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PRECISION DIGITAL CORPORATION 

 

 

ConsoliDator

®

 

Multi-Channel Controller 

Instruction Manual 

 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 

ConsoliDator 8 

ConsoliDator 4 

 

Eight 4-20 mA Inputs  

 

Four 4-20 mA Inputs 

 

Eight 24 VDC @ 20 mA 

 

Four 24 VDC @ 20 mA 

 

Two 4-20 mA Outputs 

 

Four 4-20 mA Outputs 

 

Features and Highlights 

 

Nine Form C 10 A Relays 

 

Powered from AC or DC 

 

Four Pulse Inputs 

 

32-Point Linearization 

 

Four Digital Inputs 

 

RS-232 Modbus

®

 RTU 

 

Panel or wall mount 

 

Square Root Function 

 

Sum and Difference 
Functions 

 

FREE Programming & 
data logging software 

PC 

Software 

Included!

www.calcert.com

[email protected]

1.800.544.2843

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Содержание ConsoliDator PD940-8K9-15

Страница 1: ...0 mA Two 4 20 mA Outputs Four 4 20 mA Outputs Features and Highlights Nine Form C 10 A Relays Powered from AC or DC Four Pulse Inputs 32 Point Linearization Four Digital Inputs RS 232 Modbus RTU Panel or wall mount Square Root Function Sum and Difference Functions FREE Programming data logging software PC Software Included www calcert com sales calcert com 1 800 544 2843 0 5 10 15 20 25 30 ...

Страница 2: ...nties of merchantability or fitness for a particular purpose All trademarks mentioned in this document are the property of their respective owners Copyright 2009 2017 Precision Digital Corporation This document contains ratings and requirements necessary for proper installation Distribution of modified versions is strictly prohibited Any text chart diagram or table reproduced must be reproduced in...

Страница 3: ...solated Converter PDA8485 N USB to RS422 485 Non Isolated Converter PDA9232 01 ConsoliDator Null Modem Cable PDA9232 02 RS 232 Computer Cable Setup Programming Services Part Number Description PDN CSETUP2 Custom Setup Programming PDN CERTCAL Certificate of Calibration PDN CERTCAL2 Certificate of Calibration with Data J1 INPUT J2 OUTPUT J3 INPUT J4 INPUT J5 RELAY J7 POWER J6 RELAY J8 RELAY NO NC C ...

Страница 4: ...20 mA Analog Input Connections 15 Flow Meter Pulse Input Connections 16 Digital Input Connections 16 Analog Output Connections 17 Note All inputs and outputs share a common ground DO NOT power inputs and outputs with the same power supply Relay Connections 17 Switching Inductive Loads 18 Serial Communication Connections 19 Serial Communication Using RS 422 485 19 External Keypad Connections 19 NAV...

Страница 5: ...ode 34 Annunciator High or Low Alarm Modes 34 Plunger Lift by Differential Pressure Mode 35 Plunger Lift by Time Mode 35 Lead Lag Modes Pump Alternation Control 36 Linear Pulse Width Modulation Mode 38 Proportional Plus Integral Pulse Width Modulation Mode 39 Setting 4 20 mA Outputs 40 Linear Scaling of 4 20 mA Output 40 PID Control Using 4 20 mA Output 40 OPERATION 41 Manual and Simulation Modes ...

Страница 6: ... Input From Live Signal 16 Figure 10 4 20 mA Output Powered by ConsoliDator 17 Figure 11 4 20 mA Output Powered by External Supply 17 Figure 12 Relay Connections 18 Figure 13 AC and DC Loads Protection 18 Figure 14 Low Voltage DC Loads Protection 18 Figure 15 Serial Connections 19 Figure 16 External Keypad Connections 20 Figure 17 Linear Response Graph 25 Figure 18 Square Root Response Graph 26 Fi...

Страница 7: ...nd relays to 1500 VAC Isolation to 500 VAC between analog inputs and analog outputs requires powering analog outputs with external supply Signal and output power grounds are connected to earth chassis ground DC Power not isolated ENVIRONMENTAL Operating temperature range 0 to 50 C 32 to 122 F Storage temperature range 40 to 60 C 40 to 140 F Relative humidity 0 to 90 non condensing All functions op...

