PD9000 Installed in NEMA 4 Steel Enclosure

PD9000 Shown with Enclosure, Light/Horn, and Sun Hood Accessories

Overview

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

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

Auto-Tune PID Control
Digital Switches (HOA)

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

All this functionality is easily programmed using the free software or via the front panel pushbuttons. Choose the model that best suits your application, from monitoring only to fully loaded controllers with an extensive combination of inputs, outputs, and communication protocols. The standard product offering is listed in the ordering guide and other models are available for special order. The Modbus Client, Snooper, & Spoofer and USB Data Logger Add-On features expand the functionality of the ConsoliDator+.

The ConsoliDator+ has been Certified by Underwriters Laboratory (UL & C-UL) for use in ordinary locations (electrical safety) and in Div 2 hazardous area locations (nonincendive).

Features

NEMA 4X Panel Mount Multivariable Controller
Convenient Display, Control, & Alarm of Multiple 4-20 mA, Pulse, & Modbus Inputs
Numeric & Bargraph Color Display (320 x 240 pixels) 5.7" (145 mm)
Sunlight Readable Display, White Backlight
Isolated 24 VDC Transmitter Supplies 200 mA / Analog Input: 1,600 mA Max
99 Channels, 32 Totalizers, 30 Timers, & 199 Modbus Inputs
64 High & Low Alarms, Combine Multiple Alarms Into Logic AND & OR Alarms
Simulation & Manual Control Modes for Testing and Setup
Modular Design for Inputs & Outputs Flexibility
Up to (28) 4-20 mA Isolated Inputs or Pulse Inputs
Up to (25) 10 Amp Form C Relays (With Eight Analog or Pulse Inputs)
Up to (25) Isolated 4-20 mA Outputs (With Eight Analog or Pulse Inputs)
Operating Temperature Range: -25°C to 55°C (-13 to 131°F)
Pulse, Analog, & Modbus Input Flow Rate / Total / Grand Total Capability
50-Point Linearization, Square Root, and Exponent for Open Channel Flow
Round Horizontal Tank Volume Calculation; Just Enter Diameter & Length
Open Channel Flow Math Formulas for Weirs & Flumes
Multi-Pump Alternation Control or On / Off Control with Random Varying Set Point
Programmable Displays, Function Keys & Digital Inputs
Math Functions: Sum, Diff, Average, Multiply, Divide, % Efficiency, & More
Modbus Client (Master) & Snooper / Server with 99 Programmable Outputs
Direct Modbus PV Inputs – Snooper / Server Mode
Modbus Spoofer Feature to Replace Servers Removed from Network
RS-485 Serial Communication with Modbus RTU / ASCII & Ethernet TCP/IP
USB Data Logger Feature: Up to 8 Log Files with up to 12 Parameters Each
Input Power Options: 90-264 VAC or 24 VDC
(20) Screens with up to Eight PVs Each
ConsoliDator+ Configuration Software
Type 4X, IP66 Front – Field Enclosures Available
Auto-Tune PID Control for Multiple Control Loops
PID Control with Analog, Digital, or Relay Outputs
Digital Selector Switch (HOA) Function to Route Inputs & Outputs
3-Year Warranty

Screens

The ConsoliDator+ can be programmed to display the data on up to 20 different screens in a variety of formats and colors, with and without bargraphs. The following screens show a typical main screen and channel details screen:

Main Screen

Channel Details Screen

Screen with Feet & Inches Units

Inputs & Outputs

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

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

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

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

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

Notes:

Each 4-20 mA input has its own isolated 24 VDC power supply to power the transmitter.
Each 4-20 mA output has its own isolated 24 VDC power supply to power the output loop.
Each relay is Form C and rated at 10 A.
Input / output connections are made to removable screw connectors.
Every ConsoliDator+ has five digital inputs (additional digital inputs can be obtained by using the Pulse Inputs).
Every ConsoliDator+ has four digital outputs.
Every ConsoliDator+ has RS-485 with Modbus.
All ConsoliDator+ models can be powered from either AC or DC Power.
The Data Log Drive is used for the Data Logger Add-On feature.
Ethernet with Modbus TCP is an option.
Micro USB is used for programming the ConsoliDator+ with Free Software.

Use copper wire with 60°C or 60/75°C insulation for all line voltage connections. Observe all safety regulations. Electrical wiring should be performed in accordance with all applicable national, state, and local codes to prevent damage to the controller and ensure personnel safety.

Setting Channel Parameters

What makes the ConsoliDator+ easy to program is its intuitive setup screens. As shown in the first image below, the setup screen allows you to see all the relevant information you need when creating or editing a channel - all on one screen! When creating a new channel, the channel number is auto-generated for you. All you have to do is populate the appropriate fields such as the channel tag name, function, input, and units.

Scaling the inputs and outputs, selecting number of decimals, and turning the bargraph on/off and inputing its values are also programmed from this screen. Multiple colors can also be selected for the text, background and bargraphs to customize the look of the display screens.

During programming, the soft keys will change based on the screen in place. For instance, pressing the edit key will bring up the letters/numbers keypad and appropriate navigation keys will appear (Shown in the bottom image). See the PD9000 manual for details on setup and programming.

Individual Channel View

To view the details of any channel, press Menu and then press View – Channel. Select the channel of interest. Navigate through the different items using the navigation keys. A green bar indicates the selected item, press the R-key to step into and see more details about the inputs and outputs related to the channel in view.

In the following examples, the screens show all the parameters associated with Channel 1 including analog input, slot number and its current value, setpoints and status of alarms, and analog output and its mA value. The bargraphs in each of these screens examples represent the current value in gallon units.

Alarm set points are indicated
by horizontal lines.

Low & High Alarm Indication

If applicable, alarms may be acknowledged, and totals may be reset from the channel view screens. The alarm set points are indicated by a line at the corresponding value on the bargraph. Color selection for alarm conditions can be done in the Setup – Alarm menu or in the System – Display menu.

Active Low Alarm: Indicated by horizontal and vertical lines. The top of the vertical line is the reset point of the low alarm. The low alarm is indicated on the right side of the bargraph.

Active High Alarm: Indicated by horizontal and vertical lines. The bottom of the vertical line is the reset point of the high alarm. The high alarm is indicated on the left side of the bargraph.

HOA Screen View

The image on the right shows the screen displaying Tank level in gallons, Alert! message indicating the pump has been turned off manually, HOA switch is the Off position, Pump 1 relay shows the runtime and number of cycles.

The HOA switch can be switched to automatic control by pressing the F4 key (AUTO).

Block Diagram for HOA Switch

Modbus Client, Snooper & Spoofer Add-On Features

The ConsoliDator+ Multivariable Controller supports Modbus RTU, Modbus ASCII, Enron Modbus, and Ethernet Modbus TCP/IP. The Server mode is a standard ConsoliDator+ feature; it responds to requests and accepts writes from a Modbus client.

The ConsoliDator+ is now available with Modbus Client, Snooper, and Spoofer capabilities and has the ability to scan and display up to 199 Modbus registers. This feature can be “unlocked” on any ConsoliDator+ purchased after February 15, 2021 by purchasing the PDK9000-M1 Key for $500 and entering the Key value into the ConsoliDator+.

ConsoliDator+ Modbus Client, Snooper, and Spoofer

Client Mode

The Client mode can request process variables from server devices; the input variables can be scaled, combined with other variables using math functions, and they can be written to other server devices using the Modbus output functions. The controller can request up to 199 Modbus values, as inputs from other Modbus devices. The inputs can be used as the source for channels, math functions, alarms, relay control, etc.

