ConsoliDator™ Multi-Channel Controller Instruction Manual ConsoliDator 8 Features ConsoliDator 4 Features • • • • • • Eight 4-20 mA Inputs Eight 24 VDC @ 20 mA Two 4-20 mA Outputs Four 4-20 mA Inputs Four 24 VDC @ 20 mA Four 4-20 mA Outputs Common Features & Advantages • • • • • • • • Nine 10 A Relays Four Pulse Inputs Four Digital Inputs 90-264 VAC and 8-30 VDC Powered ® RS-232 Modbus RTU Serial Communication Full Graphical 4.75" x 3.
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ConsoliDator Multi-Channel Controller Instruction Manual INTRODUCTION The ConsoliDator is an easy to use multiple-channel controller. It accepts 4-20 mA inputs, flow meter pulse inputs, and digital inputs. It is equipped with multiple relays, which all have user-definable actions, 4-20 mA outputs, and Modbus protocol serial communication capabilities.
ConsoliDator Multi-Channel Controller Instruction Manual TABLE OF CONTENTS INTRODUCTION ----------------------------------------------------------------------- 3 ORDERING INFORMATION -------------------------------------------------------- 3 TABLE OF CONTENTS-------------------------------------------------------------- 4 SPECIFICATIONS--------------------------------------------------------------------- 7 General------------------------------------------------------------------------------------------- 7
ConsoliDator Multi-Channel Controller Instruction Manual Programming Relays ---------------------------------------------------------------------- 28 Supervisory or Summary Alarm Modes --------------------------------------------- 28 High or Low Alarm Modes -------------------------------------------------------------- 29 High or Low Pulse Alarm Modes ----------------------------------------------------- 30 Trigger Alarm Mode ---------------------------------------------------------------------- 32 Annunc
ConsoliDator Multi-Channel Controller Instruction Manual Disclaimer The information contained in this document is subject to change without notice. Precision Digital Corporation makes no representations or warranties with respect to the contents hereof, and specifically disclaims any implied warranties of merchantability or fitness for a particular purpose. All trademarks mentioned in this document are the property of their respective owners.
ConsoliDator Multi-Channel Controller Instruction Manual SPECIFICATIONS Except where noted all specifications apply to operation at +25°C (77°F). General DISPLAY Graphical: 4.75" x 3.5" (121 mm x 89 mm) LCD with backlight 320 X 240 pixels; Numerical: ±999999 DISPLAY UPDATE CALIBRATION PASSWORD 2 seconds (0.5 Hz) All ranges are calibrated at the factory. Programmable password restricts modification of programmed settings and use of manual control functions.
ConsoliDator Multi-Channel Controller Instruction Manual 4-20 mA Analog Inputs ACCURACY ±0.03% of span ±1 count TEMPERATURE DRIFT 50 PPM/°C from 0 to 50°C ambient User selectable from zero to six places with automatic overflow. 4-20 mA, Minimum span of 1 mA DECIMAL POINT INPUT RANGE INPUT IMPEDANCE NORMAL MODE REJECTION TRANSMITTER POWER SUPPLY ENGINEERING UNITS 130 Ω, current limited Greater than 100 dB at 50/60 Hz. Each input is equipped with +24 VDC current limited.
ConsoliDator Multi-Channel Controller Instruction Manual Relays RATING SPDT (form C); rated 10 A @ 120/240 VAC or 5 A @ 28 VDC resistive load; 1/3 HP @ 120/240 VAC for inductive loads.
ConsoliDator Multi-Channel Controller Instruction Manual 4-20 mA Transmitter Outputs OUTPUT RANGE CALIBRATION SCALING RANGE ASSIGNMENT & OPERATION ACCURACY 4.00 to 20.00 mA Factory calibrated for 4-20 mA Any process range. Assign to any analog or pulse input channel for linear scaling or for manually tuned PID control output. TEMPERATURE DRIFT 50 PPM/°C from 0 to 50°C ambient. Output & Input drifts are separate. Self powered or externally powered by 12 to 32 VDC ±0.05% F.S. ±0.
ConsoliDator Multi-Channel Controller Instruction Manual SAFETY INFORMATION ! CAUTION: Read complete instructions prior to installation and operation of the controller. WARNING: Risk of electric shock. WARNING Hazardous voltages present. Installation and service should be performed only by trained service personnel.
ConsoliDator Multi-Channel Controller Instruction Manual INSTALLATION Unpacking Remove the instrument from its box. Inspect the packaging and contents for damage. Report any damages to the carrier. If any part is missing or the controller malfunctions, please contact your supplier or the factory for assistance. Wall Mounting (For PD980 & PD940 Models) • Obtain four #10 screws and nuts. • Prepare four 1/4" holes through mounting surface spaced as shown.