Страница 8: ... count for K Factor 1 SIGNAL RANGE 100 mVp p to 15 Vp p 1 Hz to 10 kHz K FACTOR Programmable from 0 00001 to 999999 pulses unit DISPLAY OPTIONS Rate and total values displayed on screen Bargraphs user selectable to indicate either total or rate ENGINEERING UNITS Show Total Rate combinations GAL GPS GAL GPM GAL GPH GAL GPD MG MGD BBL BPH BBL BPD LTR LPs LTR LPM LTR LPH LTR LPD CF CFS CF CFM CF CFH ...

Страница 9: ...ntering alarm state Supervisory Alarm Use to indicate CPU failure or analog input signal loss High or Low Pulse Action Assign to analog or pulse input channel for pulsing on off timed relay control Programmable pulse width and delay Trigger Assign to pulse channel for indication of user defined total increment Programmable for scaled pulse output Plunger Lift Assign to analog and or pulse channels...

Страница 10: ...t to input when powered by external supply Modbus Serial Communications COMPATIBILITY EIA 232 PROTOCOL Modbus RTU DEVICE ADDRESS Programmable between 1 and 247 TRANSMIT DELAY Programmable between 0 and 300 ms BAUD RATE Programmable from 1200 to 38400 DATA 8 bit 1 start bit 1 stop bit PARITY EVEN NONE with 1 stop bit or NONE with 2 stop bits ConsoliDator Software SYSTEM REQUIREMENTS Windows 95 98 M...

Страница 11: ...ad 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 www calcert com sales calcert com 1 800 544 2843 0 5 10 15 20 25 30 ...

Страница 12: ...the factory for assistance Wall Mounting For PD980 PD940 Models Obtain four 10 M5 screws and nuts Prepare four 1 4 6 mm holes through mounting surface spaced as shown Allow at least 2 5 mm of free space on all sides so that the removable screw terminals and DB9 connector may be accessed for wiring Secure instrument to surface 7 25 184 mm 8 00 203 mm Dia 0 25 6 mm 4 places Figure 1 Wall Mount Dimen...

Страница 13: ...1 4 6 mm clearance holes through mounting surface spaced as shown Prepare panel cutout 8 35 W x 7 37 H 212 mm x 187 mm Center cutout vertically and horizontally with respect to holes Maximum allowable inner radii 0 1 2 5 mm Remove all connectors Insert controller and secure to surface PANEL 4 CLEARANCE HOLES Dia 0 25 6 mm 8 16 207 mm 8 86 225 mm CUTOUT Figure 2 Panel Mount Dimensions PD981 PD941 w...

Страница 14: ...er 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 CONNECT ONLY ONE OF THE POWER INPUTS 120 250 VAC Power 90 VAC min 264 VAC max Use three terminal power connector as shown in Figure 3 Unit is protected internally 5 A max slow blow 250 V min UL Recognized external fuse recommended 8 30 VDC Power Use ...

Страница 15: ...s may be connected in any of the modes shown below External Power Supply 2 Wire 4 20 mA Transmitter ANALOG INPUT 2 Wire 4 20 mA Self Powered Transmitter GND GND ANALOG INPUT Figure 4 Transmitter Powered by Ext Supply or Self Powered GND 2 Wire 4 20 mA Transmitter ANALOG INPUT 3 Wire 4 20 mA Transmitter Signal ANALOG INPUT GND Figure 5 Transmitters Powered by ConsoliDator 3 Wire 4 20 mA Transmitter...

Страница 16: ...Digital Inputs are wired to two terminal connectors Normally open switch contacts may be used as shown in Figure 8 Figure 9 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 Figure 9 will be interpreted as ON ...