Modbus inputs setup screen for Client mode

Snooper Mode

The Snooper mode can listen and read the process variables being transmitted on the RS-485 bus without causing any disruptions to the network. The controller can read up to 199 Modbus values, as inputs from other Modbus devices being polled by a Modbus Client. The inputs can be used as the source for channels, math functions, alarms, relay control, etc.

Modbus inputs setup screen for Snooper mode

Spoofer Mode

The Spoofer mode is designed to replace existing Modbus Servers without requiring changes to the Client configuration. Each process value can be assigned a specific Device ID and Register Number to mimic the original Client configurations.

Modbus Output setup screen for Spoofer mode

ConsoliDator+ USB Data Logger Add-On Feature

The PDK9000-D1 Data Logger Add-On Feature for the PD9000 ConsoliDator+ allows you to log data to an external USB flash drive and create logs that contain the same type of process data or a mix of just about anything you might want to log. Each log can contain up to 12 process variables, inputs, outputs, timers, alarm status, relay status or a combination of parameters such as mA inputs, digital inputs, Modbus inputs, channels, totals, timers, and more. The data logger can be controlled in many ways; the start/stop, enable switch, log trigger, or log interval. See the PD9000 instruction manual for more details.

The PDK9000-D1 Data Logger Add-On feature that is ordered with the ConsoliDator+ will be activated at the factory. This Add-On feature can be ordered for existing ConsoliDator+ units with a firmware version 2.2 or greater, at any time. The user will receive a key they can enter into the ConsoliDator+ to unlock the Add-On feature.

Setup Data Log

The Setup Data Logs menu is used to configure settings that are used for logging data to an external USB flash drive. Any data parameter can be logged; up to 8 data logs can be created. Each data log can contain from 1 to 12 parameters.

Setup New Data Log

The setup of the data logs is easy, intuitive, and flexible. You can create logs that contain the same type of process data or you can have a mixed of just about anything you might want to log.

Navigate to the Data Logs menu
Press the New key (F4) to create a new log
An untitled log is created

Log #:	Enter log file name
Add:	Add items to be logged
Start / Stop:	Control the log start & stop
Enable Switch:	Select an additional log control
Log Trigger:	Trigger log on a specific event
Log Interval:	Log at the specified interval
Log with Units:	Each log entry will have the corresponding engineering units

Do not change the units for totals, while the data logger is running; the accumulated total will not be converted to the new units and the reflected value will not be accurate.

Add Items to Be Logged

Each log can contain up to 12 process variables, inputs, outputs, timers, alarm status, relay status, or a combination of any of the following parameters:

1. mA Inputs
2. Digital Inputs
3. Modbus Inputs
4. Channels
5. Totals
6. Timers

7. Alarms
8. mA Outputs
9. Relay Outputs
10. Digital Outputs
11. Modbus Outputs

Setup Log Start / Stop

The log Start / Stop is used to give the system or the operator control to start and stop the log process.

The Start / Stop function is available in the View Log menu via the function keys.

The Start / Stop function can be activated with:

Screen F1-F4 function keys
Digital inputs
Modbus inputs
Modbus outputs
Channel Control: Schedule, Sampler

Setup Log Enable Switch

The log Enable Switch can be any item with a binary value (on / off, 0 / 1, true / false). Log entries will be made only if the Enable Switch is in the on position.

The Enable Switch input can be:

Digital input
Modbus input
Channel
Alarm
Relay Output

Setup Log Trigger

The Log Trigger can be any event from the list below. Log entries will be made every time the input is activated.

The Log Trigger input can be:

Digital input
Modbus input
Channel
Alarm
Relay Output

The Modbus outputs can be used to trigger log entries.

Setup Log Interval & Log Units

The Log Interval can be from 1 sec to 99:59:59 hh:mm:ss. Log entries will be made at the selected interval.

In this example the log must be started, and the digital input 1 must be on to log the tanks volume every minute.

To log continuously without the need to start or enable the log, deselect the Start / Stop and the Enable Switch settings.

If engineering units are not needed, deselect the Log with Units setting.

If Start / Stop is enabled, the log will stop on a power cycle. Make sure to monitor if the power is turned off and re-start the log when the power is turned on.

Setup USB Drive

The System – USB Drive provides status information about the connected flash drive.

USB Drive Status
Capacity
Used Space
Free Space

Stop when Full: This should be selected, if the oldest logged data is more important than logging new data.

If Stop when Full is not selected, the oldest block of data will be deleted to make room for new data.

The USB Drive menu is available only through the front panel.

Safely Remove Flash Drive

To safely remove the flash drive:

Go to the System – USB Drive screen, navigate to the Remove Device button using the down arrow key, then press the Remove key.

This procedure allows the USB drive to finish writing any log data in progress and prevent the lost or corruption of data.

View Data Logs

In the View Data Logs menu you can see a list of the active data logs. Press the right arrow key to go to the log list and to see details of any of the logs.

The screen shows a snapshot of the log in progress. If the log is not running, the screen will only show the log # and name. Press Start Log followed by Log Entry to capture the first log.

Press the Stop Log key to stop logging the selected log. The Start / Stop function can be enabled or disabled during the log setup. This function is independent for each log.

After the log is started, the system will capture the first log according to the log setup selected.

The Log Entry key allows the user to capture a snapshot of the process any time.

Important

There is no provision for viewing previous log records on the screen. The flash drive must be removed and connected to a computer to download the saved logs.

Except where noted all specifications apply to operation at +25°C.

