Precision Digital ConsoliDator+ is a multi-channel controller that is both easy to use and satisfies various 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 bar graph 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.
The ConsoliDator+ takes full advantage of its color display by allowing the user to customize screen colors for bar graphs, alarm conditions, and input channels.
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 px) 5.7″ (145 mm)
Sunlight Readable Display, White Backlight
Isolated 24 VDC Transmitter Supplies 200 mA / Analog Input; 1,600 mA Max
64 High & Low Alarms, Combine Multiple Alarms Into Logic AND & OR Alarms
Simulation & Manual Control Modes for Testing Setup
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)
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
Multi-Pump Alternation Control or Simple On / Off Control
Programmable Displays, Function Keys & Digital Inputs
Math Functions: Sum, Diff, Average, Multiply, Divide, % Efficiency, & More
Direct Modbus PV Inputs – Slave Mode
Customize Modbus Outputs to Read Multiple Registers in One Block
RS-485 Serial Communication with Modbus RTU
Field Selectable Input Power: 85-264 VAC or 24 VDC
(20) Screens with up to Eight PVs Each
Automatic or Manual Scanning
ConsoliDator+ Configuration Software
NEMA 4 Field Mount Enclosure Accessory
Light / Horn & Control Station Accessory for Remote Operation
Display: Color; QVGA (320×240 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. 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 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) 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 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 Day & Time: Select day of the week & time Alarm OR: Any active input alarm triggers the OR alarm Alarm AND: All alarms must be active to trigger the AND alarm Alarm Ack & Reset: Automatic only (Non-latching) Automatic and manual Manual only (Latching) Manual with Ack only after alarm is cleared (Latching with Clear) Alarm Indication: 1. Bargraph, panel, and text can be set up to change color on alarm 2. Enable internal buzzer 3. Assign external relay to drive a horn Internal Buzzer: 60 dBA @ 24 inches (61 cm) Enable/disable in System – General menu. Associated with alarm Horn setting External Horn (Sold separately): Assign any relay to the Horn function to activate an external horn when alarm condition is detected. Live Channel Calibration: Live calibration of channels is independent of the input calibration used for scaling. Input & Output Cards: Max Number of I/O Cards: 7, Analog Inputs: 4/card, Pulse Inputs: 4/card, Analog Outputs: 5/card, Relays: 5/card Number of Screens: Up to 20 screens with 1 to 8 PVs or items per screen. Enable or disable screen title, channel #, and bargraph Automatic or manual scanning Scan time: 1 to >1000 sec, independent for each screen. F1-F4 keys are assigned per screen Function Keys: User programmable (See defaults below) F1 = Previous ← F2 = Next → F3 = Scan/Stop F4 = Ack Number of Channels Up to 99 channels Input Source: 4-20 mA, Pulse, Digital, Modbus, another Channel, Total, Timer, Alarm, Date & Time, mA Output, Relay Output, Digital Output, or Modbus Output 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 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 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. 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 AC power failure. Note: DC supply must be less than 24 VDC; otherwise the system runs on DC power. 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. 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 (Device), cable included. 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 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. Warranty: 3 years parts and labor
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 may be setup 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 may be different than rate units. Use the custom units to convert to any unit (e.g. Gallons to MGal: Factor = 0.000001) Pulse Input K-Factor: K-Factor = pulses/units of measure Calculates total directly from pulse input, digital input, or Modbus input. Create rate channel by entering K-Factor, units and time base in sec, min, hr, or day. Decimals: 0 to 15 Count Down: Total may be setup 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 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
Real Time Clock
Date Format: Month, day, year (e.g. July 16, 2020) Time Format: 24 hour; 00: Midnight hh:mm:ss Battery: 3 V, P/N: CR2032 included 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
Converts number of pulses to volume or other units
Apply multiplier to a channel
Scale Linear 2-Pt
Scale a channel
Multi-point scaling of a channel
Scale Square Root
Apply square root to a channel – Differential Pressure from two channels
Apply exponent for weirs and flumes open channel flow calculation
Round Horizontal Tank
Calculate volume in round horizontal tank with flat ends
Convert base units to any units
Assign fixed value
Add two or more channels
Subtract any two channels
Difference always positive
Convert channel value to positive
Find the average of channels
Assign % weight to two or more channels
Multiply two channels
Divide two channels
Calculate input to output efficiency ((A-B)/A)*100%
Greatest value in a group of channels
Smallest value in a group of channels
Calculate net value when Tare function is applied via function key
Maximum value reached by the process
Minimum value reached by the process
