Precision Digital PD941 User Manual

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ConsoliDator®

Multi-Channel Controller

Instruction Manual

ConsoliDator 8 ConsoliDator 4

 Eight 4-20 mA Inputs  Four 4-20 mA Inputs  Eight 24 VDC @ 20 mA  Four 24 VDC @ 20 mA  Two 4-20 mA Outputs  Four 4-20 mA Outputs

Features and Highlights

 Nine Form C 10 A Relays  Powered from AC or DC  Four Pulse Inputs  32-Point Linearization  Four Digital Inputs  RS-232 Modbus  Panel or wall mount  Square Root Function  Sum and Difference

Functions

 FREE Programming &

data logging software

Software

Included!

RTU

PRECISION DIGITAL CORPORATION

89 October Hill Road • Holliston MA 01746 USA Tel (800) 343-1001 • Fax (508) 655-8990

www.predig.com

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ConsoliDator Multi-Channel Controlle

Instruction Manual

Visit our Web Site

http://www.predig.com/

Disclaimer

The information contained in this document is subject to change without notice. Precision Digital Corporation 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.

All trademarks mentioned in this document are the property of their respective owners.

This document contains ratings and requirements necessary for proper installation. Distribution of modified versions is strictly prohibited. Any text, chart, diagram, or table reproduced must be reproduced in its entirety without alteration.

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ConsoliDator Multi-Channel Controlle

Instruction Manual

INTRODUCTION

The ConsoliDator is an easy to use multiple-channel controller. It accepts 4-20 mA inputs, flow meter pulse inputs, and digital inputs. It is equipped with multiple relays, which all have user-definable actions, 4-20 mA outputs, and Modbus protocol communication capabilities.

ORDERING INFORMATION

ConsoliDator Controllers

4-20

Model Mounting

PD980-8K9-15 Wall PD981-8K9-15 Panel PD940-8K9-15 Wall PD941-8K9-15 Panel

Inputs

8 4 2 9

4 4 4 9

Accessories

Model Description

PDA2901 NEMA 4X Enclosure for PD981 or PD941 models. PDA2904 NEMA 4X Large Enclosure for PD981 or PD941 models. PDP2901 Sub Panel with Terminal Strips for PDA2901 Enclosure. PDP2902 Low-Cost Sub Panel without Terminal Strips for PDA2901. PDP2904 Sub Panel with Terminal Strips for PDA2904 Enclosure. PDP2905 Low-Cost Sub Panel without Terminal Strips for PDA2904. PDA6901 2" Pipe Mounting Kit for PDA2901 Enclosure. PDA6902 2" Pipe Mounting Kit for PDA2904 Enclosure. PDX6901 Snubber .01µF, 470Ω, Flexible Leads. PDA7485-I RS-232 to RS422/485 Isolated Converter PDA7485-N RS-232 to RS422/485 Non-Isolated Converter PDA8232-N USB to RS-232 Converter PDA8485-I USB to RS422/485 Isolated Converter PDA8485-N USB to RS422/485 Non-Isolated Converter PDA9232-01 ConsoliDator Null Modem Cable PDA9232-02 RS-232 Computer Cable

Setup & Programming Services

Part Number Description

PDN-CSETUP2 Custom Setup & Programming PDN-CERTCAL Certificate of Calibration PDN-CERTCAL2 Certificate of Calibration with Data

PDA2901 Optional enclosure features quick-release latches, a hinged front panel and internal space for mounting additional components such as relays and switches.

Pulse

Inputs

Model: PDP2901 Sub Panel for PDA2901 Enc

POWER

GND

DC POWER

RELAY

NO NCC

RELAY 9

GND HN

C POWER

4-20

Outputs

INPUT

C O

Y M M

4 O N

EXTERNAL KEYPAD

OUTPUT

N U T

ANALOG

COMMON

OUTPUT 1

OUTPUT 2

INTERNAL POWER

INPUT

GND/

RET

NALOG 5/

NALOG 6/

FLOW 1

FLOW 2

INPUT

GND/

RET

NALOG 1ANALOG 2ANALOG 3ANALOG 4

RELAY

NO NCC

RELAY 5

RELAY 6

RELAY

NO NCC

RELAY 1

RELAY 2

Relays

DIGITAL INPUTS

ANALOG

COMMON

OUTPUT 3

OUTPUT 4

INTERNAL POWER

GND/

RET

NALOG 7/

NALOG 8/

FLOW 3

FLOW 4

GND/

RET

NO NCC

RELAY 7

RELAY 8

NO NCC

RELAY 3

RELAY 4

PDP2901 Optional sub panel features terminal strips for convenient installation of all power, analog, and relay lines using up to 8 AWG wire.

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ConsoliDator Multi-Channel Controlle

Instruction Manual

TABLE OF CONTENTS

INTRODUCTION ----------------------------------------------------------------------- 3 ORDERING INFORMATION -------------------------------------------------------- 3 TABLE OF CONTENTS -------------------------------------------------------------- 4 SPECIFICATIONS --------------------------------------------------------------------- 7

General ------------------------------------------------------------------------------------------- 7 4-20 mA Analog Inputs --------------------------------------------------------------------- 8 Flow Meter Pulse Inputs -------------------------------------------------------------------- 8 Digital Inputs ----------------------------------------------------------------------------------- 8 Relays -------------------------------------------------------------------------------------------- 9 4-20 mA Transmitter Outputs ----------------------------------------------------------- 10 Modbus® Serial Communications ----------------------------------------------------- 10 ConsoliDator® Software ------------------------------------------------------------------ 10 Compliance Information ------------------------------------------------------------------ 10

SAFETY INFORMATION ---------------------------------------------------------- 11 INSTALLATION ---------------------------------------------------------------------- 12

Unpacking ------------------------------------------------------------------------------------- 12 Wall Mounting ------------------------------------------------------------------------------- 12 Panel Mounting ------------------------------------------------------------------------------ 13 Connections ---------------------------------------------------------------------------------- 14

Power Connections ---------------------------------------------------------------------- 14 Input Signal Connections --------------------------------------------------------------- 15

4-20 mA Analog Input Connections ---------------------------------------------- 15 Flow Meter Pulse Input Connections --------------------------------------------- 16 Digital Input Connections ----------------------------------------------------------- 16

Analog Output Connections ------------------------------------------------------------ 17

Note: All inputs and outputs share a common ground. DO NOT power inputs and outputs with the same power supply.Relay Connections -------- 17

Relay Connections ----------------------------------------------------------------------- 18

Switching Inductive Loads ---------------------------------------------------------- 18

Serial Communication Connections ------------------------------------------------- 19

Serial Communication Using RS-422/485 -------------------------------------- 19

External Keypad Connections --------------------------------------------------------- 19

NAVIGATING AND EDITING ----------------------------------------------------- 20 SETUP AND PROGRAMMING -------------------------------------------------- 21

Main Setup Menu --------------------------------------------------------------------------- 22

General Functions ------------------------------------------------------------------------ 22

Buzzer ----------------------------------------------------------------------------------- 22 Time Out -------------------------------------------------------------------------------- 22 Password -------------------------------------------------------------------------------- 22 Backlight --------------------------------------------------------------------------------- 23 Baud Rate ------------------------------------------------------------------------------- 23 Parity ------------------------------------------------------------------------------------- 23 Modbus ID ------------------------------------------------------------------------------ 23

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ConsoliDator Multi-Channel Controlle

Instruction Manual

Tx Delay --------------------------------------------------------------------------------- 23

Configuring 4-20 mA Inputs ------------------------------------------------------------- 24

Display Preferences --------------------------------------------------------------------- 24

Decimal Point -------------------------------------------------------------------------- 24 Units -------------------------------------------------------------------------------------- 24 Bargraph -------------------------------------------------------------------------------- 24

Input Scaling & Math Functions ------------------------------------------------------- 25

Linear ------------------------------------------------------------------------------------ 25 Square Root ---------------------------------------------------------------------------- 26 Exponent -------------------------------------------------------------------------------- 27 Integration Mode ---------------------------------------------------------------------- 28 Fixed Value ----------------------------------------------------------------------------- 28 Summation & Difference ------------------------------------------------------------ 28 Multi-Point Linearization ------------------------------------------------------------- 29

Sensor Input Setup ----------------------------------------------------------------------- 29

Setting Flow Meter Pulse Inputs ------------------------------------------------------- 30

Display Parameters ---------------------------------------------------------------------- 30 Input Configuration Parameters ------------------------------------------------------- 30

Programming Relays ---------------------------------------------------------------------- 31

Supervisory or Summary Alarm Modes --------------------------------------------- 31 High or Low Alarm Modes -------------------------------------------------------------- 31 Multi-Channel High or Low Alarm Modes ------------------------------------------ 32 High or Low Pulse Alarm Modes ----------------------------------------------------- 33 Trigger Alarm Mode ---------------------------------------------------------------------- 34 Annunciator High or Low Alarm Modes --------------------------------------------- 34 Plunger Lift by Differential Pressure Mode ----------------------------------------- 35 Plunger Lift by Time Mode ------------------------------------------------------------- 35 Lead-Lag Modes (Pump Alternation Control) ------------------------------------- 36 Linear Pulse Width Modulation Mode ----------------------------------------------- 38 Proportional Plus Integral Pulse Width Modulation Mode ---------------------- 39

Setting 4-20 mA Outputs ----------------------------------------------------------------- 40

Linear Scaling of 4-20 mA Output ---------------------------------------------------- 40 PID Control Using 4-20 mA Output -------------------------------------------------- 40

OPERATION -------------------------------------------------------------------------- 41

Manual and Simulation Modes --------------------------------------------------------- 45 Contrast Adjustment Control ----------------------------------------------------------- 46

MODBUS® SERIAL COMMUNICATION --------------------------------------- 47

Modbus Register Tables ----------------------------------------------------------------- 47

CONSOLIDATOR MONITOR SOFTWARE ----------------------------------- 52

Connecting to PC --------------------------------------------------------------------------- 52 Installing Software ------------------------------------------------------------------------- 52 Using ConsoliDator Monitor Software ----------------------------------------------- 52

Data Logging ------------------------------------------------------------------------------ 53 Programming Through Software ------------------------------------------------------ 53

OVERALL DIMENSIONS ---------------------------------------------------------- 54 TROUBLESHOOTING TIPS ------------------------------------------------------ 55

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ConsoliDator Multi-Channel Controlle

Instruction Manual

Table of Figures

Figure 1. Wall Mount Dimensions (PD980 & PD940) ..................................... 12

Figure 2. Panel Mount Dimensions (PD981 & PD941) ................................... 13

Figure 3. Power Connections .......................................................................... 14

Figure 4. Transmitter Powered by Ext. Supply or Self-Powered .................. 15

Figure 5. Transmitters Powered by ConsoliDator ......................................... 15

Figure 6. Three-Wire Transmitters Powered Externally ................................ 15

Figure 7. Flow Meter Pulse Input Connections .............................................. 16

Figure 8. Digital Input From Switch Closure .................................................. 16

Figure 9. Digital Input From Live Signal ......................................................... 16

Figure 10. 4-20 mA Output Powered by ConsoliDator .................................. 17

Figure 11. 4-20 mA Output Powered by External Supply .............................. 17

Figure 12. Relay Connections ......................................................................... 18

Figure 13. AC and DC Loads Protection ......................................................... 18

Figure 14. Low Voltage DC Loads Protection ................................................ 18

Figure 15. Serial Connections ......................................................................... 19

Figure 16. External Keypad Connections ....................................................... 20

Figure 17. Linear Response Graph ................................................................. 25

Figure 18. Square Root Response Graph ....................................................... 26

Figure 19. Exponent Response Graph............................................................ 27

Figure 20. Pulse Relay Timing Diagram ......................................................... 33

Figure 21. Linear PWM Relay Timing Example .............................................. 38

Figure 22. PD980 & PD940 Overall Dimensions ............................................. 54

Figure 23. PD981 & PD941 Overall Dimensions ............................................. 54

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ConsoliDator Multi-Channel Controlle

Instruction Manual

SPECIFICATIONS

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

General

DISPLAY Graphical: 4.75" x 3.5" (121 mm x 89 mm) LCD with backlight

DISPLAY UPDATE RATE

PROGRAMMING METHOD

CALIBRATION All ranges are calibrated at the factory.