General

Display	Color; QVGA (320 x 240 pixels), 5.7" (145 mm) diagonally, white backlight Bargraph: Twenty divisions Numerical: Up to 15 digits (±999,999,999,999,999) Feet & Inches Format: 99,999' 11.9"
Screen Bargraph	Enable/disable: Channels, totals, timers Bargraph scale: 0 – 100%, independent of channel scale. Twenty divisions: 5% each. Screen: Select to show bargraph or not.
Color Selection	65 colors selection Customize bargraph, panel background, and text for normal and alarm conditions.
Decimal Point	0 to 15 decimal places, user selectable
Engineering Units	User selectable units or custom units Time, Distance, Volume, Pressure, Weight, Temperature, Current, Voltage, Percent, Amps, Volts, Counts, Logic, and Custom, Any unit/unit of time or other units.
Feet & Inches Units	Data entry format: Decimal (e.g. 50.58 feet) Display format: 50' 6.96"
Units Conversion	Units’ conversion is supported for channels, totals, timers, and any function using those parameters. Channel scaling must be in the intended base units (e.g. Gallons/min)
Boot-Up Time	Less than 10 seconds All inputs and outputs
Display Update Rate	User selectable: 0.1 to 0.5 sec (10 updates/sec to 2 updates/sec)
Programming Method	Front panel buttons, external buttons, or ConsoliDator+ Software
Number of Alarms	Up to 64 high or low, Logic AND & OR Automatic (non-latching) or latching On & Off time delays Can be assigned to one or more relays. Note: Alarms are independent from relays.
Alarm Types	Single Source: One input Multi-Source: Two or more inputs Interval: Enter time interval and On Time Day & Time: Select day of the week & time Alarm OR: Any active input alarm triggers the OR alarm Alarm AND: All alarms must be active to trigger the AND alarm
Alarm Ack & Reset	Automatic only (Non-latching) Automatic and manual Manual only (Latching) Manual with Ack only after alarm is cleared (Latching with Clear)
Alarm Indication	Bargraph, panel, and text can be set up to change color on alarm Enable internal buzzer Assign external relay to drive a horn
Internal Buzzer	60 dBA @ 24 inches (61 cm) Enable/disable in System – General menu Associated with alarm Horn setting
External Horn (Sold Separately)	Assign any relay to the Horn function to activate an external horn when alarm condition is detected.
Live Channel Calibration	Live calibration of channels is independent of the input calibration used for scaling.
Input & Output Cards	Max Number of I/O Cards: 7 Analog Inputs: 4/card Pulse Inputs: 4/card Analog Outputs: 5/card Relays: 5/card
Number of Screens	Up to 20 screens with 1 to 8 PVs or items per screen Enable or disable screen title, channel #, and bargraph Automatic or manual scanning Scan time: 1 to >1000 sec, independent for each screen F1-F4 keys are assigned per screen
Function Keys	User programmable (See defaults below) F1 = Previous 🡠 F2 = Next 🡢 F3 = Scan/Stop F4 = Ack
Number of Channels	Up to 99 channels Input Source: 4-20 mA, Pulse, Digital, Modbus, another Channel, Total, Timer, Alarm, Date & Time, mA Output, Relay Output, Digital Output, or Modbus Output
Channel Functions	There is an extensive number of functions that can be applied to the inputs, see Channel & Math Functions in the instruction manual.
Number of PID Control Channels	Up to (8) PID control loops can be set up with (8) analog inputs and (8) analog outputs. Note: (2) analog input cards and (2) analog output cards are used. The (3) remaining slots can be used for relays.
Programmable Switches	Up to (32) programmable digital switches can be used to route any input, output, or process variable.
Password	Programmable password restricts modification of programmed settings. View and Setup menus are password protected, function keys and digital inputs are not protected.
Simulation Mode	Inputs, channels, totals, timers, and alarms can be simulated from the View menu or from a function key. Simulation mode is not saved on power down. Alert! message is provided for simulated items.
Manual Control	Analog outputs and relays can be controlled manually from the View menu or from a function key. Manual control mode is not saved on power down. Alert! message is provided for outputs in manual control. Note: If it is necessary to turn relays off and maintain the condition through power cycle, configure the relays to Always Off.
Non-Volatile Memory	Settings stored for a minimum of 10 years
AC Powered Models (-6)	Three-terminal connector (L, N, GND) 90-264 VAC, 47 to 63 Hz, 60 W max
DC Powered Models (-7)	Two-terminal connector (G, 24V) 24 VDC ±10%, 60 W max Means of Protection: Class 2 (Reinforced) Overvoltage Category: Class II
Fuse	Units are protected internally with auto-resettable fuse AC: 1.25 A max DC: 3.7 A max
External Fuse	Recommended external fuse slow-blow 120 VAC: 2.0 A 240 VAC: 1.0 A 24 VDC: 4 A
Isolation & Grounding	1500 V Analog inputs/outputs-to-power line
	500 V Analog input-to-input, input-to-output, analog output-to-output
	All analog inputs and analog outputs are isolated from each other.
Environmental	Operating temperature range: -25 to 55°C (-13 to 131°F)* Storage temperature range: -40 to 60°C (-40 to 140°F) Relative humidity: 0 to 90% non-condensing
Front Sealing	Type 4X, IP66
Pollution Degree	2
Maximum Altitude	2000 m (6,562 feet)
Internal Fan	Automatic temperature-controlled fan turns on if the inside temperature reaches 50°C and increases the speed as the temperature rises to 60°C.
Internal Heater	Automatic temperature-controlled heater located behind the LCD turns on at 0°C, delivering the minimum power. If the temperature drops below -10°C, the heater delivers its maximum power.
Connections	Removable screw terminal blocks Inputs/Outputs: 12 to 24 AWG wire Digital I/O: 16 to 30 AWG RS-485: 12 to 24 AWG wire RJ45 Ethernet connection USB ports: Micro-USB used for programming; cable included. Data Log Drive: Type A, used with Data Logger Add-On feature.
Tightening Torque	Screw terminal connectors: Analog I/O & Relays: 0.5 Nm (4.5 lb-in) Digital I/O terminals: 0.23 Nm (2 lb-in)
Enclosure	Enclosure Body: Thermoplastic Polyester Color: Gray Display Window: Clear Polycarbonate, GE LEXAN HP12W Front Panel Keys: Silicone rubber
Mounting	Panel-mounting frame and twelve screws (provided) Cutout: 10.0" x 10.0" ±0.05" (254 mm x 254 mm ±1.3 mm) (H x W) Panel thickness: 0.07" – 0.35" (1.8 mm – 8.9 mm) Clearance behind panel: 6" (152 mm)
Overall Dimensions	10.85" x 10.85" x 4.87" (276 mm x 276 mm x 124 mm) (H x W x D)
Weight	Ex: PD9000-XY-4PI-8AI-10AO-10RY 7.4 lb (3.4 kg) approx.
Field Enclosure	This device is an open-type controller and is required to be installed in a suitable enclosure that can only be accessed with the use of a tool or key. Panel mounting fasteners shall be tightened to a torque value of 0.8 Nm (7 lb-in).
Warranty	3 years parts and labor. See Warranty Information and Terms & Conditions on www.predig.com for complete details.

Totalizer

Number of Totalizers	Up to 32 totalizers 15 digits with comma separator
Totalizer Inputs	Calculates total based on selected rate channel, pulse input, digital input, or triggered event for non-rate channels. Total is stored in non-volatile memory if power is lost.
Maximum Total	18 digits 999,999,999,999,999,999
Rate Channel Input	4-20 mA input, Pulse input, Modbus input
Rate & Total Decimal Point	Independent and user selectable from 0 to 15 places
Totalizer Reset	Via front panel keys or digital inputs
Non-Resettable Total	Total can be set up to be non-resettable to prevent unintentional reset. This can be changed in the Setup Totals menu.
Total Units Conversion	Input: Rate channel Total units can be different than rate units. Use the custom units to convert to any unit (e.g. Gallons to Billion gallons BGAL: Factor = 0.000000001)
Pulse Input K-Factor	K-Factor = pulses/units of measure Calculates total directly from pulse input, Modbus input, channel, total, or Modbus output. Create rate channel by entering K-Factor, units and time base in sec, min, hr, or day. Decimals: 0 to 15
Count Down	Total can set up to count down from a predetermined value entered by the user.
Preset Value	Enter the preset value to count up or down. Reset total sets total to the preset value; to reset to zero uncheck the Preset box.
Roll-Over	Enter the value for total to roll-over to 0 Example: Roll-Over = 1,000,000 Total goes to 0 after 1 million
Negative Total	Allow total value to count below 0 for bi directional flow based on rate channel
Total Bargraph	Bargraph can be scaled to represent the expected maximum total
Function Keys	Screen Setup: Assign F1-F4 to Reset Total, Enter Total, Add To, or Remove From Total
Previous Total	This is the total prior to the last reset. Multiple previous totals can be set up by selecting a previous total as the input to a new total. The date & time is captured with the previous total.
Daily Total	This is the total for the day, starting at midnight. Daily total can be the input for previous totals to keep a record of a few days. The date is captured with the previous total.
Grand Total	Uses another total as the input and it is setup as non-resettable
Non-Rate Total	This total takes the input from a non-rate channel, a trigger causes the total to increment, or decrement based on the settings selected (e.g. Input from weight scale added when digital input is triggered).

