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 32 timers that can be used to control many processes or events.
The ConsoliDator+ takes full advantage of its color display by allowing the user to customize screen colors for bargraphs, alarm conditions, and input channels.
All this functionality is easily programmed using the free software or via the front panel pushbuttons. Choose the model that best suits your application, from monitoring only to fully loaded controllers with an extensive combination of inputs, outputs, and communication protocols. The standard product offering is listed in the ordering guide and other models are available for special order. The Add-On features expand the functionality of the ConsoliDator+.
- 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, 32 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: -40 to 60°C (-40 to 140°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
- Field Selectable Input Power: 85-264 VAC or 24 VDC
- (20) Screens with up to Eight PVs Each
- Automatic or Manual Scanning
- Free ConsoliDator+ Configuration Software
- NEMA 4 & 4X Field Mount Enclosures Available
- 3-Year Warranty
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:
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-GP-4PI-8AI-10AO-10RY looks like. This model 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, and (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.
All units can be powered from AC or DC; both power connections can be used at the same time. The DC power supply can serve as backup power if the voltage is 24 V or less, otherwise the controller will run on DC power.
- 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+.
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. 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 key pad 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 these screens examples represent the current value in gallon units.
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.
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+.
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
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
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
Setup Data Log
Setup New Data 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|
Add Items to Be Logged
2. Digital Inputs
3. Modbus Inputs
8. mA Outputs
9. Relay Outputs
10. Digital Outputs
11. Modbus Outputs
Setup Log Start / Stop
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 Enable Switch input can be:
- Digital input
- Modbus input
- Relay Output
Setup Log Trigger
The Log Trigger input can be:
- Digital input
- Modbus input
- Relay Output
Setup Log Interval & Log Units
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.
Setup USB Drive
- USB Drive Status
- Used Space
- Free Space
If Stop when Full is not selected, the oldest block of data will be deleted to make room for new data.
Safely Remove 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
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
Relay connections are made to three-terminal connectors labeled individually. There are five relays per card.
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.
For additional external protection choose R and C as follows:
R: 0.5 to 1 Ω for each volt across the contactsC: 0.5 to 1 μF for each amp through closed contacts
- 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.
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.
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.
Units: Inches (mm)
- 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
- Panel cutout: 10.0" x 10.0" ±0.05" (254 mm x 254 mm ±1.3 mm)See Panel Cutout Dimensions.
- Panel thickness: 0.07" – 0.35" (1.8 mm – 8.9 mm)
- Clearance: Allow 6" (152 mm) behind panel
PD9000-ENC ConsoliDator+ NEMA 4X Plastic and NEMA 4 Steel Enclosures
The PD9000-ENC enclosures provide a convenient way to mount the PD9000 ConsoliDator+ to walls and other vertical structures. The enclosures are available in painted steel and plastic and come pre-cut with one cutout to mount the PD9000.
The enclosures are available in various sizes, with the larger enclosures capable of housing other pieces of equipment, such as the PDA1024-01 power supply.
Note: The enclosure and ConsoliDator+ are ordered and packaged separately.
- House One ConsoliDator+ PD9000
- Cutout for One ConsoliDator+ Provided
- ConsoliDator+ Mounts in Cover
- ConsoliDator+ Mounts Inside PDA3939 Clear Cover
- Sub-Panels Available
- PDA6909 Pipe Mounting Kit Available
- Light / Horn & Button Available
- UL Listed Plastic Enclosures
- UL Listed, CSA Certified Steel Enclosures
Sub-PanelsPrecision Digital offers plastic and steel sub-panels for the ConsoliDator+ enclosures that provide a convenient way to mount additional items to the base of the enclosure. They can be drilled to accept screws for easy mounting of relays, contactors, securing wiring clips, or installing other internal devices.
Sub-Panels for Plastic Enclosure
PDA0007 Enclosure Ventilation Kit
- Prevents condensation inside the enclosure
- UL & CSA Type 4X IP66
- Use with steel or plastic enclosures
- For wall thickness of 16 gauge to 1/4"
- Corrosion resistant polycarbonate
- Comes with two vents
PDA9000SH ConsoliDator+ Sun Hood
The PDA9000SH ConsoliDator+ Sun Hood provides shade for the ConsoliDator+ when it is mounted in direct sunlight. It is adhered to the ConsoliDator+ enclosure with industrial grade double sided tape (provided).
- Provides shade in direct sunlight
- Easy to install
- Industrial grade double-sided tape provided
MOD-LH Light / Horn
The Light / Horn is available in three different light configurations and is designed to be mounted in any of the PD9000-ENC ConsoliDator+ enclosures.
- The first option is a factory ordered Light / Horn with a color of either red, green, yellow, blue, or white.
- The second option is a Light / Horn the user determines the light color (red, green, yellow, blue or white) by connecting the appropriate wire.
- The third option is a Light / Horn with red, yellow, and green layers the user can turn on independently.
The light on the Light / Horn can be wired to flash (not available on PDA-LH5C) or stay steady on and the horn is rated at 85 dB.
The light and horn can be controlled independently of each other via separate relays on the ConsoliDator+; and since the controller's relays can be reset in a variety of ways, there are several ways the Light / Horn can operate. For instance, the horn can be programmed to silence at any time via the soft keys on the front of the ConsoliDator+, and reset the light automatically when the alarm clears.
When MOD-LH is ordered, the accompanying enclosure on the order comes with the holes pre-drilled for the Light / Horn and the Button, and the user performs the mounting and wiring. The ConsoliDator+ and enclosure are sold separately.
The PDA-LH Light / Horn and the PDA-BUTTON Button can also be ordered as separate items and the user performs all hole-drilling, mounting, and wiring as desired.
PDA1024-01 24 VDC Power Supply for DIN Rail
SPECIFICATIONSOutput Voltage: 21.6 ~ 29 VDC; ±10% 1.5A rated current.
Dimensions: 1.40" x 3.50" x 2.10"
(35 mm x 90 mm x 54.5 mm) (W x H x D)