PASSWORD Programmable password restricts modification of programmed

NON-VOLATILE MEMORY

POWER AC: 90-264 VAC, 47 to 63 Hz, 20 VA

FUSE AC: Unit is protected internally. 5 A max, slow blow, 250 V min UL

ISOLATION & GROUNDING

ENVIRONMENTAL Operating temperature range: 0 to 50°C (32 to 122°F)

CONNECTIONS Removable screw terminal blocks accept 12 to 24 AWG wire.

TIGHTENING TORQUE

ENCLOSURE Type 1; Powder-coated steel; Color: warm gray

MOUNTING Wall Mount (PD980 & PD940): four screws/bolts

OVERALL DIMENSIONS

WEIGHT 5.5 lb (2.5 kg)

WARRANTY

EXTENDED WARRANTY

320 X 240 pixels; Bargraph: Twenty divisions; Numerical: ±999999 or 99’ 11.9” (feet and inches)

1 every 2 seconds

Front panel buttons, external buttons, PC with ConsoliDator software, or Modbus registers.

settings and use of manual control functions.

Settings stored for a minimum of 10 years.

DC: 8-30 VDC, 15 W

Recognized external fuse recommended. DC: 5 A max, slow blow, 250 V (or 50 V min) UL Recognized

external fuse recommended.

AC power is isolated from all inputs, outputs and relays to 1500 VAC. Isolation to 500 VAC between analog inputs and analog outputs requires powering analog outputs with external supply. Signal and output power grounds are connected to earth (chassis) ground. DC Power not isolated.

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

*All functions operate down to -10°C (14°F.) LCD response is slower below 0°C (32°F) and may need contrast adjustment to be readable.

DB9 male for serial connection.

Screw terminal connectors: 4.5 lb-in (0.5 Nm)

Panel Mount (PD981 & PD941): four screws/bolts Cutout: 7.37" x 8.35" (187 mm x 212 mm)

Wall Mount 8.75" x 8.00" x 3.00" (222 mm x 203 mm x 76 mm)

(H x W x D)

Panel Mount 8.66" x 9.36" x 3.10" (220 mm x 238 mm x 79 mm)

(H x W x D)

1 year parts and labor

1 or 2 years, refer to Price List for details

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ConsoliDator Multi-Channel Controlle

Instruction Manual

4-20 mA Analog Inputs

INPUT 4-20 mA; minimum span of 1 mA

ACCURACY

TEMPERATURE DRIFT

INPUT FUNCTION Linear, Square Root, Programmable Exponent, Multi-Point

MATH FUNCTION Sum or difference of 2 or more channels.

TOTALIZER Calculates total based on rate and time base of second,

TOTALIZER RESET Via front panel buttons (password restricted)

DECIMAL POINT User selectable zero to six places with automatic overflow.

INPUT RANGE 4-20 mA, Minimum span of 1 mA

INPUT IMPEDANCE

NORMAL MODE REJECTION

TRANSMITTER POWER SUPPLY

ENGINEERING UNITS User selectable units or custom-entered units.

±0.03% of span 1 count 50 PPM/C from 0 to 50°C ambient

(up to 32), or Fixed Value

minute, hour, or day; stored in non-volatile memory every 5 minutes; supports linear inputs only.

130 

Greater than 100 dB at 50/60 Hz.

Each input is equipped with +24 VDC current limited to 40 mA. External supply may be substituted.

Flow Meter Pulse Inputs

ACCURACY ±1 count for K-Factor > 1

SIGNAL RANGE 100 mVp-p to 15 Vp-p; 1 Hz to 10 kHz

K-FACTOR Programmable from 0.00001 to 999999 pulses/unit

DISPLAY OPTIONS Rate and total values displayed on screen.

ENGINEERING UNITS Show Total/Rate combinations:

RATE & TOTAL DECIMAL POINT

TOTALIZER Calculates total based on rate. Reading stored in non-

TOTALIZER RESET Via front panel buttons (Password restricted)

Bargraphs user selectable to indicate either total or rate.

GAL & GPS, GAL & GPM, GAL & GPH, GAL & GPD, MG & MGD, BBL & BPH, BBL & BPD, LTR & LPs, LTR & LPM, LTR & LPH, LTR & LPD, CF & CFS, CF & CFM, CF & CFH, CF & CFD, MCF & MCD.

Independent and user selectable from zero to six places with automatic overflow.

volatile memory every 5 minutes for power-loss recovery.

Digital Inputs

INPUT TYPES Normally open switch: External excitation not required.

INPUT IMPEDANCE

SIGNAL REQUIREMENTS Minimum input pulse (closed contact or LO) duration: 1 sec

Open collector transistor: Open circuit voltage = 3 VDC Closed Circuit Current = 18.5 mA Switch closure or logic LO to terminals interpreted as "ON" LO = 0 to 1 VDC, HI = 2.5 to 12 VDC

240 

Maximum input pulse frequency: 30 cycles per minute

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ConsoliDator Multi-Channel Controlle

Instruction Manual

Relays

RATING SPDT (form C); rated 10 A @ 120/240 VAC or 5 A @ 28 VDC

ISOLATION 1500 VAC between coil and contacts

DEADBAND 0-100% of full scale, user selectable

ELECTRICAL NOISE SUPPRESSION

ASSIGNMENT & OPERATION

MANUAL OVERRIDE

ACKNOWLEDGE Front panel ACK key resets relays in Supervisory, Summary and

TIME DELAY Programmable on/off delays, 0-999.9 sec

AUTO INITIALIZATION

resistive load; 1/3 HP @ 120/240 VAC for inductive loads. Minimum load: 50 mA for AC, 10 mA @ 5 VDC

An external suppressor (snubber) should be connected to each relay contact switching inductive loads, to prevent disruption to the microprocessor’s operation. Recommended suppressor value: 0.01 µF/470 , 250 VAC (Order: PDX6901.)

Any relay may be assigned to any analog or flow meter pulse input channel. Multiple relays may be assigned to the same channel. All relays are programmed independently.

High or Low Alarm: Assign to analog or pulse channel for on/off relay control.

Multi-Channel High or Low Alarm: Assign two or more analog channels. Indicate common high or low condition.

Annunciator High or Low: Assign to analog or pulse channel for on/off relay control with reset capability from digital input switch.

Summary Alarm: Use to indicate any relay entering alarm state.

Supervisory Alarm: Use to indicate CPU failure or analog input signal loss.

High or Low Pulse Action: Assign to analog or pulse input channel for pulsing on/off timed relay control. Programmable pulse width and delay.

Trigger: Assign to pulse channel for indication of user-defined total increment. Programmable for scaled pulse output.

Plunger Lift: Assign to analog and/or pulse channels to control a plunger lift system.

Lead-Lag Alternation (Sequence): Link multiple relays for sequential operation. (Up to 9 relays.) Programmable override set points to turn on up to 5 relays.

Pulse Width Modulation: Assign to analog or pulse channel for on/off signal modulated by input. User selectable cycle time.

PI Control: Assign to analog or pulse channel for Proportional plus Integral on/off modulated duty cycle. Manual tuning required.

Override any relay (Password restricted.) Relays do not respond to input in this mode.

Annunciator Alarm Modes.

Independent for each relay.

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

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Instruction Manual

4-20 mA Transmitter Outputs

OUTPUT RANGE 4.00 to 20.00 mA

CALIBRATION Factory calibrated for 4-20 mA

SCALING RANGE Any process range.

ASSIGNMENT & OPERATION

ACCURACY

TEMPERATURE DRIFT

OUTPUT LOOP POWER Self powered or externally powered by 12 to 32 VDC

OUTPUT LOOP RESISTANCE

ISOLATION 1500 V output-to-power line; 500 V output-to-input when

Assign to any analog or pulse input channel for linear scaling or for manually tuned PID control output.

±0.05% F.S. 0.01 mA 50 PPM/C from 0 to 50C ambient.

Powered by controller: 10 to 600  Powered by external 12 VDC: 10 to 300  Powered by external 24 VDC: 10 to 600  Powered by external 32 VDC: 10 to 900 

Output & Input drifts are separate.

Modbus® Serial Communications

COMPATIBILITY EIA-232

PROTOCOL Modbus RTU

DEVICE ADDRESS Programmable between 1 and 247

TRANSMIT DELAY Programmable between 0 and 300 ms

BAUD RATE Programmable from 1200 to 38400

DATA 8 bit (1 start bit, 1 stop bit)

PARITY EVEN, NONE with 1 stop bit, or NONE with 2 stop bits.

ConsoliDator® Software

SYSTEM REQUIREMENTS

COMPATABILITY Separate versions for ConsoliDator 4 and ConsoliDator 8.

COMMUNICATION RS-232 using null-modem serial cable.

LOGGING REPORTS

LOGGING REPORT Log to comma separated value (.csv) file compatible with

CONFIGURATION Configure inputs and outputs. Store ConsoliDator settings file on PC

Windows® 95/98/ME/NT4/2000/XP

Programmable between 1 sec. and 10 min.

spreadsheet applications such as Microsoft® Excel.

for programming other controllers or restoring settings.

Compliance Information

UL LISTED USA and Canada: UL 508 Industrial Control Equipment

UL FILE NUMBER E160849

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ConsoliDator Multi-Channel Controlle

SAFETY INFORMATION

Instruction Manual

CAUTION: Read complete

instructions prior to installation and operation of the controller.

WARNING Hazardous voltages present. Installation and service should be performed only by trained service personnel.

WARNING: Risk of electric shock.

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ConsoliDator Multi-Channel Controlle

Instruction Manual

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.

Wall Mounting

(For PD980 & PD940 Models)

 Obtain four #10 (M5) screws and nuts.  Prepare four 1/4" (6 mm) holes through mounting surface spaced as shown.  Allow at least 2” (5 mm) of free space on all sides so that the removable screw

terminals and DB9 connector may be accessed for wiring.

 Secure instrument to surface.

Dia. 0.25" (6 mm) 4 places

7.25" (184 mm)

Figure 1. Wall Mount Dimensions (PD980 & PD940)

8.00" (203 mm)

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ConsoliDator Multi-Channel Controlle

Instruction Manual

Panel Mounting

(For PD981 & PD941 Models)

 Obtain four #8 (M4) screws and nuts.  Obtain four washers with at least 5/16" (8 mm) O.D. If the device will be subjected to

vibration, lock washers are necessary.

 Prepare four 1/4" (6 mm) clearance holes through mounting surface spaced as shown.  Prepare panel cutout.

 8.35" W x 7.37" H (212 mm x 187 mm)  Center cutout vertically and horizontally with respect to holes.

 Maximum allowable inner radii: 0.1" (2.5 mm.)  Remove all connectors.  Insert controller and secure to surface.

PANEL

CUTOUT

8.86" (225 mm)

Figure 2. Panel Mount Dimensions (PD981 & PD941)

4 CLEARANCE HOLES Dia. 0.25" (6 mm)

8.16" (207 mm)

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ConsoliDator Multi-Channel Controlle

Instruction Manual

Connections

Connections are made to removable screw terminal connectors and a DB9 male serial connector. They are located around the sides of the controller.