Real Time Clock

Date Format	Month, day, year (e.g. July 16, 2020)
Time Format	24 hour; 00: Midnight hh:mm:ss
Battery	3V, P/N: CR2032 included Battery replacement only with a Panasonic CR2032 Lithium Metal 3V coin cell battery.
Display Date & Time	Displayed on the top line of Setup and View menus, including day of the week.
Screens	Date & Time can be added to any screen.
Channels	Date & Time can be the input to a channel. Display Format: yyyy/mm/dd hh:mm:ss

Channel & Math Functions

Scale Functions	K-Factor	Converts number of pulses to volume or other units
	Scale Factor	Apply multiplier to a channel
	Scale Linear 2-Pt	Scale a channel
	Scale Multi-Point*	Multi-point scaling of a channel
	Scale Square Root	Apply square root to a channel – Differential Pressure from two channels
	Scale Exponent	Apply exponent for weirs and flumes open channel flow calculation
	Round Horizontal Tank	Calculate volume in round horizontal tank with flat ends
	Units Conversion	Convert base units to custom units
	Percent (Bargraph)	% bargraph of any: 4-20 mA input, channel, total, timer, or mA output
	Text (Percent)	Text displayed based on the % input value
Math Functions	Constant	Assign fixed value
	Summation	Add two or more channels
	Difference	Subtract any two channels
	Abs Difference	Difference always positive
	Absolute Value	Convert channel value to positive
	Average	Find the average of channels
	Weighted Average	Assign % weight to two or more channels
	Multiply	Multiply two channels
	Divide	Divide two channels
	Exponent	Set the base and the exponent; both can be constants or variables
	Logarithm	Set the base and the value; both can be constants or variables
	Modulo	Set constants or variables for A mod B
	Trigonometry	Sine, cosine, tangent, arc sine, arc cosine, arc tangent. Select the input and angle
	% Efficiency	Calculate input to output efficiency ((A-B)/A)*100%
Open Channel Flow Functions	Parshall Flumes	Q = K H^n Enter constant, head variable, exponent, and units
	V-Notch Weirs	Q = K H^2.5 Enter constant, head variable, and units
	Cipolletti Weirs	Q = K L H^1.5 Enter constant, crest length, head variable, and units
	Rectangular Weirs w/o Contractions	Q = K L H^1.5 Enter constant, crest length, head variable, and units
	Rectangular Weirs with Contractions	Q = K (L-0.2H) H^1.5 Enter constant, crest length, head variable, and units
	Note: Enter K value for Q = cuFt/sec; select any flow rate units to be displayed or used as input to a totalizer.
	IMPORTANT! *Scale Multi-Point: There is no minimum input span requirement; it is up to the user to make sure the input values are correct.
Additional Functions	Compare
Additional Functions
	Greatest	Greatest value in a group of channels
	Least	Smallest value in a group of channels
	Middle of 3	Outputs the middle value of three inputs
	Measure
	Tare	Calculate net value when Tare function is applied via function key
	Maximum	Maximum value reached by the process
	Minimum	Minimum value reached by the process
	Duration	Keep track of time a condition has been present (e.g. high alarm active)
	Rate of Change	Calculates how fast a process is changing /sec, /min, /hr, /day
	Filter
	Window Average	Enter time to calculate the average
	IIR (First Order)	Infinite Impulse Response (slow)
	Cutoff	PV = 0 below cutoff Flip Side: 0 above (-)
	Limits	Sets PV upper & lower limits.
	Round	Round (to nearest) Floor (always down) Ceiling (always up) Less (toward zero) More (away from zero)
	Hysteresis	Resists a directional change using a time delay, filters change in the trending direction
	Delay	Enter the number of seconds to delay the output
	Pulse Filter	Use to filter discrete inputs, set minimum and maximum on/off time in seconds
	Control
	Sampler	Trigger relay sample and select sampling time (e.g. Turn relay on for 30 sec every time total increases by 1,000 Gallons)
	On-Off Control	Set on & off control based on PV
	On-Off Control with Random Varying On/Off Points	Select Randomizer, enter on/off points +/- random variation
	Select A or B	Switch between 2 inputs
	Select 1,2,3…	Select 1 from 3 or more inputs, it works as a selector switch
	Schedule	Daily or weekly event The available actions depend on the configuration of inputs and outputs.
	Capture	Set a trigger event to capture a value in real time
	PID Control	Set up channel for PID control
	PWM Control	Set up channel for pulse width modulation control to be used with PID control loop
	Switch Position	Set up channel to read the digital switch position (0, 1, 2, 3)
	Relays
	Cycle Count	Number of relay cycles since reset
	Runtime	Relay runtime (ON) hh:mm:ss
	Modbus
	Time Since Read	Time since a Modbus client device read a register
	Time Since Write	Time since a Modbus client wrote to a register

List of Engineering Units

Time	seconds, minutes, hours, days & /sec, /min, /hr, /day
Distance (Height)	cm, m, Inch, Feet, Ft-In, Yard, km, miles, custom
Volume	Gallons, GAL, L, IGAL, M3, BBL, BUSH, cuYD, cuFt, cuIn, LiBBL, BBBL, HECtL, quarts, pints, fl oz, mL, DT, M/T, MGAL, custom
Pressure	psi, Pa, bar, hPa, kPa, MPa, GPa, inH2O, cmH2O, inHg, mmHg, atm, kg/cm2, kg/m2, mbar, Mbar, Torr, mTorr, custom
Weight	grams, Oz, Lb, lb, g, kg, ounces, tons, tonnes, custom
Temperature	C, F, K, Ra
Percent	%, PCT, Percent, custom
Amps	mA, Amps, custom
Volts	V, mV, Volts, custom
Counts	Pulses, Cycles, Counts, custom
Logic	ON, OFF, OPEN, CLOSED, YES, NO, START, RUNNING, STOP, STOPPED, PUMP ON, PUMP OFF, OK, OKAY, ERROR, WARNING, custom
Custom	Enter unit’s name, type, base unit, and factor.

4-20 mA Analog Inputs

Number of Inputs	(4) Analog inputs/card (28) Analog inputs max, no other I/O
Typical Input	4-20 mA
Input Range	0-24 mA
Accuracy	±0.03% of full scale ±1 count
4-20 mA Display Value	Up to six recommended ±999,999 More digits can be used, but the stability will be affected. Increase the filter value and lower the display update rate or use rounding to get a more stable reading.
Number of PID Control Loops	(8) PID control loops can be set up with (8) analog outputs connected to SCRs. Note: (4) digital outputs can be used to control SSR (Solid State Relays).
Transmitter Power Supply	Isolated 24 VDC @ 200 mA/input Max current: 1,600 mA (All inputs) (8) Analog Input @ 200 mA max (28) Analog Input @ 20 mA max Available on AC or DC powered units
Temperature Drift	Better than 20 ppm/°C from -40 to 60°C ambient
Filter	Window average: None, 0.5, 1, 2, 4, 8 sec IIR (Infinite Impulse Response): 16, 32 sec Glitch Filter: Discards a single sample caused by high frequency noise
Filter Bypass	0 to 100 % of full scale Filter is ignored, if the signal change is greater than bypass value
Channel Input Scale Function	Scale Linear 2-Point, Scale Multi-Point (2 to 50 points)* Scale Square Root Scale Exponent (Open Channel Flow) Scale Factor Round Horizontal Tank (Volume) Units Conversion (mA Input Reading) Percent Bargraph Text (Percent)
Channel Input Live Calibration	Each channel can be calibrated using live calibration signal from a sensor or a calibrator.
Input Protection	Each 4-20 mA input is protected by an autoresettable fuse, 30 VDC max. The fuse resets automatically after the fault condition is removed.
Input Impedance	125 Ω typical, including auto-resettable fuse
Hart Transparency	The controller does not interfere with existing HART communications; it displays the 4-20 mA primary variable, and it allows the HART communications to pass through without interruption. The controller is not affected if a HART communicator is connected to the loop. The controller does not display secondary HART variables.
Isolation	1500 V: Input-to-power line 500 V: Input-to-input, input-to-output All analog inputs and analog outputs are isolated from each other.
Normal Mode Rejection	100 dB at 50/60 Hz
Common Mode Rejection	90 dB at 50/60 Hz