ConsoliDator Multi-Channel Controller Instruction Manual Panel Mounting (For PD981 & PD941 Models) • Obtain four #8 screws (M4.2) and nuts. • Obtain four washers with at least 5/16" O.D. If the device will be subjected to vibration, lock washers are necessary. • Prepare four 1/4" (6.3 mm) clearance holes through mounting surface spaced as shown. • Prepare panel cutout. • 7.37" H x 8.35" W (187 mm x 212 mm) • Center cutout vertically and horizontally with respect to holes.
ConsoliDator Multi-Channel Controller Instruction Manual Connections Connections are made to removable screw terminal connectors and a DB9 male serial connector. They are located around the sides of the controller. ! Use copper wire with 60°C or 60/75°C insulation for all line voltage connections. Observe all safety regulations. Electrical wiring should be performed in accordance with all applicable national, state, and local codes to prevent damage to the instrument and ensure personnel safety.
ConsoliDator Multi-Channel Controller Instruction Manual Input Signal Connections Input signal connections are made to terminal connectors, which are labeled individually on the controller. 4-20 mA Analog Input Connections Analog 4-20 Input connections are made to three-terminal connectors. The following figures show examples for typical applications. Each of the 4-20 mA inputs may be connected in any of the modes shown below.
ConsoliDator Multi-Channel Controller Instruction Manual Flow Meter Pulse Input Connections Flow Meter Pulse Inputs are wired to two-terminal connectors. A square waveform is used in the illustration, but the input is capable of reading many other types of signals within the voltage and frequency ranges specified. FLOW-METER + G Signal Source + Ground Figure 7. Flow Meter Pulse Input Connections Digital Input Connections Digital Inputs are wired to two-terminal connectors.
ConsoliDator Multi-Channel Controller Instruction Manual Analog Output Connections The following figures show examples for 4-20 mA transmitter output connections. Terminal connectors are labeled individually on the side of the case. In order to obtain isolation from analog inputs, outputs must be powered from an external supply as shown in Figure 11. ANALOG OUTPUT +24 LOOP IN LOOP OUT GND + Remote Display, Chart Recorder, etc. Figure 10.
ConsoliDator Multi-Channel Controller Instruction Manual Relay Connections Relay connections are made to three-terminal connectors labeled on the side of the case. RELAY OUTPUT NO - C - NC Figure 12. Relay Connections Switching Inductive Loads The use of suppressors (snubbers) is strongly recommended when switching inductive loads to prevent disrupting the microprocessor’s operation. The suppressors also prolong the life of the relay contacts.
ConsoliDator Multi-Channel Controller Instruction Manual Serial Communication Connections A DB9 male connector is used for Modbus serial communication. RS-232 PORT 3 TRANSMIT REQUEST TO SEND RECEIVE COMMON 7 2 1 Figure 15. Serial Connections External Keypad Connections Normally open pushbuttons may be wired to the six-terminal external keypad connector when the front panel of the controller is not accessible. Keys 1 to 5 refer to the front buttons from left to right.
ConsoliDator Multi-Channel Controller Instruction Manual NAVIGATING AND EDITING The device displays various screens throughout programming and operation. Functions are programmed within their respective menu screens in many cases accompanied by user prompts. Soft-Keys and Buttons The unit is equipped with five buttons located below the display. The function of each button corresponds to its soft-key, which appears at the bottom of the display.
ConsoliDator Multi-Channel Controller Instruction Manual SETUP AND PROGRAMMING • There is no need to recalibrate the instrument when first received from the factory. The device is factory calibrated prior to shipment, for all input types. The calibration equipment is certified to NIST standards. • Overview Setup and programming is done through the front buttons. After power and signal connections have been completed and verified, apply power to the instrument.
ConsoliDator Multi-Channel Controller Instruction Manual Main Setup Menu The main setup menu is the access point for setting up Inputs, Outputs, and General Functions during the programming process. The number of inputs and outputs shown on this screen are determined by the particular model. • To access this menu from the operation screen: Press the SETUP key.
ConsoliDator Multi-Channel Controller Instruction Manual Backlight Settings Selecting [YES] under Save BL automatically turns the backlight off if no buttons are pressed for five minutes. This is recommended unless it is necessary to have the backlight constantly on. When [NO] is selected, the backlight will remain on indefinitely. Modbus Settings Baud Rate: Parity: Modbus ID: Tx Delay: Select any available baud rate. Select EVEN – 8E1 for Even parity, 1 stop bit.