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 instrument and ensure personnel safety.

Power Connections

Power connections are made to one of the power terminal connectors. All units are capable of being powered either by AC or by DC for the ranges specified.

CONNECT ONLY ONE OF THE POWER INPUTS

120-250 VAC Power (90 VAC min, 264 VAC max)

 Use three-terminal power connector as shown in Figure 3.  Unit is protected internally. 5 A max, slow blow, 250 V min UL Recognized

external fuse recommended.

8-30 VDC Power

 Use two-terminal power connector as shown in Figure 3.  5 A max, slow blow, 250 V (or 50 V min) UL Recognized external fuse

recommended.

AC POWER

120-250V 47-63 Hz

GND N H

DC POWE

8-30V

+ GND

AC HOT AC NEUTRAL EARTH GROUND

Figure 3. Power Connections

DC GROUND DC +

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ConsoliDator Multi-Channel Controlle

Instruction Manual

Input Signal Connections

Input signal connections are made to terminal connectors, which are labeled individually on the controller.

4-20 mA Analog Input Connections

Analog 4-20 Input connections are made to three-terminal connectors. The following figures show examples for typical applications. Each of the 4-20 mA inputs may be connected in any of the modes shown below.

ANALOG INPUT

GND

ANALOG INPUT

GND

External

Power

Supply

Figure 4. Transmitter Powered by Ext. Supply or Self-Powered

NALOG INPUT

GND

2-Wire

4-20 mA

Transmitter

2-Wire 4-20 mA

Self-Powered

ANALOG INPUT

GND

2-Wire

4-20 mA

Transmitter

Figure 5. Transmitters Powered by ConsoliDator

3-Wire 4-20 mA

Transmitter

Signal

ANALOG INPUT

GND

Power +

External Power Supply

Figure 6. Three-Wire Transmitters Powered Externally

Signal -

3-Wire 4-20 mA

Transmitter

Signal +

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ConsoliDator Multi-Channel Controlle

Instruction Manual

Flow Meter Pulse Input Connections

Flow Meter Pulse Inputs are wired to two-terminal connectors. A square waveform is used in the illustration, but the input is capable of reading many other types of signals within the voltage and frequency ranges specified.

FLOW-METE

Signal Source

round

Figure 7. Flow Meter Pulse Input Connections

Digital Input Connections

Digital Inputs are wired to two-terminal connectors. Normally open switch contacts may be used as shown in Figure 8. Figure 9 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 9) will be interpreted as ON.

DIGITAL INPU

Switch Contact

Figure 8. Digital Input From Switch Closure

DIGITAL INPU

Live Signal Source

Figure 9. Digital Input From Live Signal

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Analog Output Connections

The following figures show examples for 4-20 mA transmitter output connections. Terminal connectors are labeled individually on the side of the case. In order to obtain isolation from analog inputs, outputs must be powered from an external supply as shown in Figure 11.

ANALOG OUTPUT

+24

LOOP IN

LOOP OUT

GND

Remote Display,

Chart Recorder, etc.

Figure 10. 4-20 mA Output Powered by ConsoliDator

ANALOG OUTPUTS

+24

LOOP IN

LOOP OUT

GND

External Power

Supply

Remote Display,

Chart Recorder, etc.

Figure 11. 4-20 mA Output Powered by External Supply

Note: All inputs and outputs share a common ground. DO NOT inputs and outputs with the same power supply.

power

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Relay Connections

Relay connections are made to three-terminal connectors labeled on the side of the case.

RELAY OUTPUT

NO - C - NC

Figure 12. Relay Connections

Switching Inductive Loads

The use of suppressors (snubbers) is strongly recommended when switching inductive loads to prevent disrupting the microprocessor’s operation. The suppressors also prolong the life of the relay contacts. Suppression can be obtained with resistor-capacitor (RC) networks assembled by the user or purchased as complete assemblies. Refer to the following circuits for RC network assembly and installation:

Figure 13. AC and DC Loads 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.

Use diode with a reverse breakdown

voltage two to three times the circuit

voltage and forward current at least

as lar

Figure 14. 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.

e as the load current.

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Serial Communication Connections

A DB9 male connector is the port for RS-232 serial communication (using Modbus protocol.) The ConsoliDator can be connected to Data Circuit-Terminating Equipment (DCE) such as a radio transmitter with a regular straight-through serial cable. In cases where connecting to Data Terminal Equipment (DTE), such as a PC, a Female-Female Null Modem cable is necessary. Many computers are equipped with at least one 9-pin RS-232 serial port. For distances up to 50 ft, a shielded serial or null-modem cable is adequate. More information can be found in Modbus Serial Communications (page 47)

When connecting the ConsoliDator to change the ConsoliDator's parity parameter to "NONE - 8N2," for None parity, 2 stop bits.

A null modem cable looks similar to a standard serial cable, but internally the transmit and receive lines cross unlike in a standard serial cable and for Computer-to-ConsoliDator, both ends must be Female.

Serial Communication Using RS-422/485

For long distances or noisy environments RS-422 and RS-485 offer superior performance compared to RS-232. Differential signals can help nullify the effects of ground shifts and induced noise signals that can appear as common mode voltages on a network. RS-422 was designed for greater distances than RS-232. In its simplest form, a pair of converters from RS-232 to RS-422 (and back again) can be used to form an “RS-232 extension cord." Distances to 4000 ft. can be reached with RS-422.

In an application that requires more than two devices to be networked, the RS-232 data must be converted to a serial format that allows for multiple devices, such as RS-485. For example, you can connect two or more ConsoliDators to a single computer by converting all devices to RS-485, but only one ConsoliDator with RS-232.

Data Converters Available from Precision Digital

Serial converters available from Precision Digital support a wide range of devices. Please reference part number PDA7485 when requesting information.

to a PC via the PDA8232, it is strongly recommended

Figure 15. Serial Connections

External Keypad Connections

Normally open pushbuttons may be wired to the six-terminal external keypad connector for use when the front panel of the controller is not accessible. Keys 1 through 5 refer to the front buttons in order from left to right.

KEY 1

KEY 2

KEY 3

KEY 4

KEY 5

EXTERNAL KEYPAD

COMMON

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ConsoliDator Multi-Channel Controlle

Instruction Manual

Figure 16. External Keypad Connections

NAVIGATING AND EDITING

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

SETUP AUTO ACK NEXT

Selections are marked by a cursor, which appears on screen as an arrowhead. The keys below are used to navigate through menus and edit settings. Other special keys appear throughout the programming process.

Key Action

ACK

EDIT

ENTER

EXIT

MANUAL / AUTO

RST

SAVE

SETUP

SIM







 Acknowledge relay(s)

 Modify selection

 Execute current selection

 Quit present screen or mode

 Toggle operation modes

 Reset total

 Store setting to memory

 Enter main setup menu

 Enter simulation mode

 Scroll through operation screens

 Move cursor up when navigating menus  Scroll up through characters & values when editing settings

 Move cursor down when navigating menus  Scroll down through characters & values when editing settings

 Move cursor right when navigating menus  Move to next character space when editing settings

 Increase setting

 Decrease setting

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ConsoliDator Multi-Channel Controlle

SETUP AND PROGRAMMING

There is no need to recalibrate the instrument when first received from the factory.

The device is factory calibrated prior to shipment, for all input types. The calibration equipment is certified to NIST standards.

Overview

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

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

Shown to the right is a typical screen that appears upon first power-up. Actual screens will vary with the amount of inputs initially detected.

For information on button functions, see NAVIGATING AND EDITING (page 20.)

To load software and program from a PC, please familiarize yourself with the ConsoliDator Monitor Software (page 52) before you continue with device setup.

Press SETUP key to begin.

Instruction Manual

Ch1 Ch2 Ch3 Ch4

SETUP AUTO ACK NEXT

Ch 1:

Ch 2:

Ch 3:

Ch 4:

12.000

13.000

14.000

15.000

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Instruction Manual

Inputs

Channel #1 Channel #2

Main Setup Menu

The main setup menu is the access point during the programming process for setting up Inputs, Outputs, and General Functions. The number of inputs and outputs shown on this screen are determined by what your particular model is equipped with.

Use arrows to navigate and the ENTER key to select.

Channel #3 Channel #4 Channel #5 Channel #6 Channel #7 Channel #8 Flow Meter #1 Flow Meter #2 Flow Meter #3 Flow Meter #4

uzzer: ON OFF T-Out: ON OFF Change Password Save BL: YES NO Baud Rate: 19200 bps Parity: EVEN - 8E1 Modbus ID: 1 Tx Delay: 0 ms Adjust Contrast

Inputs

The Inputs box shown on this screen lists the 4-20 mA Channels and Flow Meter inputs. Individual channel setup is covered in detail in the next sections: Configuring 4-20 mA

Input (page 24) and Setting Flow Meter Pulse Inputs (page 30.)

Outputs

The Outputs box shown on this screen lists the relay and analog output channels available. Output setup is covered in Programming Relays (page 31) and Setting 4-20 mA Outputs (page 40.)

General Functions

utputs

Alarm Relay #1 Alarm Relay #2 Alarm Relay #3 Alarm Relay #4 Alarm Relay #5 Alarm Relay #6 Alarm Relay #7 Alarm Relay #8 Alarm Relay #9

Analog Out #1 Analog Out #2

EXITENTER

The General Functions box contains various options and serial communication settings.

If you are beginning a first-time setup, please read the brief descriptions below and if you are not sure of the settings, you may skip them and return after the controller’s operation is explained in later sections.

Use the arrows keys to move cursor to parameters in the General Functions box. Use

ENTER to select a parameter.

Buzzer

Buzzer sounds to indicate an active relay if [ON] is selected. Select [OFF] to disable.

Time Out

Manual mode time-out options are related to Manual and Simulation Modes (page 45.) When T-Out is set to [ON] the controller will return to Automatic mode after being left alone for 5 minutes in Manual mode. When [OFF] is selected, the controller will only switch modes if a key is pressed and then the password (if enabled) is entered.

Password

Select [Change Password] to enter a new password up to ten characters or to change an existing password. The operator will be required to enter this password to access setup or to manually override relays. It is recommended to enter the password after setup and programming is completed.

To disable a previously programmed password: Enter setup, select [Change Password] and leave the Password entry box blank.

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ConsoliDator Multi-Channel Controlle

Instruction Manual

Backlight

Selecting [YES] under Save BL automatically turns the backlight off if no buttons are pressed for five minutes. This is recommended unless it is necessary to have the backlight constantly on. When [NO] is selected the backlight is always on.

Baud Rate

Select any available baud rate.

Parity

Select [EVEN – 8E1] for Even parity, 1 stop bit. Select [NONE – 8N2] for None parity, 2 stop bits. Select [NONE – 8N1] for None parity, 1 stop bit.

Modbus ID

Specify an address for Modbus communication.

Tx Delay

Specify a serial data transmission delay (response.)

Place cursor at the channel you want to set and press ENTER.

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ConsoliDator Multi-Channel Controlle

Instruction Manual

Configuring 4-20 mA Inputs

The Analog Input setup screen is used to configure the 4-20 mA analog inputs. Each channel has a separate menu. All 4-20 mA inputs can be configured using the information provided in this section. In this menu, the Sensor box displays the live input reading in mA, and the Value box displays the scaled engineering units corresponding to the sensor input. You can verify your scaling parameters with this relationship.

Display Preferences

Begin configuring the input by naming the channel (e.g. “Tank 1”.) This name appears on screen to identify the channel during operation.