Pulse Inputs

Number of Inputs	(4) Pulse inputs/card (28) Pulse inputs max, no other I/O
Input Type	Active Square Wave, NPN, PNP, Reed Switch, Coil (Magnetic Pickup) Normal threshold: 1.2 V (0.8 to 3.0 V) High threshold: 2.5 V (2.0 V to 6.0 V) Coil threshold: 20 mV (Low) or 100 mV (High)
Signal Level	Active Square Wave: 0 to 30 V max Typical: 0 to 5 V Coil: 20 mVp-p to 30 Vp-p (Magnetic Pickup)
Input Impedance	Active, NPN, Reed: 10 kΩ pull-up to 5 V PNP: 10 kΩ pull-down to (S-) Coil: >2 kΩ (20 mV sensitivity), >10 kΩ (100 mV sensitivity)
Isolation	Pulse inputs are not isolated, (S-) terminal is connected to system GND
Input Protection	±36 V, non-isolated
Frequency Response & Signal Level	Active Square Wave 5 V: 0 to 100 kHz Coil (Magnetic Pickup): 0 to 50 kHz Frequency – Signal level (Coil: 20 mV) 20 mVp-p – 100 Hz 100 mVp-p – 10 kHz Frequency – Signal level (Coil: 100 mV) 100 mVp-p – 90 Hz 500 mVp-p – 5 kHz 20 Vp-p – 50 kHz
Minimum Frequency	250 μHz with High Gate = 4,000 sec
Low Gate	1 to 99 sec
High Gate	2 to 4,000 sec (Must be higher than low gate)
Low Speed	100 Hz maximum Used for contact debouncing
Pulse Counter	8,388,607 maximum, used for troubleshooting purposes only
Accuracy	±1 count for K-Factor > 1 or 30 ppm
K-Factor	Programmable pulses/unit of measure with up to 14 decimal resolution
Scale Pulse Input	Scale Linear 2-Point Scale Multi-Point Scaling*: 2 to 50 points Scale Factor Units Conversion
Live Calibration	Pulse input channel can be calibrated using live calibration signal from a sensor.
IMPORTANT! *Scale Multi-Point: There is no minimum input span requirement; it is up to the user to make sure the input values are correct.

Modbus Inputs - Server

Availability	Standard feature
Number of Inputs	199 Modbus RTU or ASCII
Scale Modbus Input	Modbus input can be used as the input for creating channels and totals, the same way the 4-20 mA inputs are used.
Data Type	Bit-Logic Signed/Unsigned: 16 (Short), 32 (Long), 64 (Long-Long) Float 32, Float 64 (Double)
Decimal Point	User selectable
Comm Break & Timeout	Specify what value to hold when a communication break occurs and how long to wait for new data before reporting a break condition.
Input Action	Specify what should happen when new data is written to the input register (e.g. Add to Total 1, Log Entry – All Logs).

Digital Inputs & Outputs

Digital Inputs	5 Inputs, non-isolated, 30 VDC max Standard feature on all ConsoliDator+ models Low: 0 to 1.2 V High: 2.8 to 30.0 V Internal pull-up: 5 kΩ to 5 V Max pulse frequency: 1 kHz @ 5 Vp-p +5 V terminal: Internal pull-up 100 Ω Note: Pulse inputs can be used as digital inputs
Digital Input Types	Normally open switch: External excitation not required (Current: 1 mA) Open collector: 4.1 V open circuit voltage Logic level: 0 to 30 V
Assignment & Operation	Active Low or Active High Functions: Remote front panel button, total functions, timer control, alarm functions, screen navigation, horn functions, reset relay information. Digital inputs can be used as input source for channels, totals, and alarms.
Digital Outputs	4 Outputs Standard feature on all ConsoliDator+ models Low: 0 V (no load), 1.5 V max @ 10 mA sink (External pull-up) High: 5.0 V (no load), 3.5 V @ 10 mA load Maximum current: 30 mA Output impedance: 100 Ω Output protection: 150 mA auto resettable fuse Max frequency: 5 Hz
Digital Output Assignment	Digital outputs require logic units as the input. Input sources: Digital input, Modbus input, channel, alarm, horn, always on, or always off
Input / Output Protection	±36 V, non-isolated

Relays

Number of Relays	(5) Relays/card (30) Relays max with (4) analog or (4) pulse inputs, no other I/O
Rating	SPDT (Form C) Resistive load: Rated 10A @ 120/240 VAC or 8A @ 30 VDC Inductive load: NO contacts: 5A, 1/3 HP, 120 VAC; 30,000 cycles NC contacts: 1/8 HP, 120 VAC; 50,000 cycles Minimum load: 100 mA @ 5 VDC
Maximum Current per Relay & Number of Relays	11 relays or more: 5A @ 120/240 VAC or 30 VDC. Limited due to heat dissipation inside the enclosure.
Isolation	1500 VAC, 50/60 Hz for 1 min between coil and contacts
Deadband	0-100% of full scale, user selectable
Electrical Noise Suppression	TVS diodes & snubbers on all contacts. Recommended additional external snubber: 0.01 μF/470 Ω, 250 VAC (Order: PDX6901)
Assignment & Operation	Any relay can be assigned to any alarm, channel, total, timer, digital input, Modbus input, pump alternation, horn, always on, or always off. Multiple relays can be assigned to the same alarm or channel. All relays are programmed independently.
	High & Low Alarm: Defined by set and reset points in the Alarm menu
	High or Low Alarm: Assign relay to any alarm or channel for on/off relay control Note: Automatic reset only for channel
	Multi-Source High or Low Alarm: Assign relay to multi-source alarm to indicate common high or low condition.
	Pulse Action: Set any relay for pulsing on/off timed relay control. Programmable pulse width (on/off time) and on/off delay.
	Sampling: Relay must be assigned to channel setup for Sampler function with user-defined total increment and sampling time.
	Pump Alternation: Any relay can set up to alternate with any relay in the group. Multiple alternation groups can set up.
Acknowledge	Front panel Ack key or digital input acknowledges individual or all alarms; relays associated with acknowledged alarm are turned off.
Alarm Relay	Assign any relay to be driven by any alarm; acknowledging the alarm turns off the relay (nonfail-safe mode).
Time Delay	Programmable on/off delays, 0.0 to 999.9 sec Independent for each relay.
Auto Initialization	When power is applied to the controller, relays will reflect the state of the input to the controller.
Fail-Safe Operation	The relay coil is energized when the process variable is within safe limits and the relay coil is de-energized when the alarm condition exists.

4-20 mA Transmitter Outputs

Number of Analog Outputs	(5) Analog outputs/card (35) Analog outputs max with no other I/O cards (Seven I/O slots)
Output Range	4.00 to 20.00 mA, nominal
Calibration	Factory calibrated for 4-20 mA
Scaling Range	Any process range Reverse scaling allowed
Assignment & Operation	Assign to any analog or pulse input, digital input, Modbus input, channel, total, timer, alarm, or fixed value (none). Note: Multiple 4-20 mA outputs can be assigned to the same input.
Accuracy	±0.03% F.S. ±0.005 mA
Temperature Drift	20 ppm/°C from -40 to 60°C ambient. (Output & Input drifts are separate)
Output Loop Power	Powered by controller: 24 VDC @ 24 mA max or powered externally by 12 to 32 VDC
Output Loop Resistance	Powered by controller: 10 to 600 Ω External 12 VDC: 10 to 200 Ω External 24 VDC: 10 to 600 Ω External 32 VDC: 10 to 1000 Ω
Isolation	1500 V: Output-to-power line 500 V: Output-to-output, output-to-input All analog inputs and analog outputs are isolated from each other.