ConsoliDator Multi-Channel Controller Instruction Manual Configuring 4-20 mA Inputs The Analog Input menu is used to configure the 4-20 mA analog inputs. Each has a separate menu. All 4-20 mA inputs can be configured using the information provided in this section. • To access Analog Input menu: Select a channel from the Inputs window in the main setup menu. Analog Input: 1 Input Type: 4-20 mA Transmitter Channel ID: Analog: 1 mA: High Value: 16.00 mA 16.00 Low Value: 4.00 mA 4.
ConsoliDator Multi-Channel Controller Instruction Manual Scaling the 4-20 mA Input High Value Low Value Upper process value corresponding to the high mA level, which appears to the right of the screen. The high mA level may be captured using a live signal source or entered manually if no signal source is present. To set up high mA value using a live signal: • Verify that a signal source is connected to the selected channel and transmitting the high process mA level (e.g. 20.00 mA).
ConsoliDator Multi-Channel Controller Instruction Manual Setting Flow Meter Pulse Inputs The Flow Meter Input menu is used to configure a flow meter pulse input. All pulse input screens offer the same options as described in this section. Options are configured individually for each pulse input. • To access Flow Meter menu: Select a Flow Meter input from the Inputs window in the main setup menu. Flow Meter: 1 State: Channel ID: K Factor: Flow: 1 1000.00 pls / GAL Max Value: 50.
ConsoliDator Multi-Channel Controller Instruction Manual Flow Meter Pulse Input Display Preferences Channel ID Max Value Rate Fmt: Total Fmt Units Display Enter a name for the channel, which appears on the operation screens, and wherever else the channel is referenced. Specify the rate or total maximum. When this level is reached, the channel's bargraph will appear completely filled. Select a position for the rate display decimal point by shifting left or right (zero to five places).
ConsoliDator Multi-Channel Controller Instruction Manual Programming Relays Each relay has an Alarm Setup menu used to program its functions. Functions are programmed individually for each relay except in the case of Lead-Lag mode. Each relay has the same available functions. All relays may be manually overridden. Before the relays are set up, verify that the inputs have been configured. • To access Alarm Setup menu: Select a relay from the Relays window in the main setup menu.
ConsoliDator Multi-Channel Controller Instruction Manual High or Low Alarm Modes High or Low functions are used to turn the relay on and off at selected process points. If it is necessary to have an external reset using a digital input channel or the ACK key select Annunciator High or Low Alarm Modes instead. • • Select [HIGH] from Alarm Mode options to turn relay on (energize) when high set point is reached and off when low reset point is reached.
ConsoliDator Multi-Channel Controller Instruction Manual High or Low Pulse Alarm Modes Pulse Modes are used to generate an on/off continuous pulsing signal. • Select [HIGH: Pulse Mode] from Alarm Mode options to continuously pulse relay when high set point is reached. Pulsing stops when low reset point is reached. • Select [LOW: Pulse Mode] from Alarm Mode options to continuously pulse relay when low set point is reached. Pulsing stops when high reset point is reached.
ConsoliDator Multi-Channel Controller Instruction Manual Set Point Reached Delay ON Pulse Width Pulse Delay Figure 17. Pulse Relay Timing Diagram Example Pulse Mode Scenario: The unit is set to the following: Alarm Mode: [HIGH: Pulse Mode] High Value: [16 mA] Low Value: [10 mA] Delay ON: [2 sec] Delay OFF: [3 sec] Pl. Width: [1 sec] Pl. Delay: [2.5 sec] The following describes operation based on the above settings: 1. The process reaches 16 mA: 2 seconds pass with no relay action. 2.
ConsoliDator Multi-Channel Controller Instruction Manual Trigger Alarm Mode • Select Trigger mode to pulse the relay once each time the total from a flow meter pulse input channel is incremented by a certain value. Alarm Setup: 1 Alarm Mode: Channel: Set Point: Pl Width: Trigger [A] Flow: 1 10.00 GAL 1.0 sec EDIT Channel Set Point Pl. Width EXIT Assign the relay to any flow meter pulse input. Enter process variable set point.
ConsoliDator Multi-Channel Controller Instruction Manual Annunciator High or Low Alarm Modes The Annunciator functions are similar to High or Low Alarm Modes except for the addition of a reset capability from the ACK key, a digital input channel (normally open pushbutton switch), or External Key 4. • Select [ANNUNCIATOR: HIGH] from Alarm Mode options to turn relay on (energize) when high set point is reached and off when low reset point is reached.