Move cursor to Channel ID and press EDIT. Use arrow keys to scroll through characters and move to the next position. Press SAVE to store new setting to memory.

Next, set display options. Move cursor to Configure Display Parameters and press ENTER. The box that appears contains the parameters for decimal point, engineering units, and bargraph extents for this channel. Use EDIT and arrow keys. Remember to press SAVE when finished.

Decimal Point

Format specifies the decimal point position for this channel. Use the arrow keys to shift left or right (zero to five places.)

Units

Select from any available engineering units or choose to enter a combination of characters by pressing the CUSTOM key. If this channel is to be used for integration totalizing, do not select rate units as the integration time base is added separately.

Bargraph

Max Value and Min Value are used to set the span of the bargraph (in scaled engineering units) for this channel. The bargraph will appear 100% full at Max Value and 0% at Min Value.

Analog Input: 1

nput Type: 4-20 mA Transmitter

Function: NONE - Linear

Channel ID: Analog 1

Configure Function Parameters

Configure Sensor Input

Configure Display Parameters

Sensor: Value:

12.00 mA 12.000 mA

EXIT

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ConsoliDator Multi-Channel Controlle

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Instruction Manual

Input Scaling & Math Functions

The ConsoliDator is capable of various functions for scaling the 4-20 mA inputs. Linear Square Root, Programmable Exponent, and Integration are two-point scaling functions. Multi-Point is capable of handling up to 32 scaling points and requires that the ConsoliDator

Monitor Software be used to enter these points.

Linear

Linear mode refers to basic 2-point scaling of a 4-20 mA signal in engineering units. The graph in Figure 17 shows the display response based on example scaling parameters. For this mode select [Linear] from Function options, then follow Sensor

Input Setup (page 29) to enter your scaling parameters.

Process Scaling Parameters

Input

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

Display

(mA)

4.00 0.00

5.00 6.25

6.00 12.50

7.00 18.75

8.00 25.00

9.00 31.25

(%)

High Value: 100.00 Low Value: 0.00

Sensor: 20.00 Sensor: 4.00

Linear Response

100.00

80.00

60.00

40.00

Display (%

20.00

0.00

4.00 8.00 12.00 16.00 20.00

Sen so r ( m A)

Figure 17. Linear Response Graph

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ConsoliDator Multi-Channel Controlle

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Instruction Manual

Square Root

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 18 shows the display response based on example scaling parameters. For this mode select [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”. To enter a cutoff value, select Configure Function Parameters. Press EDIT and use arrow keys to change the value. Press SAVE when complete.

Follow Sensor Input Setup (page 29) to enter your scaling parameters.

Note: An input that goes below the Low Value parameter results in a display of “-999999” indicating underrange condition. This can be prevented using the cutoff feature.

Process Scaling Parameters

Input

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

Display

(mA)

4.00 0.00

5.00 25.00

6.00 35.36

7.00 43.30

8.00 50.00

9.00 55.90

(%)

High Value: 100.00 Low Value: 0.00

Sensor: 20.00 Sensor: 4.00

Square Root Response

100.00

80.00

60.00

40.00

Display (%

20.00

0.00

4.00 8.00 12.00 16.00 20.00

Sen so r ( m A)

Figure 18. Square Root Response Graph

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ConsoliDator Multi-Channel Controlle

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Instruction Manual

Exponent

Exponent mode refers to 2-point scaling with programmable exponent (programmable root) extraction typically used in open-channel flow applications with weirs and flumes to linearize the signal from a level transmitter and display the flow rate in engineering units. The graph in Figure 19 shows the display response based on example parameters and exponent of “1.5”. For this mode select [Exponent] from Function options. To enter an exponent, select Configure Function Parameters. Press EDIT and use arrow keys to change the value. Press SAVE when complete.

The exponent 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”. To enter a cutoff value, select Configure Function Parameters. Press EDIT and use arrow keys to change the value. Press SAVE when complete.

Follow Sensor Input Setup (page 29) to enter your scaling parameters.

Note: An input that goes below the Low Value parameter results in a display of “-999999” indicating underrange condition. This can be prevented using the cutoff feature.

Process Scaling Parameters Exponent

Input

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

Display

(mA)

4.00 0.00

5.00 1.56

6.00 4.42

7.00 8.12

8.00 12.50

9.00 17.47

(%)

High Value: 100.00 Low Value: 0.00

Sensor: 20.00 Sensor: 4.00

Ex ponent Response

100.00

80.00

60.00

40.00

Display (%

20.00

0.00

4.00 8.00 12.00 16.00 20.00

Sen so r ( m A)

Figure 19. Exponent Response Graph

1.50000

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ConsoliDator Multi-Channel Controlle

Instruction Manual

Integration Mode

Integration mode is able to totalize from any 4-20 mA channel over a time base of second, minute, hour, or day. During operation, the channel’s display screen shows bargraph total, numeric total, and numeric rate. To begin setup, select from the following under Function options [Integration: SEC], [Integration: MIN], [Integration: HOUR], or [Integration: DAY]. Follow Sensor Input Setup (page 29) to enter your scaling parameters for the rate.

Note: Integration Mode is available for 2-point linear calibration only.

Fixed Value

Fixed Value mode may be used to create a constant display as if a steady signal is applied to the input, without requiring a transmitted signal. Controller outputs assigned to this channel will respond the same way it would with a constant signal. Any transmitted source connected on the corresponding input is ignored while fixed value mode is selected. To begin setup, select [Fixed Value] from Function options. Next, select Configure Function Parameters. In the box that appears, enter a value in engineering units by pressing EDIT and using the arrow keys. Press SAVE when complete and then EXIT to return to input menu.

Summation & Difference

Summation mode begins with a linearly scaled input, but adds the ability to link one or more separate channels for addition to its own display. Difference mode follows the same link principle, but subtracts one or more channels from itself. During operation, the channel that is used to set-up the link is the one that displays the sum or difference. Verify the appropriate channel has been selected. i.e. To display a summation for Channel 1 plus another channel, make sure you are in Analog Input: 1 setup screen. Remember to scale the other channels that you have chosen to link.

First, enter your scaling parameters. Reference Sensor Input Setup (page 29.)

For Summation, select [Summation], from Function options. Select Configure Function Parameters from the Analog Input setup screen. In the Function Setup box shown to the right, use arrow keys and ON/OFF key to select channels to be linked. The settings shown in the screen to the right are programmed to add Channel 2 to Channel 1.

Analog Input: 1

nput Type: 4-20 mA Transmitter

Function: Summation

Channel ID: Analog: 1

unction Setup:

Assign Channels:

hannel = 1+2+3+4+5+6+7+8

Link:

For Difference, select [Difference], from Function options. Select Configure Function Parameters from the Analog Input setup screen. In the Function Setup box shown to the right, use arrow keys and ON/OFF key to select channels to be linked. The settings shown in the screen to the right

Analog Input: 1

nput Type: 4-20 mA Transmitter

Function: Difference

Channel ID: Analog: 1

unction Setup:

Assign Channels:

hannel = 1-2-3-4-5-6-7-8

Link:

OFF EXIT

are programmed to subtract Channel 2 from Channel 1.

OFF EXIT

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ConsoliDator Multi-Channel Controlle

Instruction Manual

Multi-Point Linearization

Multi-Point Linearization must be configured using a PC and supplied ConsoliDator Monitor Software. After communication has been established between PC and ConsoliDator, select System Settings from the software’s menu bar. Next, select a channel to set up from the Analog Input Channels drop-down menu and press Edit Channel. Select [Multi-Point Linearization] from Channel Function drop-down menu. Use Add, Edit, and Del to manipulate the Multi-Point Data Table. Continue with other settings in this menu and press Save when complete. Reference ConsoliDator Monitor Software (page 52) for help setting up the PC connection.

Sensor Input Setup

The simplest method is to assign low sensor input reading to a corresponding process value (zero point) and then assign a high sensor input reading to a corresponding process value (span.) The sensor input may be read from a live signal or entered manually.

1. Select Configure Sensor Input.

2. In the new box that appears move cursor to Low Value and press EDIT. Use the arrows to enter a process value associated with a low sensor point. Press SAVE.

3. Move cursor to High Value and press EDIT. Use the arrows to enter a process value associated with a high sensor point. Press SAVE.

4. Next, enter the Sensor points corresponding to the process values entered in (2)- (3) – for example: 4.00 mA and 20.00 mA. To read a live signal corresponding with the process value follow (a.) To enter a signal point manually follow (b.)

a. Verify connections and set transmitter to the appropriate level. Allow to

settle for a few seconds. Position cursor at the Sensor parameter – located under the corresponding process value on the screen – and press LIVE.

b. To manually enter a signal level into the Sensor parameter

corresponding to the process value entered in (2), position cursor in front of Sensor – located under Low Value on the screen – and press EDIT. Use the arrow keys to enter a sensor value in mA. Press SAVE when completed.

5. Verify entries and press EXIT.

Notes:

1. Controller requires a minimum span of 1 mA.

2. High and Low process values may be scaled in a negative direction for a decreasing process.

For example: 100 gal High Value at 4 mA Sensor and 0 gal High Value at 20 mA Sensor.

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ConsoliDator Multi-Channel Controlle

Setting Flow Meter Pulse Inputs

The Flow Meter menu is used to configure a flow meter pulse input. All pulse input screens offer the same options as described in this section. Options are configured individually for each pulse input.

To access Flow Meter menu: Select a Flow Meter input from the Inputs window in the main setup menu.

To enter parameters in this menu, use EDIT key, then use arrow keys to modify the entries. Press SAVE when complete.

Display Parameters

Instruction Manual

low Meter: 1

State:

Channel ID: Flow: 1 ENABLED

K Factor: 1000.00 pls / GAL

Max Value: 50.00 GPM

K-Fac Fmt: 9999.99 GPM

Rate Fmt: 9999.99 GPM

Total Fmt: 9999.99 GAL

Units: GAL & GPM

Display: RATE

EDIT EXIT

Channel ID

Enter a name for the channel, which appears on the operation screens, and wherever else the channel is referenced.

Max Value

Specify the rate or total maximum. When this level is reached, the channel's bargraph will appear completely filled.

Rate Fmt:

Select a position for the rate display decimal point by shifting left or right (zero to five places.)

Total Fmt

Select a position for the total display decimal point by shifting left or right (zero to five places.)

Units

Display

Select from any available unit combinations for flow.

Set to display [RATE] or [TOTAL] based bargraphs during operation. This entry also determines whether assigned relay actions (other than Trigger Relay) are linked to rate or total values. The picture on page 43 shows a typical screen when set to display total.

Input Configuration Parameters

State

K Factor

K-Fac Fmt

Enable or disable the input by selecting [ENABLED] or [OFF]. If a certain flow meter input is not going to be used, [OFF] must be selected.

Specify the conversion factor "K" in pulses per unit.

Select a position for the K Factor decimal point by shifting left or right (zero to five places.)

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Programming Relays

Each relay has an Alarm Setup menu used to program its functions. Functions are programmed individually for each relay except in the case of Lead-Lag mode. Each relay has the same available functions. All relays may be manually overridden. Before the relays are set up, verify that the inputs have been configured.

To access Alarm Setup menu: Select a relay from the Relays window in the main setup menu.

Use Alarm Mode setting to assign relay action. When a mode is selected, relay menu options change accordingly. If the relay will not be used, [OFF] should be selected.

Supervisory or Summary Alarm Modes

Select [Supervisory Alarm] from Alarm Mode options to turn relay on (energize) when a CPU failure is detected or if a process input is lost (no signal present.)

Select [Summary Alarm] from Alarm Mode options to turn relay on when any other relay enters alarm state.