Timers

Number of Timers	Up to 30
Time Format	hh:mm:ss with 0 decimals selected Seconds with 1 or more decimals
Automatic Actions	Power Up: Timer action on power up Error: Action when an error is detected Reset: Event causes the timer to reset Start: Event triggers the timer to start Stop: Event causes the timer to stop
Start / Stop Reset	The function keys and digital inputs can be used to start, stop, and reset the timers, regardless of the automatic actions selected.
Assignment & Operation	Timers can be triggered, stop, and reset, by rising or falling signals from 4 20 mA input, pulse, digital, Modbus input, channel, total, other timers, alarm, mA output, relay, or Modbus output.
Count Down Timer	Select count down and enter starting time
Timer Alarm	Timer can be used to trigger alarms
Bargraph	Select bargraph during setup and scale the bargraph for 0 – 100% target time
Timer Control	Access timer control via the View Timer menu or assign a function key to timer control in the Screens menu
Timer & Relay	Timer can be assigned to drive relays based on selected set and reset points.

Modbus Outputs - Server

Availability	Standard feature
Data Type	Bit-Logic Signed/Unsigned: 16 (Short), 32 (Long), 64 (Long-Long) Float 32, Float 64 (Double)
Register Numbers	The register numbers are automatically generated based on the Modbus output number and the output’s data type. Bit – Logic: 04101 – 04199 Signed/Unsigned 16: 44101 – 44199 Signed/Unsigned 32: 44201 – 44398 Signed/Unsigned 64: 45001 – 45396 Float 32: 44401 - 44598 Float 64: 44601 - 44996
Engineering Units	Select the engineering units for the process variable assigned to the output
Decimal Point	User selectable. For short and long integers this is a multiplier applied to the input value, but it is not displayed on the server’s screen. The Modbus client uses this setting to read the correct value from the server. Example: Ch 1 value = 4,379.26 MB Output Data Type: Signed 32 Decimals = 0 🡢 Output = 4,379 Decimals = 3 🡢 Output = 4,379,260
Output Action	Specify what should happen when the output register is read by the client (e.g. Start timer 1, Log Entry – All Logs).

Modbus Serial Communications

Compatibility	RS-485 (EIA-485)
Protocols	Modbus RTU or Modbus ASCII Modbus Enron is supported by the Client and the Spoofer modes.
Device Address	1 to 247 (Server)
Transmit Delay	0 to 999 ms
Receive Timeout	1 to 9 seconds
Baud Rate	1,200 to 115,200 bps
Data	8 bit (1 start bit, 1 stop bit)
Parity	Even, Odd, None with 1 stop bit, or None with 2 stop bits
Modbus Inputs	199 for all mode
Modbus Outputs	99 for all modes. The outputs can be grouped together to be sent as blocks of registers. These Modbus outputs are in addition to the outputs listed in the Modbus Register Tables, see PD9000 instruction manual.
Communication Break	Reports a break condition after the response timeout has elapsed. The break condition can be: Zero, a default value, or the text Break. The Client goes into break condition after the server device fails to respond and the timeout has elapsed. The Snooper and Server modes go into break condition after no new data is received within the response timeout window. Alarms can be programmed to go on, off, or stay as is when a break condition is detected. The analog outputs can set up to generate a fixed mA current when a break condition is detected.

Modbus Client, Snooper & Spoofer

Add-On Feature PDK9000-M1	Client, Snooper & Spoofer The Modbus Client is an option in the ConsoliDator+. It can be purchased at the time the order is placed or it can be purchased and enabled at any time. The Modbus Snooper & Spoofer features are part of the Client Add-On feature.
Modes	Client: Requests data from servers and writes data to servers.
	Snooper: Listens to the RS-485 network communications and reads the selected registers.
	Spoofer: A channel is configured to pretend being a device that has been removed from the network. The device ID and register number is used.

Client & Snooper Settings

Availability	Order Add-On Feature model PDK9000-M1 at any time.
Number of Output PVs	99 process variables can be written by the Client mode to Modbus servers. Modbus server inputs and outputs are available over the Ethernet port, in Client mode also.
Server ID	Enter the server ID or address containing the process variables to be read or written by the Client or read by the Snooper.
Function Code	Select which Modbus function code to use for reading the server device or for writing to a server by the ConsoliDator+ Client.
Register Address	0-65,533 (Base 0) Reg. No. 30001-39999, 40001-49999 Reg. No. 300001-365534 or 400001-465534 Specifies which register(s) to read from the server device.
Data Type	Select the data format used by the server device. Bit – Logic (Coil) Signed/Unsigned: 16 (Short, 2 byte) 32 (Long, 4 byte) 64 (Long Long, 8 byte) Float 32 (4 byte), Float 64 (Double, 8 byte)
Byte Order	ABCD, CDAB, BADC, or DCBA (big-endian, swapped, or little-endian)
Client Poll Time	1.0 to 999.9 sec. Time between read commands.
Server Response Timeout	99:59:59 hrs.: Time allowed for the server to respond before the Modbus client generates a communication break condition. The timeout should be greater than the poll time. Server/Snooper mode: Time the Modbus input will wait for new data before going into a break condition. If the timeout is disabled, the last value will remain until a new value is received.

Spoofer Settings

Availability	Order Add-On Feature model PDK9000-M1 at any time.
Number of Output PVs	99 process variables can be replaced by the ConsoliDator+ Spoofer feature.
Number of Input PVs	199 process variables can be written by a client to the Spoofer inputs replacing other Modbus servers.
Server ID	Enter the server ID or address being replaced by the ConsoliDator+ Spoofer.
Function Code	Select the Modbus function code used by the server device.
Register Address	Enter the address 0-65,533 (Base 0) for the process variable of the replaced server.
Data Type	Select the data format used by the server.
Byte Order	Select the byte order ABCD, CDAB, BADC, or DCBA (big-endian, swapped, or little-endian)
Engineering Units	Select the engineering units for the process variable.
Decimals	Enter the number of decimals required.
Output Action	Select an action to be performed by the controller, when the Spoofer output is read by a Modbus client or leave as None.

