The ConsoliDator+ is a multi-channel 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 RTU inputs and displays them both in 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, and Ethernet Modbus TCP/IP protocol communication capabilities. Additionally, the controller is equipped with up to 32 timers that can be used to control many processes or events.
All this functionality is easily programmed using 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.
- NEMA 4X Panel Mount Multi-Channel Controller
- Convenient Display, Control, & Alarm of Multiple 4-20 mA & Pulse 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 Slave Inputs
- 64 High & Low Alarms assigned to up to 25 Relays with AND/OR Logic
- Modular Design for Input & Output 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)
- Pulse, Analog, & Modbus Input Flow Rate / Total / Grand Total Capabili
- 50-Point Linearization, Square Root, and Exponent for Open Channel Fl
- Round Horizontal Tank Volume Calculation; Just Enter Diameter & Length
- Multi-Pump Alternation Control or Simple On / Off Control
- Programmable Displays, Function Keys & Digital Inputs
- Math Functions: Sum, Diff, Average, Multiply, Divide, % Efficiency, & More
- Display Direct Modbus PV Inputs – Slave Mode
- RS-485 Modbus RTU Standard & Ethernet Modbus TCP/IP Optional
- Free ConsoliDator+ Configuration Software
The ConsoliDator+ can be programmed to display the data on up to 20 different screens in a variety of formats, with and without bargraphs. The following screens show a typical main screen and channel details screen:
Channel Details Screen
Inputs & Outputs
If all Input / Output slots are used exclusively for one function, the ConsoliDator+ can accept up to (28) isolated 4-20 mA and pulse inputs, (25) isolated 4-20 mA outputs, and (25) relays. See the Ordering Guide for standard configurations. In addition, the ConsoliDator+ has digital inputs and outputs and RS485 capabilities as standard and Ethernet as an option. The following shows the connections for a ConsoliDator+ with four pulse inputs, eight isolated 4-20 mA inputs, 10 isolated 4-20 mA outputs and 10 Form C relays.
- 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.
- 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-generatied 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. 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 an amber line at the corresponding value on the bargraph.
Active Low Alarm: Indicated by red 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 red 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.
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 Lantronix DeviceInstaller software, available for download from the Lantronix’s Website at www.lantronix.com/products/xport/. 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.
GeneralDisplay: Color; QVGA (320x240 px), 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.
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
Display Update Rate: User selectable: 0.1 to 10 sec (10 updates/sec to 1 update/10 sec)
Programming Method: Front panel buttons, external buttons, or ConsoliDator+ Software
Number of Alarms: Up to 64 high or low Automatic (non-latching) or latching On & Off time delays. May 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
Alarm OR: Any active input alarm triggers the OR alarm
Alarm AND: All input 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)
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.
Calibration: All inputs and outputs are calibrated at the factory. Field calibration not possible.
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, Alarm, or Math
Password: Programmable password restricts modification of programmed settings
Non-Volatile Memory: Settings stored for a minimum of 10 years.
Power (User Selectable Based on Wiring): Three-terminal connector (L, N, GND), AC: 80-264 VAC, 47 to 63 Hz, 60 W max DC: 113-370 VDC, 60 W max (L, N), Two-terminal connector (G, 24V) DC: 24 VDC ±10%, 60 W max
Backup Power Supply: If AC and DC power are connected, the 24 VDC can be used as backup power in case of AC power failure.
Fuse: Unit is 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.
Note: DC Power is not isolated. DC- is connected to Earth Ground. Digital I/O, USB, and Ethernet are grounded.
Environmental: Operating temperature range: -40 to 60°C (-40 to 140°F)
Storage temperature range: -40 to 60°C (-40 to 140°F)
Relative humidity: 0 to 90% non-condensing
*All functions operate down to -40°C (-40°F.) If the LCD response is slower, increase the display refresh setting.
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 (Device) and Type A (Host)
Tightening Torque: Screw terminal connectors: 5 lb-in (0.56 Nm)
Digital I/O terminals: 2.5 lb-in (0.28 Nm)
Enclosure: Enclosure Body: Thermoplastic Polyester, Color: Gray, Display Window: Clear Polycarbonate, GE LEXAN HP12W, Front Panel Keys: Silicone rubber
Panel-Mount: 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: Panel-Mount: 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
Panel-Mount: 7.4 lb (3.4 kg) approx.
Warranty: 3 years parts and labor
4-20 mA Analog InputsNumber 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 full digits (Recommended) ±999,999. More digits may be used, but the stability will be affected. Increase the filter value and display update rate to get a more stable reading.
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: 0.5, 1, 2, 4, 8 sec, IIR: 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: Linear 2-Point, Multi-Point (up to 50 points) Square Root, Programmable Exponent, Scale Factor, Round Horizontal Tank (Volume), None (mA Input Reading)
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
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 InputsNumber 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 High Gate: 4,000 sec
Gate: Low Gate: 1 to 99 sec
High Gate: 2 to 4,000 sec (Must be higher than low gate)
Accuracy: ±1 count for K-Factor > 1 or 30 ppm
K-Factor: Programmable pulses/unit with up to 15 decimal resolution
Scale Pulse Input: Linear 2-Point
Multi-Point Scaling: 2 to 50 points
Modbus InputsNumber of Inputs: 199 Modbus RTU
Scale MB Input: Modbus input may be used as the input for creating channels and totals, the same way 4-20 mA inputs are used.
Data Type: Bit-Logic
Signed/Unsigned: 16 (Short), 32 (Long), 64 (Long-Long)
Float 64 (Double)
Decimal Point: User selectable
Comm Break & Timeout: Specify what value to hold on comm. break 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 value to total).
TotalizerNumber 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 trigger event for non-rate channels.
Reading stored in non-volatile memory, if power is lost.
Maximum Total: 15 digits, 999,999,999,999,999
Rate Channel Input: 4-20 mA input, Pulse input, Modbus input, Digital 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 may be setup to be non-resettable to prevent unintentional reset. This can be changed in the Setup Totals menu.
Total Conversion Factor: Input: Rate channel
Total units may be different than rate units.
Use the Total CF to convert to non-listed units (e.g. Gallons to MGal = 0.000001)
Pulse Input K-Factor: K-Factor = pulses/units of measure
Calculates total directly from pulse input or from rate channel
Decimals: 0 to 15
Count Down: Total may be setup to count down
Preset Value: Enter the preset value to count up or down.
Reset total sets total to the preset value.
Roll-Over: Enter the value for total to roll-over to 0
Negative Total: Allow total value to count below 0 for bi-directional flow based on rate channel
Total Bargraph: Bargraph may 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
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|
|Scale Square Root||Apply square root to a channel|
– Differential Pressure
from two channels
|Scale Exponent||Apply exponent for weirs|
and flumes open channel
|Calculate volume in round|
horizontal tank with flat ends
|Units Conversion||Convert standard units to|
|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|
|Average||Find the average of channels|
|Weighted Average||Assign % weight to two or|
|Multiply||Convert standard units to|
|% Efficiency||Calculate input to output efficiency|
|Percent (Bargraph)||Multiply two|
|On-Off Control||Multiply two|
|Cycle Count||Multiply two|
|Time Since Read||Multiply two|