ConsoliDator Multi-Channel Controller Instruction Manual Plunger Lift by Differential Pressure Mode • Select [PLUNGER LIFT: DP] from Alarm Mode options to operate a plunger lift system that monitors differential pressure. Alarm Setup: 1 Alarm Mode: PLUNGER LIFT: DP Tubing Ch: [A] Flow: 1 Casing Ch: [2] Analog: 2 Switch Ch: [1] Reed SW: 1 Set Point: 100.00 GPM Delay ON: 1.
ConsoliDator Multi-Channel Controller Instruction Manual Plunger Lift by Time Mode • • Select [PLUNGER LIFT: TIME] from Alarm Mode options to operate a plunger lift system based on time by specifying the on and off durations in the cycle. This mode may also be used as a timer to cycle the relay on and off. Alarm Setup: 1 Alarm Mode: PLUNGER LIFT: TIME Rly On/Off: OFF Time ON: 1.0 min Time OFF: 5.
ConsoliDator Multi-Channel Controller Instruction Manual Lead-Lag Modes (Pump Alternation Control) Lead-Lag Modes are similar to High or Low Alarm Modes except up to nine relays may be linked to operate in sequence. This mode is commonly used for pump alternation control. For example: If relays #1, #2, and #3 are linked in this menu, relay #1 turns on the first time the set point is reached and off when the reset point is reached, relay #2 cycles the second time, and relay #3 cycles the third time.
ConsoliDator Multi-Channel Controller Instruction Manual Lead-Lag Override Function Lead-Lag mode supports an override function, which allows up to five linked relays to turn on if programmed points are reached. Override set points also operate in sequence. They are not assigned to particular relays. • Use OVER key in Lead-Lag menu to access override menu. Lead-Lag Override: 1 Over Type: Override 1 & 2 ON Set Pt. #1: 170.0 GAL Set Pt. #2: 180.0 GAL EDIT Over Type Set Pt.
ConsoliDator Multi-Channel Controller Instruction Manual Linear Pulse Width Modulation Mode Linear PWM Mode is used to create an on/off pulse signal with a modulated duty cycle. In this mode the percentage of the relay cycle in which the relay is in the on state varies with relation to the process value. See Figure 18 for an example showing that the cycle time (period) remains the same, but the relay-on percentage of the cycle changes with the process value.
ConsoliDator Multi-Channel Controller Channel 100% Value 0% Value Cycle Time Instruction Manual Assign the relay to any analog or pulse input. Enter the process value at which the pulse width will be 100% of cycle. Enter the process value at which the pulse width will be 0% of cycle. Enter the period for 1 cycle (maximum 6550 sec). A.
ConsoliDator Multi-Channel Controller Instruction Manual Proportional Plus Integral Pulse Width Modulation Mode PWM PI Control Mode is used to create an on/off pulse signal with a duty cycle modulated by the proportional integral settings. In this mode the percentage of the relay cycle in which the relay is in the on state varies with relation to the process value feedback and the PI settings.
ConsoliDator Multi-Channel Controller Instruction Manual Setting 4-20 mA Outputs The Analog Output menu is used to configure the 4-20 mA outputs. Each output has a separate screen. All 4-20 mA outputs can be configured using the information provided in this section. • To access Analog Output menu: Select an analog output from the Outputs window in the main setup menu. Linear Scaling of 4-20 mA Output • Select [LINEAR] from Mode options to set the analog output for a linear scale from 4 to 20 mA.
ConsoliDator Multi-Channel Controller Instruction Manual PID Control Using 4-20 mA Output To set the analog output for PID control, select [PID CONTROL] from Mode options. Analog Output: 1 Mode: PID CONTROL Set-point: Feedbk Ch: 8.00 mA [1] Analog: 1 Prop. Gain: 32.0 Int. Time: 0.1 sec / rpt Deri. Time: 0.0 sec Cycle Time: 1.0 sec Int. Limit: 1.0 % Inc / Dec: % Increasing EDIT Set Point Feedbk Ch Prop. Gain Int. Time Deri. Time Cycle Time Int.
ConsoliDator Multi-Channel Controller Instruction Manual OPERATION The instrument displays various screens showing bargraphs, numerical values, and relay status throughout operation. For information on general button functions, see NAVIGATING AND EDITING section on page 20. • Press the VIEW key to scroll through multiple and individual channel operation screens. Multiple Channel Operation Screen Below is an example of what a multiple channel operation screen may look like for a four input application.
ConsoliDator Multi-Channel Controller Instruction Manual Single Analog Input Operation Screen For each analog input channel, there is a detailed individual channel operation screen, which shows a bargraph with relay set points, numerical values, sensor input, and relay status for the relays assigned to that particular channel. 100 ft Ch 1: 87.5 H2 L2 H3 L3 ft Sensor In: 18.000 mA Rly: 2: 3: Low: 40.0 8.0 High: 50.0 OFF 20.