High or Low Alarm Modes

Alarm Setup: 1

High or Low functions are used to turn the relay on and off at selected process points. If it is necessary to have an external reset using a digital input channel or the ACK key select Annunciator High or Low Alarm Modes instead.

Select [HIGH] from Alarm Mode options to turn relay on (energize) when high set point is reached and off when low reset point is reached.

Select [LOW] from Alarm Mode options to turn relay on when low set point is reached and off when high reset point is reached.

Channel

High Value

Low Value

Delay ON

Assign the relay to any analog or pulse input.

Enter high process variable set/reset point.

Enter low process variable set/reset point.

Enter the delay between when the set point is reached and the relay turns on (energizes.)

Delay OFF

Enter the delay between when the reset point is reached and the relay turns off (de-energizes.)

Alarm Mode: HIGH

Channel: [1] Analog: 1

High Value: 16.00 mA

Low Value: 8.00 mA

Delay ON: 1.0 sec

Delay OFF: 0.5 sec

EDIT EXIT

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ConsoliDator Multi-Channel Controlle

Multi-Channel High or Low Alarm Modes

Multi-Channel High or Low modes are used as an alarm triggered by a set point common to the linked channels.

Select [HIGH: Multi-Chan] from Alarm Mode options to turn relay on (energize) when high set point is reached by any linked channel, and off when all linked channels are below reset point.

Select [Low: Multi-Chan] from Alarm Mode options to turn relay on (energize) when low set point is reached by any linked channel, and off when all linked channels are above reset point.

Channel

High Value

Low Value

Delay ON

Delay OFF

Link Channels

Assign the relay to any analog or pulse input.

Enter high process variable set/reset point.

Enter low process variable set/reset point.

Enter the delay between when the set point is reached and the relay turns on (energizes.)

Enter the delay between when the reset point is reached and the relay turns off (de-energizes.)

Select the channels to link .

Instruction Manual

Alarm Setup: 1

Alarm Mode: HIGH: Multi-Chan

High Value: 160.0 GAL

Low Value: 8.0 GAL

Delay ON: 1.0 sec

Delay OFF: 0.5 sec

Link Channels:

1 2 3 4 5 6 7 8

ON:

EDIT EXIT

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ConsoliDator Multi-Channel Controlle

High or Low Pulse Alarm Modes

Pulse Modes are used to generate an on/off continuous pulsing signal.

Select [HIGH: Pulse Mode] from Alarm Mode options to continuously pulse relay when high set point is reached. Pulsing stops when low reset point is reached.

Select [LOW: Pulse Mode] from Alarm Mode options to continuously pulse relay when low set point is reached. Pulsing stops when high reset point is reached.

High Value

Low Value

Delay ON

Delay OFF

Pl. Width

Pl. Delay

Over

Enter high process variable set/reset point.

Enter low process variable set/reset point.

Enter a delay between when the set point is reached and the pulse signal starts.

Enter a delay between when the reset point is reached and the pulse signal stops.

Enter pulse duration (Energized relay.)

Enter duration between pulses (De-energized relay.)

Enter override menu to override the channel alarm settings.

Instruction Manual

Set Point Reached

Delay ON

Pulse Width

Pulse Delay

Figure 20. Pulse Relay Timing Diagram

Example Pulse Mode Scenario

The unit is set to the following: Alarm Mode: [HIGH: Pulse Mode] High Value: [16 mA] Low Value: [10 mA] Delay ON: [2 sec] Delay OFF: [3 sec]

Pl. Width: [1 sec] Pl. Delay: [2.5 sec]

The following describes operation based on the above settings: The process reaches 16 mA: 2 seconds pass with no relay action. Relay begins pulsing: on for 1 second, off for 2.5 seconds. ON-OFF alternation continues while the process is above 10 mA. The process reaches 10 mA: Pulse sequence continues for 3 seconds and then stops completely until 16 mA is reached again.

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ConsoliDator Multi-Channel Controlle

Trigger Alarm Mode

Select Trigger mode to pulse the relay once each time the total from a flow meter pulse input channel is incremented by a certain value.

Instruction Manual

Alarm Setup: 1

Alarm Mode: Trigger

Channel: [A] Flow: 1

Set Point: 10.00 G AL

Pl Width: 1.0 sec

EDIT EXIT

Channel

Set Point

Assign the relay to any flow meter pulse input.

Enter process variable set point. Each time the total increases by this value, the relay will be pulsed one time.

Pl. Width

Enter duration for the relay to pulse on (energize.)

Annunciator High or Low Alarm Modes

The Annunciator functions are similar to High and Low Alarm Modes except for the addition of a reset capability from the ACK key, a digital input channel (normally open pushbutton switch), or External Key 4.

Select [ANNUNCIATOR: HIGH] from Alarm Mode options to turn relay on (energize) when high set point is reached and off when low reset point is reached.

Select [ANNUNCIATOR: LOW] from Alarm Mode options to turn relay on when low set point is reached and off when high reset point is reached.

Channel

High Value

Low Value

Delay ON

Delay OFF

Reset Ch

Assign the relay to any analog or pulse input.

Enter high process variable set/reset point.

Enter low process variable set/reset point.

Enter the delay between when the set point is reached and the relay turns on (energizes.)

Enter the delay between when the reset point is reached and the relay turns off (de-energizes.)

Select a digital input channel to be used to reset the relay.

Alarm Setup: 1

Alarm Mode: ANNUNCIATOR: HIGH

Channel: [A] Flow: 1

High Value: 16.00 GPM

Low Value: 8.00 GPM

Delay ON: 1.0 sec

Delay OFF: 0.5 sec

Reset Ch: [1] Reed SW: 1

EDIT EXIT

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ConsoliDator Multi-Channel Controlle

Plunger Lift by Differential Pressure Mode

Select [PLUNGER LIFT: DP] from Alarm Mode options to operate a plunger lift system that monitors differential pressure.

Instruction Manual

Alarm Setup: 1

Alarm Mode: PLUNGER LIFT: DP

Tubing Ch: [A] Flow: 1

Casing Ch: [2] Analog: 2

Switch Ch: [1] Reed SW: 1

Set Point: 100.00 GPM

Delay ON: 1.0 sec

After Flow: 5 min

EDIT EXIT

Tubing Ch

Select a 4-20 mA input or pulse input (flow) as the tubing pressure or flow rate.

Casing Ch

Select a 4-20 mA input or pulse input (flow) as the casing pressure or flow rate.

Switch Ch

Set Point

Select the channel that monitors a (pressure) switch input.

Enter the process variable point at which the relay closes a valve. The point may either be differential pressure or flow from a turbine meter.

Delay On

Enter the time between when the set point is reached and the relay turns on (energizes.)

After Flow

Enter a time long enough to guarantee that the plunger will fall to the bottom of the well.

Plunger Lift by Time Mode

Select [PLUNGER LIFT: TIME] from Alarm Mode options to operate a plunger lift system based on time by specifying the on and off durations in the cycle.

This mode may also be used as a general timer to cycle the relay on and off.

Alarm Setup: 1

Alarm Mode: PLUNGER LIFT: TIME

Rly On/Off: OFF

Time ON: 1.0 min

Time OFF: 5.0 min

Relay On/Off

TIME ON:

TIME OFF

EDIT EXIT

Select [ON] to enable relay function or [OFF] to disable.

Enter relay-on duration.

Enter relay-off duration.

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ConsoliDator Multi-Channel Controlle

Lead-Lag Modes (Pump Alternation Control)

Lead-Lag modes are used to operate up to 9 relays in sequence. This mode is commonly used for pump alternation control. For example: If relays #1, #2, and #3 are linked in this menu, relay #1 turns on the first time the set point is reached and off when the reset point is reached, relay #2 cycles the second time, and relay #3 cycles the third time. The sequence then repeats beginning with relay #1.

Select [LEAD-LAG: HIGH] from Alarm Mode options to turn relay on when high set point is reached and off when low reset point is reached.

Select [LEAD-LAG: LOW] from Alarm Mode options to turn relay on when low set point is reached and off when high reset point is reached.

Channel

High Value

Low Value

Delay ON

Assign the relay to any analog or pulse input.

Enter high process variable set/reset point.

Enter low process variable set/reset point.

Enter the delay between when the set point is reached and the relay turns on (energizes.)

Delay OFF

Enter the delay between when the reset point is reached and the relay turns off (de-energizes.)

Link Relays

Select between two and nine relays to operate in sequence.

Note: Linked relays must be set to [OFF] in their respective menus. (i.e. If Alarm Setup 1 links Relay #2, Alarm Setup 2 must read "Alarm Mode: [OFF]")

Instruction Manual

Alarm Setup: 1

Alarm Mode: LEAD-LAG: HIGH

Channel: TANK 1

High Value: 160.0 GAL

Low Value: 8.0 GAL

Delay ON: 1.0 sec

Delay OFF: 0.5 sec

Link Relays:

1 2 3 4 5 6 7 8 9

ON:

OVER

EDIT EXIT

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ConsoliDator Multi-Channel Controlle

Lead-Lag Override Function

Lead-Lag mode supports an override function, which allows up to five linked relays to turn on if programmed points are reached. Override set points also operate in sequence. They are not assigned to particular relays.

Use OVER key in Lead-Lag menu to access override menu.

Over Type

Set Pt. #1 (#2, #3, #4)

Choose number relays to override main relay (Up to 4 additional set points for a maximum of 5 relays operating at once.)

Specify each process set point for the override relays to activate.

Instruction Manual

Lead-Lag Override: 1

ver Type: Override 1 & 2 ON

Set Pt. #1: 170.0 GAL

Set Pt. #2: 180.0 GAL

EDIT EXIT

Example:

[LEAD-LAG: HIGH] is used to link relays #1, #2, and #3. In the Alarm Menu, High Value is set at 160.0 GAL and Low Value is set at 8.0 GAL. In the Override Menu, Over Type is set to [Override 1 & 2 ON.] Set Pt. #1 is set to 170.0 GAL and Set Pt. #2 is set to 180.0 GAL.

When the input reaches 160.0 GAL, the first relay in the sequence (Relay #1) turns on. When 170.0 GAL is reached, the next relay (Relay #2) turns on. If at this point the input decreases and drops below 8.00 GAL, both relays will turn OFF simultaneously. If instead, the input reaches 180.0 GAL, the third relay will turn ON and all three will remain ON until 8.0 GAL has been reached.

Note: In most override applications the number of relays linked should equal the total number of set points. However, linking additional relays is allowed. In the example, if 5 relays were linked and the total set points remained at 3, it would only be possible for 3 of the 5 to be on at once, but all 5 would sequence.

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ConsoliDator Multi-Channel Controlle

Instruction Manual

Linear Pulse Width Modulation Mode

Alarm Setup: 1

Linear PWM Mode is used to create an on/off pulse signal with a modulated duty cycle. In this mode the percentage of the relay cycle in which the relay is in the on state varies with relation to the process value.

See Figure 21 for an example showing that the cycle time (period) remains the same, but the relay-on percentage of the cycle changes with the process value.

Select [PWM: Linear] from Alarm Mode options to modulate the pulse relay signal in linear mode.

Channel

100% Value

Assign the relay to any analog or pulse input.

Enter the process value at which the pulse width will be 100% of cycle.

0% Value

Enter the process value at which the pulse width will be 0% of cycle.

Cycle Time

Note 1: Due to the life expectancy of mechanical relays, it is strongly recommended that cycle times be as long as possible (many minutes.) Using a cycle time of less than a few minutes can wear out a relay and cause faulty operation. Note 2: Relay is a constant OFF when process variable is at or below 10% of full span and a constant ON when process variable is at or above 90% of full span to prevent abrupt switching from occurring and causing damage to relays.