Data Logger – USB Drive

USB Data Logger Add-On Feature PDK9000-D1	The Data Logger is an option in the ConsoliDator+. It can be purchased at the time the order is placed or it can be purchased and enabled at any time. The Data Logger feature is available on ConsoliDator+ units with a firmware version 2.2 or greater.
Storage Device	External USB flash drive Format: FAT32 (32 GB maximum) Recommended drive: SanDisk 32GB maximum.
Number of Data Logs	8, maximum
Number of Variables / Log	12, maximum
Number of Log Variables	96 variables, maximum (8 logs x 12 variables / log)
Number of Log Records	The number of records depends on the flash drive size. Examples for 32 GB: 1) 4 logs with 8 variables each 1 min rate: ~160,000,000 records Log time: 60 years 2) 8 logs with 12 variables each 1 min rate: ~70,000,000 records Log time: 16 years
Log File Type	csv (comma separated value)
Maximum Log File Size	100 MB A new file is automatically created when the log file exceeds 100 MB.
Stop When Full	This should be selected if the oldest logged data is more important than logging new data. If Stop When Full is not selected, the oldest block of data will be deleted to make room for new data.
Remove Device	Use the Remove Device button, in the System – USB Drive, to safely remove the USB drive and prevent data corruption.
Alert! Message	An Alert! message is displayed in place of the Menu key if the USB drive is removed.
Start / Stop	Selecting this feature enables the Start / Stop function key in the View – Data Logs menu. The Start / Stop function can be activated using the digital inputs, F1-F4 function keys in the Setup – Screens menu, Channel control schedule, Modbus inputs, and Modbus outputs.
Log Enable Switch	The Enable Switch setting can be used to control the log process using digital inputs, Modbus inputs, Channel control, alarms, or relay outputs. Logs are recorded only if the Enable Switch input is in the active (on) condition.
Log Trigger	The Log Trigger setting is used to log data on a specific event; a log can be triggered using digital inputs, Modbus inputs, Channel control, alarms, relays.
Manual Log	The user can record a log entry at any time by using the F4 key in the View – Logs menu or by assigning a function key in the Setup – Screens menu.
Log Interval	00:00:01 to 23:59:59 hrs:min:sec

How to Enable Add-On Features

To enable the Data Logger features, see Add-On Features in the PD9000 instruction manual.

IMPORTANT!

The USB Data Logger functions are available only if the Add-On feature has been enabled in the System – General Settings, see Add-On Features in the PD9000 instruction manual.

Sample Data Log File

Ethernet Communications

Device	Lantronix Xport-05
Protocol	Modbus TCP/IP (Default) Modbus UDP/IP Modbus RTU Over TCP/IP Modbus RTU Over UDP/IP
Port Settings (Do Not Change)	Protocol: RS-232 Baud Rate: 9600 Data Bits: 8 Flow Control: None Parity: None, Stop Bits: 1
Network Stack	IPv4
Ethernet Mac/Phy	10/100 Mbps
Additional Specifications	Refer to the Lantronix webpage at https://www.lantronix.com/products/xport.
Ethernet Port Configuration	Use the System menu for basic Ethernet configuration or download the Lantronix Device Installer software to fully configure the Ethernet port at https://www.lantronix.com/products/xport. See Ethernet Port Setup in the instruction manual.

ConsoliDator+ Software

System Requirements	Windows® 7, 10
Compatibility	The software and firmware versions must be matched.
IMPORTANT!
Do not write configuration files created using older versions of the firmware and software to controllers with Add-On features enabled (Ver. 2.1 & up). This can create undesirable results, especially with the function keys F1-F4.
Connection	Standard USB A to Micro-USB type B (cable included).
Configuration	Configure inputs and outputs, channels, totals, timers, alarms, etc. Configure bargraph and panel colors for normal operation, and colors for alarm indication. Save controller settings file on PC for programming other controllers or to restore settings.
Note: The ConsoliDator+ software version must be used with the corresponding firmware version (e.g. Software v2.2 & Firmware v2.2)

Compliance Information

Hazardous Area Location*

UL & C-UL Listed	For Hazardous Location Installations (US and Canada) Class I Division 2 Groups A, B, C, and D Class II Division 2 Groups F and G Class III Temperature Code: T4A
UL File Number	E516990
Front Panel	UL Type 4X, NEMA 4X, IP66; Panel gasket provided
Low Voltage Directive	CSA-C22.2 No. 61010-1 and CSA-C22.2 No. 61010-2-201 UL 61010-1 and UL 61010-2-201 Safety Requirements for Electrical Equipment for Measurement, Control, and Laboratory Use
WARNINGS!
Explosion Hazard - Batteries must only be changed in an area known to be non-hazardous. Explosion Hazard - Do NOT Connect or Disconnect Equipment unless power has been switched off or the area is known to be non-hazardous.
*Hazardous Area Location approvals apply to all PD9000 (H) models. See ordering information.

Hazardous Area Location*

UL & C-UL Listed	USA and Canada UL 508 Industrial Control Equipment
UL File Number	E160849
Front Panel	UL Type 4X, NEMA 4X, IP66; Panel gasket provided
Low Voltage Directive	CSA-C22.2 No. 61010-1 and CSA-C22.2 No. 61010-2-201 UL 61010-1 and UL 61010-2-201 Safety Requirements for Electrical Equipment for Measurement, Control, and Laboratory Use
*Ordinary Location approvals apply to all PD9000 (G) models. See ordering information.

Free ConsoliDator+ Configuration Software

Overview

The easiest and quickest way to program your ConsoliDator+ multivariable controller is to use the FREE ConsoliDator+ configuration software. The ConsoliDator+ configuration software is intuitive, and most customers can get their controller programmed as they like without even looking in the manual. Once your controller is programmed the way you want it, you can wire it up for your application per the instructions in this manual and install it. If you find that you need to adjust the programming after the controller is installed, you can use the front panel soft keys and the instructions in the manual to do so.

See The ConsoliDator+ Manual for Software Instructions

Download ConsoliDator+
Configuration Software

ConsoliDator+ Software Channel Settings Screen

Totals Settings

Enter Display Tag Name for Total
Select Input
Enter Units
Enter K-Factor Value
Set Decimal Point
Check Box for Countdown, Allow Negative, Preset Value and Enter Value, Roll-Over and Enter Value, and Non-Resettable
Select a Color Scheme for Text, Background, and Bargraph
Check Box to Display Bargraph
Enter Scaling for Bargraph

Timers Settings

Enter Display Tag Name for Timer
Select Input
Select Power Up Option
Select Error Option
Select Reset Option and Enter Value
Select Start Option and Enter Value
Select Stop Option and Enter Value
Set Decimal Point
Select Color Scheme for Text, Background, and Bargraph
Check Box to Display Bargraph
Set Scaling for Bargraph

Alarm Settings

Enter Display Tag Name for Alarm
Select Alarm Type
Select Input
Enter Set and Reset Points
Select Color Scheme for Text, Background, and Bargraph
Check Box to turn On/Off Sound Horn, Alert!, Automatic, or Ack Anytime
Select Break: Alarm Off, Alarm On, Stay As Is
Enter Value for On Delay and Off Delay
Enter Name for Alarm Color Profile
Check Box for Alarm to Flash

Inputs Settings

Enter Display Tag Name for Input Channel
Select Filter Time
Enter Bypass Value
Check Box for Glitch Filter
Check Box for Break Below and Set mA Value
Check Box to Disable Input Channel

Outputs Settings

Enter Display Tag Name for Output Channel
Select Input Source
Check Box for Fail-Safe

Screens Settings

Enter Title Name for Screen
Check Box to Show Title
Check Box to Show Channel Number
Check Box to Display Bargraph and/or Bargraph Only
Check Box to Auto Scan
Check Box for Dwell Time and Enter Dwell Time

System Display Settings

Set Backlight Brightness
Enter Display Refresh Rate
Check Box to Show Commas
Select Color Scheme for Text, Background, and Bargraph
Check Box to Show Alarm Condition Using Alarm Color Settings

General / Date & Time Settings

Enter Device Tag Name
Check Box for Enable Buzzer and Select Buzzer Sound
Set Date and Time or Check Box to Use System Date and Time
Click on the Gray Buttons to Load Defaults, Set Password, or Clear Password

ConsoliDator+ Software System General and Build Settings Screen

System Build Settings

Shows Model Number of the Connected Controller
Shows Slot Numbers and Input/Output Cards Installed on the Connected Controller