ConsoliDator Multi-Channel Controller Instruction Manual Single Flow Meter Pulse Input Operation Screen For each flow meter pulse input channel, there is a detailed individual channel operation screen, which shows a bargraph with relay set points, numerical values for rate and total, and relay status for the relays assigned to that particular channel. This screen may also be set to show a bargraph for rate rather than total. See Flow Meter Pulse Input Display Preferences section on page 27.
ConsoliDator Multi-Channel Controller Instruction Manual Digital Input Operation Screen The Digital Input screen shows the states of the digital inputs. ON is shown when a switch connected to the input is closed or when an open collector transistor is conducting. OFF is shown when the switch is open or when the open collector transistor is not conducting.
ConsoliDator Multi-Channel Controller Instruction Manual Manual Relay Control Use the Manual Mode menu to manually override relays by pressing ON or OFF keys while the relay is selected. The screen also displays the total time the relay has spent in the ON state and how many times the relay has cycled from OFF to ON. Hours and cycles may be returned to zero individually for each relay by pressing RESET while that relay is selected. If a password has been set, this menu is restricted.
ConsoliDator Multi-Channel Controller Instruction Manual MODBUS® SERIAL COMMUNICATION The controller is equipped with serial communication capability as a standard feature. The ConsoliDator can be connected to Data Circuit-Terminating Equipment (DCE) such as a radio transmitter with a regular straight-through serial cable. In other cases where connecting to Data Terminal Equipment (DTE), such as a PC, a NULL Modem cable and gender adapter may be necessary.
ConsoliDator Multi-Channel Controller Instruction Manual Modbus Register Tables Table 1. Analog Input Channels Register Addresses Address (offset from 40000) Ch. 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 Ch. 2 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 Ch. 3 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 Ch.
ConsoliDator Multi-Channel Controller Instruction Manual Table 2. Flow Meter Pulse Input Channels Register Addresses Address (offset from 40000) Ch. 1 261 262 263 264 265 266 267 268 269 270 271 Ch. 2 291 292 293 294 295 296 297 298 299 300 301 Ch. 3 321 322 323 324 325 326 327 328 329 330 331 Ch.
ConsoliDator Multi-Channel Controller Instruction Manual Table 4. Relay Channels Register Addresses Address (offset from 40000) Rly. 9 Description Rly. 1 Rly. 2 Rly. 3 Rly. 4 Rly. 5 Rly. 6 Rly. 7 Rly.
ConsoliDator Multi-Channel Controller Instruction Manual Table 5. Analog Output Channels Register Addresses Address (offset from 40000) Description Data Type 4 mA Value Floating Point 20 mA Value Floating Point Set point Value Floating Point PID Output Value Floating Point 862 Output Type Input Ch. PID KP PID KI PID KD PID Cycle Time Byte Byte Integer Integer Integer Integer 863 PID I Band Integer 864 PID Direction Integer Ch.
ConsoliDator Multi-Channel Controller Instruction Manual Overall Dimensions 8.75" (222mm) 3.0" (76mm) 8.0" (203mm) Figure 19. PD980 & PD940 Overall Dimensions 9.36" (238mm) 8.66" (220mm) 7.16" (182mm) 3.10" (79mm) 7.86" (200mm) Figure 20.
ConsoliDator Multi-Channel Controller Instruction Manual TROUBLESHOOTING TIPS Symptom No display, or only backlight is visible, but outputs still function normally “NO SENSORS FOUND” is displayed, but sensors are connected and transmitting Display response seems slower than normal Display locks up or the instrument does not respond at all Settings reprogrammed, but instrument behavior remains as previously programmed Check/Action 1. Contrast is too light: Adjust contrast in main setup menu. 2.
ConsoliDator Multi-Channel Controller Instruction Manual OTHER PRECISION DIGITAL PRODUCTS Model PD118 PD141AFO PD602 PD644 PD650 PD655 PD656 PD660 PD661 PD673 PD675 PD680 PD685 PD686 PD687 PD690 PD691 PD693 PD694 PD696 PD697 PD698 PD740 PD750 PD755 PD756 PD757 PD765 PD865 PD540 Series PD550 Series PD560 Series PD570 Series Description MINIMUX® 8 Point Scanner VIGILANTE® four Point Annunciator with First-Out Dart Low-Cost 1/8 DIN Process Meter Javelin D Volt Meter 0-300 VDC 2.
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