Страница 17: ... powered from an external supply as shown in Figure 11 Remote Display Chart Recorder etc ANALOG OUTPUT 24 LOOP IN LOOP OUT GND Figure 10 4 20 mA Output Powered by ConsoliDator Remote Display Chart Recorder etc ANALOG OUTPUTS 24 External Power Supply LOOP IN LOOP OUT GND Figure 11 4 20 mA Output Powered by External Supply Note All inputs and outputs share a common ground DO NOT power inputs and out...

Страница 18: ...Loads Protection Choose R and C as follows R 0 5 to 1 for each volt across the contacts C 0 5 to 1 µF for each amp through closed contacts Notes 1 Use capacitors rated for 250 VAC 2 RC networks may affect load release time of solenoid loads Check to confirm proper operation 3 Install the RC network at the instrument s relay screw terminals An RC network may also be installed across the load Experi...

Страница 19: ...vironments RS 422 and RS 485 offer superior performance compared to RS 232 Differential signals can help nullify the effects of ground shifts and induced noise signals that can appear as common mode voltages on a network RS 422 was designed for greater distances than RS 232 In its simplest form a pair of converters from RS 232 to RS 422 and back again can be used to form an RS 232 extension cord D...

Страница 20: ...n screen as an arrowhead The keys below are used to navigate through menus and edit settings Other special keys appear throughout the programming process Key Action ACK Acknowledge relay s EDIT Modify selection ENTER Execute current selection EXIT Quit present screen or mode MANUAL AUTO Toggle operation modes RST Reset total SAVE Store setting to memory SETUP Enter main setup menu SIM Enter simula...

Страница 21: ...uts outputs and relays are configured individually It is recommended that all inputs be configured before outputs and relays are programmed Shown to the right is a typical screen that appears upon first power up Actual screens will vary with the amount of inputs initially detected For information on button functions see NAVIGATING AND EDITING page 20 To load software and program from a PC please f...

Страница 22: ...ming Relays page 31 and Setting 4 20 mA Outputs page 40 General Functions The General Functions box contains various options and serial communication settings If you are beginning a first time setup please read the brief descriptions below and if you are not sure of the settings you may skip them and return after the controller s operation is explained in later sections Use the arrows keys to move...

Страница 23: ...n NO is selected the backlight is always on Baud Rate Select any available baud rate Parity Select EVEN 8E1 for Even parity 1 stop bit Select NONE 8N2 for None parity 2 stop bits Select NONE 8N1 for None parity 1 stop bit Modbus ID Specify an address for Modbus communication Tx Delay Specify a serial data transmission delay response Place cursor at the channel you want to set and press ENTER www c...

Страница 24: ...cursor to Channel ID and press EDIT Use arrow keys to scroll through characters and move to the next position Press SAVE to store new setting to memory Next set display options Move cursor to Configure Display Parameters and press ENTER The box that appears contains the parameters for decimal point engineering units and bargraph extents for this channel Use EDIT and arrow keys Remember to press SA...

Страница 25: ...aph in Figure 17 shows the display response based on example scaling parameters For this mode select Linear from Function options then follow Sensor Input Setup page 29 to enter your scaling parameters Process Scaling Parameters Input mA Display High Value 100 00 Low Value 0 00 4 00 0 00 Sensor 20 00 Sensor 4 00 5 00 6 25 Linea r Response 0 00 20 00 40 00 60 00 80 00 100 00 4 00 8 00 12 00 16 00 2...

Страница 26: ...Parameters Press EDIT and use arrow keys to change the value Press SAVE when complete Follow Sensor Input Setup page 29 to enter your scaling parameters Note An input that goes below the Low Value parameter results in a display of 999999 indicating underrange condition This can be prevented using the cutoff feature Process Scaling Parameters Input mA Display High Value 100 00 Low Value 0 00 4 00 0...

Страница 27: ...the cutoff value the controller will display 0 To enter a cutoff value select Configure Function Parameters Press EDIT and use arrow keys to change the value Press SAVE when complete Follow Sensor Input Setup page 29 to enter your scaling parameters Note An input that goes below the Low Value parameter results in a display of 999999 indicating underrange condition This can be prevented using the c...