Enter the period for 1 cycle (maximum 6550 sec.)

Alarm Mode: PWM: Linear

Channel: [A] Flow: 1

100% Value: 16.00 GPM

0% Value: 8.00 GPM

Cycle Time: 600 sec

EDIT EXIT

33 %

Relay output when process variable reaches 33% of the span specified by

and

0% Value 100% Value

Cycle Time

Relay output when process variable

85 %

reaches 85% of the span specified by

and

0% Value 100% Value

Cycle Time

Figure 21. Linear PWM Relay Timing Example

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ConsoliDator Multi-Channel Controlle

Proportional Plus Integral Pulse Width Modulation Mode

PWM PI Control Mode is used to create an on/off pulse signal with a duty cycle modulated by the proportional integral settings. In this mode the percentage of the relay cycle in which the relay is in the on state varies with relation to the process value feedback and the PI settings.

Set Point

Feedbk Ch

Prop. Gain

Int. Time

Cycle Time

Rly Period

Int. Limit

Inc / Dec

Enter the process target.

Select an analog input to supply the feedback signal from the system.

Enter the proportional gain expressed as a percentage.

Enter the integral time expressed as seconds per repeat.

Enter the PI calculation cycle time (Low number for fastresponding systems, high number for slow-responding systems.)

Enter a relay period.

Specify the integration limit as a percentage (Limits integral influence on the output.)

Select either [Increasing] or [Decreasing].

Instruction Manual

Alarm Setup: 1

Alarm Mode: PWM: PI Control

Feedbk Ch: [A] Flow: 1

Set Point: 12.00 GPM

Prop. Gain: 32.0 %

Int. Time: 0.1 sec / rpt

Cycle Time: 1 sec

Rly Period: 600 sec

Int. Limit: 1.0 %

Inc / Dec: Increasing

EDIT EXIT

Note: Due to the life expectancy of mechanical relays, it is strongly recommended that cycle times be as long as possible (many minutes.) Using a cycle time of less than a few minutes can wear out a relay and cause faulty operation.

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ConsoliDator Multi-Channel Controlle

Instruction Manual

Setting 4-20 mA Outputs

The Analog Output menu is used to configure the 4-20 mA outputs. Each output has a separate screen. All 4-20 mA outputs can be configured using the information provided in this section.

Linear Scaling of 4-20 mA Output

Select [LINEAR] from Mode options to set the analog output for a linear scale from 4 to 20 mA.

Example: If 4 mA Val is set to 10 gal and 20 mA Val is set to 30 gal, when the input reads 10 gal, 4 mA will be transmitted out. When the input reads 20 gal, 12 mA will be transmitted out, and when the input reads 30 gal, 20 mA will be transmitted out.

Input Ch

Assign the output to any 4-20 mA or pulse input. Note that more than one output can be scaled from the same input by simply choosing that channel in another Analog Output.

4 mA Val

20 mA Val

Enter the low process level that will result in a 4 mA signal transmission.

Enter the high process level that will result a 20 mA signal transmission.

PID Control Using 4-20 mA Output

To set the analog output for PID control, select [PID CONTROL] from Mode options.

Analog Output: 1

Mode: LINEAR Input Ch: [1] Analog: 1 4 mA Val: 10 gal 20 mA Val: 30 gal

Analog Output: 1

Mode: PID CONTROL

Set-point: 8.00 mA

Feedbk Ch: [1] Analog: 1

Prop. Gain: 32.0 %

Int. Time: 0.1 sec / rpt

Deri. Time: 0.0 sec

Cycle Time: 1.0 sec

Int. Limit: 1.0 %

Inc / Dec: Increasing

EDIT EXIT

Set Point

Feedbk Ch

Prop. Gain

Int. Time

Deri. Time

Cycle Time

Int. Limit

Inc / Dec

Enter the process target.

Select an analog input to supply the feedback signal from the system.

Enter the proportional gain expressed as a percentage.

Enter the integral time expressed as seconds per repeat.

Enter the derivative time in seconds.

Enter the PID calculation cycle time (Low number for fast-responding systems, high number for slow-responding systems.)

Specify the integration limit as percentage (Limits integral influence on the output.)

Select either [Increasing] or [Decreasing].

EDIT EXIT

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ConsoliDator Multi-Channel Controlle

Instruction Manual

OPERATION

Viewing Screens

The instrument displays various screens with bargraphs, numerical values, and relay status throughout operation. There are two basic modes of operation: Automatic, which allows the controller to function based on it’s programmed settings; and Manual mode, which disables all automatic output functions. The controller initializes in Automatic mode. When manual mode is entered, all outputs are suspended or frozen in their current state so that they can only be changed manually. Although, totalization continues while in Manual mode. The example screens that follow can be viewed in all modes of operation with only subtle differences noticeable including button names and headings.

Relay Status Screen

To the right is an example of a Relay Status screen as it would appear in Automatic mode. The screen displays the current state of the relay, the total time the relay has spent in the ON state and how many times the relay has cycled from OFF to ON. In Manual mode, this screen allows for overriding the relays and resetting the Hours and Cycles counts. This is discussed further in Manual Relay Control (page 45.)

SETUP Press to enter setup menu (Password restricted).

AUTO / MANUAL The AUTO key indicates the unit is in Automatic mode. Press it to

switch to Manual mode. Press NEXT to return to main screen. Once in Manual mode press MANUAL to switch to Automatic mode.

Note: The AUTO / MANUAL modes are password restricted.

ACK Press to acknowledge (reset) the relays assigned to Supervisory,

Summary or Annunciator Alarm functions and to silence the buzzer.

NEXT Press to scroll to the next operation screen.

elay Status:

Hours Cycles elay #1: ON 10.2 320 elay #2: OFF 215.0 566 elay #3: OFF 197.6 512 elay #4: ON 175.2 490 elay #5: OFF 121.7 251 elay #6: OFF 255.1 357 elay #7: ON 11.7 22 elay #8: ON 143.6 30 elay #9: OFF 412.5 197

ACK NEXTSETUP AUTO

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ConsoliDator Multi-Channel Controlle

Instruction Manual

Multiple Channel Operation Screen

Ch1 Ch2 Ch3 Ch4

To the right is an example of a multiple channel operation screen for a four input application. The screen reflects all of the inputs that were detected or enabled during setup. Depending on the actual number of inputs in use, this screen will adjust its size and proportions automatically.

Note: It is recommended not to exceed 8 channels or graphics may overlap.

SETUP AUTO ACK NEXT

SETUP Press to enter setup menu (Password restricted).

AUTO / MANUAL The AUTO key indicates the unit is in Automatic mode. Press it to

switch to Manual mode. Press NEXT to return to main screen. Once in Manual mode press MANUAL to switch to Automatic mode.

Note: The AUTO / MANUAL modes are password restricted.

ACK Press to acknowledge (reset) the relays assigned to Supervisory,

Summary or Annunciator Alarm functions and to silence the buzzer.

NEXT Press to scroll to the next operation screen.

100 ft

Single Analog Input Operation Screen

For each analog input channel, there is a detailed individual channel operation screen, which shows a bargraph with relay set points, numerical values, sensor input, and relay status for the relays assigned to that particular channel.

0 ft

SETUP AUTO ACK NEXTSIM

SETUP Press to enter setup menu (Password restricted).

AUTO / MANUAL The AUTO key indicates the unit is in Automatic mode. Press it to

switch to Manual mode. Press NEXT to return to main screen. Once in Manual mode press MANUAL to switch to Automatic mode.

Note: The AUTO / MANUAL modes are password restricted.

SIM / RST Press to enter a simulation mode where the input can be adjusted

manually. (Password restricted.) If the channel is set for Integration totalizing, the SIM key is replaced by RST, which is used to reset the total to zero (Password restricted.)

ACK Press to acknowledge (reset) the relays assigned to Supervisory,

Summary or Annunciator Alarm functions and to silence the buzzer.

NEXT Press to scroll to the next operation screen.

H2 L2

Ch 1:

12.000

Ch 2:

13.000

Ch 3:

14.000

Ch 4:

15.000

Ch 1:

87.5

Sensor In: 18.00 mA

ly: Low: High: : 40.0 50.0 ON : 8.0 20.0 ON

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ConsoliDator Multi-Channel Controlle

Instruction Manual

Single Flow Meter Pulse Input Operation Screen

For each flow meter pulse input channel, there is a detailed individual channel operation screen, which shows a bargraph with relay set points, numerical values for rate and total, and relay status for the relays assigned to that particular channel. This screen may also be set to show a bargraph for rate rather than total. See Setting Flow

Meter Pulse Inputs (page 30.)

SETUP Press to enter setup menu (Password restricted).

AUTO / MANUAL The AUTO key indicates the unit is in Automatic mode. Press it to

switch to Manual mode. Press NEXT to return to main screen. Once in Manual mode press MANUAL to switch to Automatic mode.

Note: The AUTO / MANUAL modes are password restricted.

RST Use this key to reset the total to zero (Password restricted.)

ACK Use to acknowledge (reset) the relays assigned to Supervisory,

Summary or Annunciator Alarm functions and to silence the buzzer.

NEXT Use this key to scroll to the next operation screen.

500 GAL

H2 L2

0 GAL

SETUP AUTO ACK NEXTRST

Rate: 220.00 GPH

ly: Low: High: : 40.0 50.0 ON

Flow: 1

300.0

GAL

Digital Inputs

Digital Input Operation Screen

The Digital Input screen shows the states of the digital inputs. ON is

Reed SW: 1 ON

Reed SW: 2

shown when a switch connected to the input is closed or when an open

Reed SW: 3

collector transistor is conducting. OFF is shown when the switch is open or when the open collector

Reed SW: 4

transistor is not conducting.

AUTOSETUP

ACK NEXT

SETUP Press to enter setup menu (Password restricted).

AUTO / MANUAL The AUTO key indicates the unit is in Automatic mode. Press it to

switch to Manual mode. Press NEXT to return to main screen. Once in Manual mode press MANUAL to switch to Automatic mode.

Note: The AUTO / MANUAL modes are password restricted.

ACK Use to acknowledge (reset) the relays assigned to Supervisory,

Summary or Annunciator Alarm functions and to silence the buzzer.

NEXT Use this key to scroll to the next operation screen.

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ConsoliDator Multi-Channel Controlle

Instruction Manual

Analog Input Numeric Screen

To the right is an example of an analog numeric summary screen for an eight input application. It shows a box for each channel with the sensor input in mA on the bottom and the scaled engineering units on top. The screen reflects all of the inputs that were detected.

Note: The total is displayed as the engineering value when that channel is set for Integration mode.

SETUP Press to enter setup menu (Password restricted).

AUTO / MANUAL The AUTO key indicates the unit is in Automatic mode. Press it to

switch to Manual mode. Press NEXT to return to main screen. Once in Manual mode press MANUAL to switch to Automatic mode.

Note: The AUTO / MANUAL modes are password restricted.

ACK Press to acknowledge (reset) the relays assigned to Supervisory,

Summary or Annunciator Alarm functions and to silence the buzzer.

NEXT Press to scroll to the next operation screen.

Analog Sensor Inputs:

Tank 1

50.000 ft

16.00 mA

Tank 3

30.000 ft

8.00 mA

Tank 5

50.000 ft

16.00 mA

Tank 7

30.000 ft

8.00 mA

SETUP AUTO A CK NEXT

Tank 2

40.000 ft

12.00 mA

Tank 4

20.000 ft

12.00 mA

ank 6

40.000 ft

12.00 mA

ank 8

20.000 ft

12.00 mA

Flowmeter Inputs:

Flow Meter Numeric Screen

To the right is an example of a flow meter numeric summary screen. It

System 1

100.00 GPM

800.00 GAL

200.00 Hz

Backup 1

0.00 GPM

0.00 GAL

0.00 Hz

shows a box for each flow channel with the input frequency, flow and total.