% bargraph of any: 4-20 mA input, channel, total, timer, or mA output
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
Enter time to calculate the average
IIR (First Order)
Infinite Impulse Response (slow)
PV = 0 below cutoff Flip Side: 0 above (-)
Sets PV’s upper & lower limits
Uses channel to trigger relay sample and select sampling time (e.g. Turn relay on for 30 sec every time total increases by 1,000 Gallons)
Set on & off control based on process value
Select A or B
Switch between 2 inputs
Daily or weekly event
Number of relay cycles since reset
Relay runtime (ON) hh:mm:ss
Time Since Read
Time since a Modbus master device read a register
Time Since Write
Time since a Modbus master wrote to a register
List of Engineering Units
None: No 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, 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, onces, 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 full digits, (Recommended) ±999,999 More digits may be used, but the stability will be affected. Increase the filter value and lower the 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) Channel Input Live Calibration: Each channel may be calibrated using live calibration signal from a sensor or a calibrator. Input Protection: Each 4-20 mA input is protected by an auto-resettable fuse, 30 VDC max. The fuse resets automatically after the fault condition is removed. Input Impedance: 125 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
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) 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 Live Calibration: Pulse input channel may be calibrated using live calibration signal from a sensor.
Number of Inputs: 199 Modbus RTU Scale MB Input: Modbus input may be used to create 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 32 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).
Digital Inputs & Outputs
Digital Inputs: 5 Inputs, non-isolated, 30 VDC max Standard feature on all ConsoliDator+ skus 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 may be used as digital inputs Digital Input Types: Normally open switch: External excitation not required (Current: 1 mA) Open collector transistor: 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+ skus 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
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 10 A @ 120/240 VAC or 8 A @ 30 VDC Inductive load: NO contacts: 1/3 HP, 120 VAC; 30,000 cycles NC contacts: 1/8 HP, 120 VAC; 50,000 cycles Minimum load: 100 mA @ 5 VDC 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 may be assigned to any alarm, channel, total, timer, digital input, Modbus input, pump alternation, horn, always on, or always off. Multiple relays may 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 may be setup to alternate with any relay in the group. Multiple alternation groups may be setup. Acknowledge: Front panel Ack key or digital input acknowledges alarms; relays associated with acknowledged alarm are turned off. Acknowledge all or any alarm. Alarm Relay: Assign any relay to be driven by any alarm; acknowledging the alarm turns off the relay (non-fail-safe mode). Time Delay: Programmable on/off delays, 0.0 to 999.9 sec Independent for each relay. Auto Initialization: When power is applied to the controller, relays will reflect the input’s state 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 or 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.
Number of Timers: Up to 32 Time Format: hh:mm:ss with 0 decimals selected Seconds with 1 or more decimals2 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 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® Serial Communications
Compatibility: RS-485 (EIA-485) Protocol: Modbus RTU Device Address: 1 to 247 Transmit Delay: 0 to 99 ms 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
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: Download the Lantronix DeviceIntaller software to configure the Ethernet port at https://www.lantronix.com/products/xport/
System Requirements: Windows® 7, 10 Compatibility: One software version for all skus Connection: Micro-USB Configuration: Configure inputs and outputs, channels, totals, timers, alarms, etc. Configure bar graph 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.
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
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 sku PD9000-GP-4PI-8AI-10AO-10RY looks like. This sku 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+ skus. 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 slave only: (35) 4-20 mA outputs, (30) 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+ skus 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-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.
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.
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.
Note: The controller may be powered by AC voltage with the 24 VDC power connection used as backup power.
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.
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 input connector 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 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.
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
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.
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.
External Keypad Connections
Units: Inches (mm)
Panel Mount ConsoliDator+ Overall Dimensions
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.