the same time, it’s recommended to use On delays. The On & Off delays are common to all the relays in the alternation group.

Alternation Groups

An alternation group is made up of a primary relay and any number of relays selected to alternate with it.

Multiple alternation groups can set up using different sources for each group. A relay should NOT be assigned to more than one group.

Alternate on Time

This is the maximum time any relay in the group will be continuously on. After the alternation time has elapsed, the relay will turn off and another relay will turn on. This feature is useful for applications where the level is maintained with one pump for a long time. Depending of the setup and conditions, it will help distribute the load among the pumps in the group.

Break

If Relay On is selected, only one of the alternation relays will be on when a break is detected.*

*Note: Break needs to be set in the analog input menu.

Setup the primary alternation relay.

Setup the additional alternation relays.

Select the primary relay to alternate with.

Alternation Sequence

The first relay on is the first relay off, when more than one relay are activated. The lowest reset point (Off) is used for the alternation cycle.

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Setup Digital Output

The Digital Output menu allows assigning the 4 outputs to various events generated by digital inputs, On/Off channels, alarms, and horn on state.

• Edit the digital output tag

• Select the input

• Select the Break condition

• Invert Output logic

Setup Modbus Output (Server)

The Modbus output is a standard ConsoliDator+ feature; this is additional to the predetermined Modbus table provided, see Modbus Register Tables on page 128.

The Modbus Output menu allows assigning up to 99 Modbus register sets (1 to 4) to output any of the values available in the system (e.g. PV channels, Totals, Relay Runtime, etc.) and selecting the desired data type from bit-logic to float 64.

The function code is 0x03 and the registers are base-1 (e.g. Reg. Address 4400 = Reg. Number 44401).

• Edit the Modbus Output tag

• Select the source for the output

• Select the data type

• The register number is assigned by the system

• Engineering units

• Number of decimals

• Output Action

Select the input to be used for the Modbus Output Additional Inputs not shown above:

• mA Input

• Digital Output

Select the data type

The register number is provided for each data type

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Setup Modbus Output (Client)

The Modbus outputs from a ConsoliDator+ Client can be written to Modbus servers, or they can be read using the Ethernet TCP/IP port. The outputs are posted periodically on a schedule or on demand by triggering a user function (e.g. F1 function: Output (Post) - MO-1).

Process variables can be read by the Client, scaled, combined with other variables using the math functions, and the results can be written to another ConsoliDator+ or any other Modbus server, such as a digital panel meter.

• Enter a tag for the process variable

• Select Client mode

• Select the input needed for the Modbus output

Enter all the parameters needed to write to a Modbus server (e.g. Modbus server panel meter)

• Server ID

• Register Address (Base 0)

• Select Enron, if applicable

• Function Code

• Data Type – Reg. No. displayed automatically

• Byte Order

• Engineering Units and decimals to be used

• Post Time: How often to write to the server

• Output Action: Select from many actions

available or leave as None

The data type must match the type required by the server device; otherwise the value will not be correct.

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Setup Modbus Output (Spoofer)

The Modbus Spoofer feature is part of the Modbus Client/Snooper add-on feature. To enable this feature, you must purchase a PDK9000-M1 and enter the key in the System – General menu. The controller must be configured as a Modbus Server/Snooper in the System – Modbus menu. See page 106 for instructions on how to enable the Add-On Features.

The Spoofer Modbus output is used to replace Modbus devices that have been removed from the network; there is no need to make changes to the client’s configuration.

The supported function codes are: 0x01, 02, 03, 04. For outputting the value from a channel use function code 0x03, enter the registers address base-0 (e.g. Reg. Address 4400 = Reg. Number 44401).

• Edit the Modbus Output tag

• Select the source for the output

• Select the data type

• The register number is displayed automatically.

Select the input for Modbus Output.

Select the data type.

Enron protocol and Float 64 data type selected. Every time the Modbus output is read by the client, the

Total 1 is reset.

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Setup Screens

The Setup Screens menu is used to set up the screens that will be displayed during operation and to set up the actions assigned to the function keys F1-F4.

Screens Settings

Up to eight PVs and/or alarms can be displayed per screen. The screens can set up to scan automatically, display bargraphs, and program the function keys to be used while the screen is visible.

These are the available settings:

• Title: User-defined title or tag

• Channels and alarms: Up to eight/screen

• Show Title: Select to display the title

• Show Channel #: Select to display the channel #

• Show Bargraphs: Select to display the bargraphs

• Bargraph Only: Select to display only the bargraphs

• Auto Scan: Select to scan the screens automatically

• Dwell Time: Number of seconds the screen is

displayed before moving to the next screen

• F1 – F4: Assign functions to be executed by the

function keys

Notes:

1. The function keys F1 – F4 can be customized according to the screen in view.

2. If the Data Logger feature is enabled, the F4 key defaults to the Remove USB function.

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Setup Function Keys

The function keys are setup independently for each screen; this allows the customization of the function keys according to the process values being displayed. For example, if totals are being displayed, one function key can be set up to reset one or all totals.

Note: Functions are available for selection only if the appropriate parameter has been set up. Example: If there are no channels with Tare, Max, or Min, Channel will not appear in the list for selection of a function.

• Channel Tare (If applicable) Minimum Maximum

• Total Reset Total Reset (Confirm) Enter Total Add To Remove From

• Timer

Timer Control Reset Start (Reset) Start (No Reset) Stop (Reset) Stop (No Reset)

Start (R) / Stop Start / Stop Start / Stop (R) Start (R) / Stop (R) Start / Reset Stop / Reset

• Switch

Next Previous

Pos. 1 Pos. 2 Pos. 3 Pos. 4

• Alarm Ack Reset Alarm Set Points

• Screens

Previous Screen Next Screen Scan / Stop Go to Screen View Channel View Total View Timer View Alarm

View Date & Time

View mA Input View Pulse Input View Digital Input View Modbus Input View mA Output View Relay Output View Digital Output

View Modbus Output View Digital Output

View Switch

Note: The View function can be used to go to any of the listed parameters or to the View screen for all parameters of the same type (e.g. View - all the channels).

F4 Assigned to Acknowledge All Alarms

• If the Data Logger feature is enabled, the F4 key is

assigned to the Remove USB function by default. This can be changed anytime.

• Data Log Log Entry Start / Stop Remove USB New File

• Simulate mA Input Pulse Input Digital Input Modbus Input Channel Total Timer Alarm

• Horn Silence Horn Snooze Horn Horn Test

• mA Output Manual Hold (Manual) Automatic Manual / Auto Hold / Auto

• Relay Reset Info Reset Info (Confirm) Force ON Force OFF Manual ON Manual OFF Hold (Manual) Automatic Manual ON / Auto Manual OFF / Auto Hold / Auto