Note: The total is displayed as the engineering value when that channel is set for Integration mode.

System 2

150.00 GPM

500.00 GAL

300.00 Hz

SETUP AUTO ACK NEXT

Backup 2

0.00 GPM

0.00 GAL

0.00 Hz

SETUP Press to enter setup menu (Password restricted).

AUTO / MANUAL The AUTO key indicates the unit is in Automatic mode. Press it to

switch to Manual mode. Press NEXT to return to main screen. Once in Manual mode press MANUAL to switch to Automatic mode.

Note: The AUTO / MANUAL modes are password restricted.

ACK Press to acknowledge (reset) the relays assigned to Supervisory,

Summary or Annunciator Alarm functions and to silence the buzzer.

NEXT Press to scroll to the next operation screen.

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ConsoliDator Multi-Channel Controlle

Instruction Manual

Manual and Simulation Modes

When manual mode is entered, all outputs are suspended or frozen in their current state until they are changed manually, although totalization continues while in Manual mode.

For example: Relay #1 is programmed to activate a pump based on the level of Channel #1. If the activation level is reached, and the pump is turned on, it will remain active through the transition from Automatic to Manual. In Manual mode, the relay will not respond to changes in the Channel #1 level even if it goes below a programmed reset point. The operator has complete control over each relay’s state and must turn Relay #1 off by doing so in the Manual Relay Control Screen (shown below on this page.)

Accordingly, when transitioning from Manual to Automatic Mode, the controller scans the inputs and updates output status ignoring changes to relay status while in Manual mode. However, if the setup and programming of the controller was modified during Manual mode, these changes take effect the moment the controller re-enters Automatic mode. You may choose to disable outputs while reprogramming by entering Manual mode.

Manual Relay Control

To the right is an example of a Manual Relay Control screen as it appears in Manual mode. The screen displays the current state of the relay, the total time the relay has spent in the ON state and how many times the relay has cycled from OFF to ON. In Manual mode, this screen allows for overriding the relays and resetting the Hours and Cycles counts.

, 

ON / OFF Press to turn selected relay on or off.

RESET Press to reset Hours and Cycles counts for selected relay.

NEXT/EXIT Press to scroll to the next operation screen.

Simulation Mode

To the right is an example of an analog input Simulation screen. Simulation is accessible to each analog input individually.

Simulation mode may be accessed while operating in Automatic mode or Manual mode. When in Automatic mode, all outputs respond to the simulation as programmed for normal operation. During Manual mode, changing the settings has no effect on outputs.

+, -

EXIT Press to exit Simulation mode.

Move cursor up or down one relay.

100 ft

H2 L2

0 ft

+- EXIT

Increase or decrease level.

Ch 1:

87.5

Sensor In: 18.00 mA

ly: Low: High: : 40.0 50.0 ON : 8.0 20.0 ON

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ConsoliDator Multi-Channel Controlle

Instruction Manual

Contrast Adjustment Control

All ConsoliDators are adjusted at the factory for optimal viewing. If additional adjustment is needed, use the contrast adjustment potentiometer located on the left side of the case, next to the DC POWER connector.

Contrast Adjust Control

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ConsoliDator Multi-Channel Controlle

Instruction Manual

MODBUS® SERIAL COMMUNICATION

The controller is equipped with serial communication capability as a standard feature. Baud Rate, Parity, Modbus ID (Address) and Transmit Delay are entered in the General Functions box, which appears in the main setup menu. The baud rate and parity selected must match the settings for all other devices on the network. Modbus ID must be unique so it will not interfere with other devices.

ConsoliDators support the following Modbus control functions:

Command Name Description

03 Read Holding Register Read multiple bytes from holding registers.

05 Write Single Coil Set single coil value control

06 Write Single Register Set single value into specified holding register.

16 Write Multiple Registers Set multiple values into specified holding registers.

Note: To save data to non-volatile memory after changing the contents of holding register(s) use the Write Single Coil command [command code 05] to “ON” at address 64251.

To control the relays via MODBUS you would use the Write Single Coil command [command code 05] and send either the “ON” or “OFF” to the appropriate alarm relay (1-9).

The ConsoliDator can also work as a "MODBUS Display" by setting the desired analog input channel to the "FIXED" type and then over MODBUS change the "K-Factor/Modbus Display" value for the corresponding channel. This input type is transparent to the rest of the functions of the unit (i.e. relays, etc...). The value, once the EEPROM save command is sent to the unit, is also maintained in EEPROM after the next power cycle.

Modbus Register Tables

Table 1. Analog Output Channels Register Addresses

Address (offset from 40000)

Description Data Type Ch. 1 Ch. 2 Ch. 3* Ch. 4*

801 819 802 820 803 821 804 822 805 823 806 824 807 825 808 826 809 827 810 828 811 829 812 830 813 831

814 832

815 833

816 834

817 835 853 871 Input Ch. Byte 818 836 854 872 PID Direction Byte

*Channels 3-4 only apply to ConsoliDator 4 (PD940 & PD941) models.

837 855 838 856 839 857 840 858 841 859 842 860 843 861 844 862 845 863 846 864 847 865 848 866 849 867

850 868

851 869

852 870

4 mA Value Floating Point

20 mA Value Floating Point

Set point Value Floating Point

PID KP Floating Point

PID KI Floating Point

PID KD Floating Point

PID Output Value Floating Point

PID Cycle Time Integer

Output Type Byte

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ConsoliDator Multi-Channel Controlle

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Table 2. Analog Input Channels Register Addresses

Address (offset from 40000)

Description Data Type Ch. 1 Ch. 2 Ch. 3 Ch. 4 Ch. 5* Ch. 6* Ch. 7* Ch. 8*

1 33 65 97 129 161 193 225 2 34 66 98 130 162 194 226 3 35 67 99 131 163 195 227 4 36 68 100 132 164 196 228 5 37 69 101 133 165 197 229 6 38 70 102 134 166 198 230 7 39 71 103 135 167 199 231 8 40 72 104 136 168 200 232

9 41 73 105 137 169 201 233 10 42 74 106 138 170 202 234 11 43 75 107 139 171 203 235 12 44 76 108 140 172 204 236 13 45 77 109 141 173 205 237 14 46 78 110 142 174 206 238 15 47 79 111 143 175 207 239 Decimal Format Byte 16 48 80 112 144 176 208 240 Ch. Online Flag Byte 17 49 81 113 145 177 209 241 Ch. ID Char. 1 Byte 18 50 82 114 146 178 210 242 Ch. ID Char. 2 Byte 19 51 83 115 147 179 211 243 Ch. ID Char. 3 Byte 20 52 84 116 148 180 212 244 Ch. ID Char. 4 Byte 21 53 85 117 149 181 213 245 Ch. ID Char. 5 Byte 22 54 86 118 150 182 214 246 Ch. ID Char. 6 Byte 23 55 87 119 151 183 215 247 Ch. ID Char. 7 Byte 24 56 88 120 152 184 216 248 Ch. ID Char. 8 Byte 25 57 89 121 153 185 217 249 Ch. ID Char. 9 Byte 26 58 90 122 154 186 218 250 Ch. ID Char. 10 Byte 27 59 91 123 155 187 219 251 Units Character 1 Byte 28 60 92 124 156 188 220 252 Units Character 2 Byte

29 61 93 125 157 189 221 253 Units Character 3 Byte

1523 1547 1571 1595 1619 1643 1667 1691 Function Mode** Byte

1901 1911 1921 1931 1941 1951 1961 1971

1902 1912 1922 1932 1942 1952 1962 1972

1903 1913 1923 1933 1943 1953 1963 1973

1904 1914 1924 1934 1944 1954 1964 1974

1905 1915 1925 1935 1945 1955 1965 1975

1906 1916 1926 1936 1946 1956 1966 1976

1907 1917 1927 1937 1947 1957 1967 1977

1908 1918 1928 1938 1948 1958 1968 1978

1909 1919 1929 1939 1949 1959 1969 1979

1910 1920 1930 1940 1950 1960 1970 1980

*Channels 5-8 only apply to ConsoliDator 8 (PD980 & PD981) models.

Engineering Value Floating Point

Max. Graph Value Floating Point

Min. Graph Value Floating Point

High Value Floating Point

High Value mA Floating Point

Low Value Floating Point

Low Value mA Floating Point

K-Factor / Modbus Display

Offset Floating Point

Conversion #1 Floating Point

Conversion #2 Floating Point

Channel Linking Byte

Function Channel Byte

Floating Point

**Function Mode Byte Values: Byte = 0: Linear Byte = 16: Square Root Byte = 32: Difference Byte = 48: Summation Byte = 64: Exponent Byte = 80: Multi-Point Byte = 96: Fixed/Modbus Display Byte = 112: Integration – Sec Byte =128: Integration – Min Byte = 144: Integration – Hour Byte =160: Integration – Day

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Table 3. Flow Meter Pulse Input Channels Register Addresses

Address (offset from 40000)

Description Data Type Ch. 1 Ch. 2 Ch. 3 Ch. 4

261 291 321 351 262 292 322 352 263 293 323 353 264 294 324 354 265 295 325 355 266 296 326 356 267 297 327 357 268 298 328 358 269 299 329 359 270 300 330 360 271 301 331 361 Rate Decimal Format Byte

272 302 332 362

273 303 333 363 Ch. Online Flag Byte 274 304 334 364 Display Format (Rate or Total) Byte 275 305 335 365 Ch. ID Character 1 Byte 276 306 336 366 Ch. ID Character 2 Byte 277 307 337 367 Ch. ID Character 3 Byte 278 308 338 368 Ch. ID Character 4 Byte 279 309 339 369 Ch. ID Character 5 Byte 280 310 340 370 Ch. ID Character 6 Byte 281 311 341 371 Ch. ID Character 7 Byte 282 312 342 372 Ch. ID Character 8 Byte 283 313 343 373 Ch. ID Character 9 Byte 284 314 344 374 Ch. ID Character 10 Byte 285 315 345 375 Rate Units Character 1 Byte 286 316 346 376 Rate Units Character 2 Byte 287 317 347 377 Rate Units Character 3 Byte 288 318 348 378 Total Units Character 1 Byte 289 319 349 379 Total Units Character 2 Byte

290 320 350 380 Total Units Character 3 Byte

Table 4. Digital Input Channels Register Addresses

Address (offset from 40000)

401 413 425 437 Digital State Byte 402 414 426 438 Inversion State Byte 403 415 427 439 Ch. ID Character 1 Byte 404 416 428 440 Ch. ID Character 2 Byte 405 417 429 441 Ch. ID Character 3 Byte 406 418 430 442 Ch. ID Character 4 Byte 407 419 431 443 Ch. ID Character 5 Byte 408 420 432 444 Ch. ID Character 6 Byte 409 421 433 445 Ch. ID Character 7 Byte 410 422 434 446 Ch. ID Character 8 Byte 411 423 435 447 Ch. ID Character 9 Byte

412 424 436 448 Ch. ID Character 10 Byte

Flow Meter Rate Floating Point

Flow Meter Total Floating Point

K Factor Floating Point

Maximum Graph Value Floating Point

Flow Meter Previous Total Floating Point

Total Decimal Format – Upper 4 bits K Factor Decimal Format – Lower 4 bits

Description Data Type Ch. 1 Ch. 2 Ch. 3 Ch. 4

Byte

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Table 5. Relay Channels Register Addresses