Modbus Settings

Select Modbus Mode
Select Baud Rate
Select Parity
Enter a Value in ms for Tx Delay
Click on the Plus or Minus Symbol to Increase or Decrease Seconds for Rx Timeout
Check the Box for Passcode and Enter a Number to Protect the Server Settings

Custom Units Settings

View or Add Custom Units
Enter a Label for Unit
Select a Unit Type
Select Unit Base
Enter a Value for Factor

PID Control Settings

4-20 mA Output for SCR Control
Pulse Width Modulation (PWM) for SSR Control
Heating & Cooling
Switch Function to Quickly Change Target Set Point
Switch Function for Easy Auto/Manual Mode Switching with Softkeys
Enter New Set Points Easily On-Screen with Set Point Softkey
Initiate Auto-Tune with Auto-Tune Softkey

Digital Switch Settings

Program for Hand-Off-Auto control or PID Output Auto-Manual Switching
Two, Three, and Four Way Switching
Each Position Can Reference Any Channel, Input, Output, Total, Etc.
Unique Name for Each Digital Switch and Switching Position
Programmable Actions to Execute a Pushbutton Function in Addition to Changing Switch Position

Set Relays to Outputs for Control by Switches

Select Switch as the Input for the Output
Switch Positions Determine Output Operation
Each Position Can Reference Any Channel

Setup Screens to Operate Digital Switches

Uses On-Screen Softkeys, No Panel Switches Required
Set a Specific Softkey to Select Any Single Position on the Digital Switch
Set a Softkey to Cycle Next or Previous Position
Display Switch Status on the Screen

ConsoliDator+ Software Specifications

System Requirements	Windows® 7, 10
Compatibility	The software and firmware versions must be matched.
IMPORTANT!
Do not write configuration files created using older versions of the firmware and software to controllers with Add-On features enabled (Ver. 2.1 & up). This can create undesirable results, especially with the function keys F1-F4.
Connection	Standard USB A to Micro-USB type B (cable included).
Configuration	Configure inputs and outputs, channels, totals, timers, alarms, etc. Configure bargraph and panel colors for normal operation, and colors for alarm indication. Save controller settings file on PC for programming other controllers or to restore settings.
Note: The ConsoliDator+ software version must be used with the corresponding firmware version (e.g. Software v2.2 & Firmware v2.2)

Download ConsoliDator+ Software

Click here to download ConsoliDator+ Software version 2.3 (.zip)*
Click here to download ConsoliDator+ Software version 2.2 (.zip)*
Click here to download ConsoliDator+ Software version 2.1 (.zip)*
Click here to download ConsoliDator+ Software version 2.0 (.zip)*
Click here to download ConsoliDator+ Software version 1.0 (.zip)*

*The ConsoliDator+ software version must be used with the corresponding firmware version
(e.g. Software v2.2 & Firmware v2.2)

Dimensions

Overall Dimensions

Units: Inches (mm)

Panel Mount ConsoliDator+ Overall Dimensions

Panel Mounting

Prepare panel cutout per the dimensions provided
Locate the panel mounting bracket and screws
Inspect the controller to assure the gasket is securely in place
Insert controller in the panel cutout, the latches on the top and bottom should hold it in place
Insert the panel mounting bracket from the back of the panel, observe the orientation of the piece marked TOP
Install the 12 screws provided to a torque value of 0.8 Nm (7 lb-in)

PD9000 Panel Cutout Dimensions and Front Panel Dimensions

Notes:

Panel cutout: 10.0" x 10.0" ±0.05" (254 mm x 254 mm ±1.3 mm),
see Front Panel Dimensions above.
Panel thickness: 0.07" – 0.35" (1.8 mm – 8.9 mm)
Clearance: Allow 6" (152 mm) behind panel

Connections

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

90-264 VAC Power

Use three-terminal power connector as shown in the Figure below.
Unit is protected internally with 1.25 A auto-resettable fuse. 2 A max, slow blow, 250 V min UL Recognized external fuse recommended.

AC Power Connections

24 VDC Power ± 10%

Use two-terminal power connector as shown in the Figure below.
Unit is protected internally with 3.7 A auto-resettable fuse. 4 A max, slow blow, 50 V min UL Recognized external fuse recommended.

DC Power Connections

Isolated Input Signal Connections

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

4-20 mA Analog Input Connections

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

Transmitter Powered by External Supply or Self-Powered

Transmitters Powered by ConsoliDator+ Isolated 24 VDC Power Supply

Transmitters Powered by ConsoliDator+’s Isolated 24 VDC Power Supply

Transmitter Powered by External Supply or Self-Powered

Three-Wire Transmitters Powered Externally

Flow Meter Pulse Input Connections

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

Flow Meter Pulse Input Connections

Digital Input Connections

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

Digital Input from Switch Closure and Live Signal

Analog Output Connections

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

Active 4-20 mA Output Powered by ConsoliDator+

Passive 4-20 mA Output Powered by External Supply

Note: Analog inputs and outputs are isolated from each other.

Digital Output Connections

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

Digital Outputs Driving 5V Solid State Relay and Alarm Annunciator

Relay Connections

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

Relay Connections

Switching Inductive Loads

The ConsoliDator+ has internal circuitry to protect the relays from inductive loads, however, 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 resistorcapacitor (RC) networks assembled by the user or purchased as complete assemblies. Refer to the following circuits for RC network assembly and installation.

AC and DC Internal Inductive Load Protection

For additional external protection choose R and C as follows:

R: 0.5 to 1 Ω for each volt across the contacts
C: 0.5 to 1 μF for each amp through closed contacts

Notes:

Use capacitors rated for 250 VAC.
RC networks may affect load release time of solenoid loads. Check to confirm proper operation.
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 large as the load current.

Low Voltage DC Loads Protection

RC Networks Available from Precision Digital

RC networks are available from Precision Digital and should be applied to each relay contact switching an inductive load. Part number: PDX6901.

Serial Communication Connections

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

Serial Connections

Ethernet Option

The Ethernet port is available on the RJ45 connector. This allows the ConsoliDator+ to connect to a local area network. The Ethernet port option is configured using the System menu. See the PD9000 ConsoliDator+ manual for ethernet port setup details.

External Keypad Connections

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

External Keypad Connections

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Product variations:

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PD9000 ConsoliDator+ Multivariable Controller

Overview

Features

Screens

Main Screen

Channel Details Screen

Screen with Feet & Inches Units

Inputs & Outputs

Setting Channel Parameters

Individual Channel View

Low & High Alarm Indication

HOA Screen View

Block Diagram for HOA Switch

Modbus Client, Snooper & Spoofer Add-On Features

Client Mode

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Spoofer Mode

ConsoliDator+ USB Data Logger Add-On Feature

Setup Data Log

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General

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List of Engineering Units

4-20 mA Analog Inputs

Pulse Inputs

Modbus Inputs - Server

Digital Inputs & Outputs

Relays

4-20 mA Transmitter Outputs

Timers

Modbus Outputs - Server

Modbus Serial Communications

Modbus Client, Snooper & Spoofer

Client & Snooper Settings

Spoofer Settings

Data Logger – USB Drive

How to Enable Add-On Features

Sample Data Log File

Ethernet Communications

ConsoliDator+ Software

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Hazardous Area Location*

Hazardous Area Location*

Free ConsoliDator+ Configuration Software

Overview

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Outputs Settings

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PID Control Settings

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Set Relays to Outputs for Control by Switches

Setup Screens to Operate Digital Switches

ConsoliDator+ Software Specifications

Download ConsoliDator+ Software

Dimensions

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Connections

90-264 VAC Power

24 VDC Power ± 10%