Страница 28: ...wn display Difference mode follows the same link principle but subtracts one or more channels from itself During operation the channel that is used to set up the link is the one that displays the sum or difference Verify the appropriate channel has been selected i e To display a summation for Channel 1 plus another channel make sure you are in Analog Input 1 setup screen Remember to scale the othe...

Страница 29: ...ss EDIT Use the arrows to enter a process value associated with a low sensor point Press SAVE 3 Move cursor to High Value and press EDIT Use the arrows to enter a process value associated with a high sensor point Press SAVE 4 Next enter the Sensor points corresponding to the process values entered in 2 3 for example 4 00 mA and 20 00 mA To read a live signal corresponding with the process value fo...

Страница 30: ...ecify the rate or total maximum When this level is reached the channel s bargraph will appear completely filled Rate Fmt Select a position for the rate display decimal point by shifting left or right zero to five places Total Fmt Select a position for the total display decimal point by shifting left or right zero to five places Units Select from any available unit combinations for flow Display Set...

Страница 31: ...other relay enters alarm state 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 p...

Страница 32: ...linked channel and off when all linked channels are above reset point Alarm Setup 1 Alarm Mode HIGH Multi Chan High Value 160 0 GAL Low Value 8 0 GAL Delay ON 1 0 sec Delay OFF 0 5 sec Link Channels 1 2 3 4 5 6 7 8 EDIT EXIT ON Channel Assign the relay to any analog or pulse input High Value Enter high process variable set reset point Low Value Enter low process variable set reset point Delay ON E...

Страница 33: ...nt is reached and the pulse signal stops Pl Width Enter pulse duration Energized relay Pl Delay Enter duration between pulses De energized relay Over Enter override menu to override the channel alarm settings Pulse Width Pulse Delay Delay ON Set Point Reached Figure 20 Pulse Relay Timing Diagram Example Pulse Mode Scenario The unit is set to the following Alarm Mode HIGH Pulse Mode High Value 16 m...

Страница 34: ...tch 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 Select ANNUNCIATOR LOW from Alarm Mode options to turn relay on when low set point is reached and off when high reset point is reached Alarm Setup 1 Alarm Mode ANNUNCIATOR HIGH Channel A Flow 1 High Value 16 00 GPM Low Value 8 00 GPM...

Страница 35: ...ble point at which the relay closes a valve The point may either be differential pressure or flow from a turbine meter Delay On Enter the time between when the set point is reached and the relay turns on energizes After Flow Enter a time long enough to guarantee that the plunger will fall to the bottom of the well Plunger Lift by Time Mode Select PLUNGER LIFT TIME from Alarm Mode options to operat...

Страница 36: ...hen low set point is reached and off when high reset point is reached Alarm Setup 1 Alarm Mode LEAD LAG HIGH Channel TANK 1 High Value 160 0 GAL Low Value 8 0 GAL Delay ON 1 0 sec Delay OFF 0 5 sec Link Relays 1 2 3 4 5 6 7 8 9 EDIT EXIT ON OVER Note Linked relays must be set to OFF in their respective menus i e If Alarm Setup 1 links Relay 2 Alarm Setup 2 must read Alarm Mode OFF Channel Assign t...

Страница 37: ...High Value is set at 160 0 GAL and Low Value is set at 8 0 GAL In the Override Menu Over Type is set to Override 1 2 ON Set Pt 1 is set to 170 0 GAL and Set Pt 2 is set to 180 0 GAL When the input reaches 160 0 GAL the first relay in the sequence Relay 1 turns on When 170 0 GAL is reached the next relay Relay 2 turns on If at this point the input decreases and drops below 8 00 GAL both relays will...

Страница 38: ...at which the pulse width will be 100 of cycle 0 Value Enter the process value at which the pulse width will be 0 of cycle Cycle Time Enter the period for 1 cycle maximum 6550 sec Note 1 Due to the life expectancy of mechanical relays it is strongly recommended that cycle times be as long as possible many minutes Using a cycle time of less than a few minutes can wear out a relay and cause faulty op...