Address (offset from 40000)

Description Data Type Rly. 1 Rly. 2 Rly. 3 Rly. 4 Rly. 5 Rly. 6 Rly. 7 Rly. 8 Rly. 9

461 493 525 557 589 621 653 685 717 462 494 526 558 590 622 654 686 718 463 495 527 559 591 623 655 687 719 464 496 528 560 592 624 656 688 720 465 497 529 561 593 625 657 689 721 466 498 530 562 594 626 658 690 722 467 499 531 563 595 627 659 691 723 468 500 532 564 596 628 660 692 724 469 501 533 565 597 629 661 693 725 470 502 534 566 598 630 662 694 726 471 503 535 567 599 631 663 695 727 472 504 536 568 600 632 664 696 728 473 505 537 569 601 633 665 697 729 Delay On Time Byte 474 506 538 570 602 634 666 698 730 Delay Off Time Byte 475 507 539 571 603 635 667 699 731 Pulse On Time Byte 476 508 540 572 604 636 668 700 732 Pulse Off Time Byte 477 509 541 573 605 637 669 701 733 After Flow Time Byte 478 510 542 574 606 638 670 702 734 Alarm Type Byte 479 511 543 575 607 639 671 703 735 Alarm Ch. Byte 480 512 544 576 608 640 672 704 736 Alarm Sec. Ch. Byte 481 513 545 577 609 641 673 705 737 Alarm Dig. Ch. Byte 482 514 546 578 610 642 674 706 738 Alarm ON/OFF Flag Byte 483 515 547 579 611 643 675 707 739 Relay State Flag Byte 484 516 548 580 612 644 676 708 740 Relay Assign Flag Byte 485 517 549 581 613 645 677 709 741 486 518 550 582 614 646 678 710 742 487 519 551 583 615 647 679 711 743 488 520 552 584 616 648 680 712 744 489 521 553 585 617 649 681 713 745 Alarm PID KP Setting Integer 490 522 554 586 618 650 682 714 746 Alarm PID KI Setting Integer 491 523 555 587 619 651 683 715 747 Alarm PID I Band Integer

492 524 556 588 620 652 684 716 748 Alarm PID Direction Byte

1351 1361 1371 1381 1391 1401 1411 1421 1431

1352 1362 1372 1382 1392 1402 1412 1422 1432

1353 1363 1373 1383 1393 1403 1413 1423 1433

1354 1364 1374 1384 1394 1404 1414 1424 1434

1355 1365 1375 1385 1395 1405 1415 1425 1435

1356 1366 1376 1386 1396 1406 1416 1426 1436

1357 1367 1377 1387 1397 1407 1417 1427 1437

1358 1368 1378 1388 1398 1408 1418 1428 1438

1359 1369 1379 1389 1399 1409 1419 1429 1439

*Override Mode Byte Values: *Override Mode Programming: Byte Value = 0: OFF (No overrides) Override Value #1 is the Set Point for Override. Byte Value = 1: Input > SP with High Alarm Override Value #2 is the High Value Alarm Set Point. Byte Value = 2: Input > SP with Low Alarm Override Value #3 is the Low Value Alarm Set Point. Byte Value = 3: Input > SP with Alarm OFF Override Value #4 is N/A. Byte Value = 4: Input < SP with High Alarm Byte Value = 5: Input < SP with Low Alarm Byte Value = 6: Input < SP with Alarm OFF

Alarm High Set point Floating Pt.

Alarm Low Set Point Floating Pt.

Alarm K Factor Floating Pt.

Alarm Diff-Pressure Floating Pt.

Relay ON Time Floating Pt.

Relay Cycles Floating Pt.

Alarm PWM Output Floating Pt.

Alarm PID Set Pt. Floating Pt.

Override Value #1* Floating Pt.

Override Value #2* Floating Pt.

Override Value #3* Floating Pt.

Override Value #4* Floating Pt.

Override Mode* Byte

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Table 6. Analog Inputs, Flow meter, and Relay State Summary

Address

(offset from 40000) Description Data Type

751 752 753 754 755 756 757 758 759 760 761 762 763 764 765 766

769 770 771 772 773 774 775 776 777 778 779 780 781 782 783 784 785 Alarm State #1 Byte 786 Alarm State #2 Byte 787 Alarm State #3 Byte 788 Alarm State #4 Byte 789 Alarm State #5 Byte 790 Alarm State #6 Byte 791 Alarm State #7 Byte 792 Alarm State #8 Byte

793 Alarm State #9 Byte

nalog Channel #1 Engineering Value

(Rate value during integration mode.)

nalog Channel #2 Engineering Value

(Rate value during integration mode.)

nalog Channel #3 Engineering Value

(Rate value during integration mode.)

nalog Channel #4 Engineering Value

(Rate value during integration mode.)

nalog Channel #5 Engineering Value

(Rate value during integration mode.)

nalog Channel #6 Engineering Value

(Rate value during integration mode.)

nalog Channel #7 Engineering Value

(Rate value during integration mode.)

nalog Channel #8 Engineering Value

(Rate value during integration mode.)

Flow Meter Rate #1 Floating Point

Flow Meter Total #1 Floating Point

Flow Meter Rate #2 Floating Point

Flow Meter Total #2 Floating Point

Flow Meter Rate #3 Floating Point

Flow Meter Total #3 Floating Point

Flow Meter Rate #4 Floating Point

Flow Meter Total #4 Floating Point

Floating Point

This register group is designed for convenient access to status readings.

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ConsoliDator Multi-Channel Controlle

Instruction Manual

CONSOLIDATOR MONITOR SOFTWARE

Each ConsoliDator is shipped with PC software on CD-ROM, which supports monitoring, data logging and controller setup/programming. You may also download this software from the web at www.predig.com. There are separate versions of the software for 4-channel and 8-channel models.

Connecting to PC

Many computers are equipped with at least one 9-pin serial port compatible with RS-232. For distances up to approximately 50 ft, a null-modem cable is adequate. The null modem cable looks similar to a standard serial cable, except both ends are female, and the transmit and receive lines in the cable cross-over unlike a standard serial cable. Reference

Serial Communication Connections (page 19) for more information.

Installing Software

Load the ConsoliDator Software CD-ROM into your CD-ROM drive. If the installation does not load automatically within a few moments, click on the Start button on the Windows® taskbar, then click RUN. Type x:\ ConsoliDator_ Monitoring_System.exe (where x is your actual CD-ROM drive letter) and press enter. Follow on-screen instructions.

Using ConsoliDator Monitor Software

Launch the program from the Start menu or desktop shortcut. Make sure you are using the correct version of the software for the number of channels your model has – 4 or 8. Verify the controller is powered up and properly connected before proceeding.

From the drop-down menu in the bottom left of the screen, select the Modbus ID that matches the same setting in the controller. Default is Modbus ID: 1. Click the Connect button in the lower left of the screen and allow a moment for the software to read data in.

Window tabs above the bargraphs navigate the various channel displays available. The screen in the top right is active when the View All Channels tab is selected. It shows all Analog Input bargraphs and numeric values along with Relay and Digital Input status. This information represents real time data sent from the controller.

Selecting a tab for a specific channel brings a chart of the style shown in the bottom right. The charts show a graphical history for each Analog Input channel along with its real time bargraph and numeric value. There is also a tab for the flow meter pulse input channels, which shows numeric total and numeric and bargraph rate for all flow channels.

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Instruction Manual

Data Logging

The software supports logging input readings to a comma separated value file (*.csv) compatible with spreadsheet applications. Log settings appear in the lower left of the screen. First, specify a time interval from the Log Rate options. Note that small intervals will result in a large file size. If logging for long periods such as days or weeks at a time, it is suggested that intervals be in the minute or greater range. Next, supply a name in Log File Name box and click Browse to specify a location to save the file. Lastly, select the Log checkbox. To view the data, launch your spreadsheet application and open or import the file. Some spreadsheet applications such as Microsoft tool that will create presentable graphs and trend lines of your data.

Programming Through Software

The software supports programming of most functions available to the controller. Not included are some of the General Functions which must be setup on the device itself through the front buttons. This section is limited to serving as an overview of programming through software, because the parameters in the software menus correspond to the parameters on the controller’s setup screens. You will need to follow the Setup and Programming section (page 21) to understand these parameters. Settings programmed through software will automatically be updated to the controller and be visible and accessible in the setup menus of the device.

To begin setup, select System Settings from the menu bar at the top of the screen. You will see the window shown to the right. From the drop-down menus in this window you can access settings for all inputs, alarms, and outputs.

When functions have been configured and loaded to the controller, you can choose to store the settings (configuration) file to your computer using the Export Settings button. The file may be used later to restore the configuration or to create a cloned copy ConsoliDator of the same model type. You may even take advantage of this to create multiple configurations modes and load them as necessary. To write the settings file to a ConsoliDator, simply click Import Settings and select the (*.set) file you would like to import to the controller’s non-volatile system memory.

Excel have a chart wizard or other

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ConsoliDator Multi-Channel Controlle

OVERALL DIMENSIONS

3.0" (76mm)

Instruction Manual

8.75" (222mm)

8.66" (220mm)

3.10" (79mm)

8.0" (203mm)

Figure 22. PD980 & PD940 Overall Dimensions

9.36" (238mm)

7.86" (200mm)

Figure 23. PD981 & PD941 Overall Dimensions

7.16" (182mm)

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ConsoliDator Multi-Channel Controlle

TROUBLESHOOTING TIPS

Symptom Check/Action

1. Contrast is too light: Adjust contrast in main setup menu.

2. Ambient temperature is below 0°C and affects

No display, or only backlight is visible, but outputs still function normally.

Periodic hard resets (power cycling) or Supervisory alarms.

“NO SENSORS FOUND” is displayed, but sensors are connected and transmitting.

Display response seems slower than normal

Display locks up or the instrument does not respond at all

Settings reprogrammed, but instrument behavior remains as previously programmed

Relay and status do not respond to signal

Controller will not communicate serially with other device.

Other symptoms not described above

LCD visibility: Adjust contrast to compensate.

3. High levels of radiated interference are present. Steps must be taken to shield controller from interference or to reduce interference present. Inductive loads are a possible source of interference. Reference Switching Inductive Loads (page 18.)

4. Grounding is inadequate or not connected. Check earth ground continuity.

1. High levels of radiated interference are present. Steps must be taken to shield controller from interference or to reduce interference present. Inductive loads are a possible source of interference. Reference Switching Inductive Loads (page 18.)

2. Grounding is inadequate or not connected. Check earth ground continuity.

Allow controller to warm-up for 10 or more minutes. If sensors still not detected, cycle the power to reboot.

Ambient temperature is too cold: Consider installing a heater with the instrument.

Cycle the power to reboot the microprocessor.

1. Meter must be in Automatic mode in order for relays to respond to signal. To enter this mode press the Manual key and follow the on-screen prompt.

2. Check Setup menu relay set and reset points.

Check baud rates and parity settings. Make sure all serial devices have agreeing parameters.

Call Technical Support for assistance.

Instruction Manual

Model:

Serial Number:

Password:

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ConsoliDator Multi-Channel Controlle

Instruction Manual

How to Contact Precision Digital

 For Technical Support please

Call: (800) 610-5239 or (508) 655-7300

Fax: (508) 655-8990

E-mail: [email protected]

 For Sales Support

Call: (800) 343-1001 or (508) 655-7300

Fax: (508) 655-8990

E-mail: [email protected]

 For the latest version of this Manual please visit:

www.predig.com

LIM980_F

v3.1.1 & Up

05/12