Страница 39: ...ocess target Feedbk Ch Select an analog input to supply the feedback signal from the system Prop Gain Enter the proportional gain expressed as a percentage Int Time Enter the integral time expressed as seconds per repeat Cycle Time Enter the PI calculation cycle time Low number for fast responding systems high number for slow responding systems Rly Period Enter a relay period Int Limit Specify the...

Страница 40: ... Output 4 mA Val Enter the low process level that will result in a 4 mA signal transmission 20 mA Val Enter the high process level that will result a 20 mA signal transmission 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 8 00 mA Feedbk Ch 1 Analog 1 Prop Gain 32 0 Int Time 0 1 sec rpt Deri ...

Страница 41: ...ys the current state of the relay the total time the relay has spent in the ON state and how many times the relay has cycled from OFF to ON In Manual mode this screen allows for overriding the relays and resetting the Hours and Cycles counts This is discussed further in Manual Relay Control page 45 Relay Status Hours Cycles Relay 1 ON 10 2 320 Relay 2 OFF 215 0 566 Relay 3 OFF 197 6 512 Relay 4 ON...

Страница 42: ...o the next operation screen 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 ft Sensor In 18 00 mA Rly Low High 2 40 0 50 0 ON 3 8 0 20 0 ON H2 L2 H3 L3 0 ft SETUP AU...

Страница 43: ...tricted ACK Use to acknowledge reset the relays assigned to Supervisory Summary or Annunciator Alarm functions and to silence the buzzer NEXT Use this key to scroll to the next operation screen 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 O...

Страница 44: ...ricted ACK Press to acknowledge reset the relays assigned to Supervisory Summary or Annunciator Alarm functions and to silence the buzzer NEXT Press to scroll to the next operation screen Flow Meter Numeric Screen To the right is an example of a flow meter numeric summary screen It shows a box for each flow channel with the input frequency flow and total Note The total is displayed as the engineer...

Страница 45: ...s Automatic mode You may choose to disable outputs while reprogramming by entering Manual mode Manual Relay Control To the right is an example of a Manual Relay Control screen as it appears in Manual mode The screen displays the current state of the relay the total time the relay has spent in the ON state and how many times the relay has cycled from OFF to ON In Manual mode this screen allows for ...

Страница 46: ...nsoliDators are adjusted at the factory for optimal viewing If additional adjustment is needed use the contrast adjustment potentiometer located on the left side of the case next to the DC POWER connector Contrast Adjust Control www calcert com sales calcert com 1 800 544 2843 0 5 10 15 20 25 30 ...

Страница 47: ...5 and send either the ON or OFF to the appropriate alarm relay 1 9 The ConsoliDator can also work as a MODBUS Display by setting the desired analog input channel to the FIXED type and then over MODBUS change the K Factor Modbus Display value for the corresponding channel This input type is transparent to the rest of the functions of the unit i e relays etc The value once the EEPROM save command is...

Страница 48: ...ar 6 Byte 23 55 87 119 151 183 215 247 Ch ID Char 7 Byte 24 56 88 120 152 184 216 248 Ch ID Char 8 Byte 25 57 89 121 153 185 217 249 Ch ID Char 9 Byte 26 58 90 122 154 186 218 250 Ch ID Char 10 Byte 27 59 91 123 155 187 219 251 Units Character 1 Byte 28 60 92 124 156 188 220 252 Units Character 2 Byte 29 61 93 125 157 189 221 253 Units Character 3 Byte 1523 1547 1571 1595 1619 1643 1667 1691 Funct...

Страница 49: ...5 Byte 280 310 340 370 Ch ID Character 6 Byte 281 311 341 371 Ch ID Character 7 Byte 282 312 342 372 Ch ID Character 8 Byte 283 313 343 373 Ch ID Character 9 Byte 284 314 344 374 Ch ID Character 10 Byte 285 315 345 375 Rate Units Character 1 Byte 286 316 346 376 Rate Units Character 2 Byte 287 317 347 377 Rate Units Character 3 Byte 288 318 348 378 Total Units Character 1 Byte 289 319 349 379 Tota...

Страница 50: ...Flag Byte 484 516 548 580 612 644 676 708 740 Relay Assign Flag Byte 485 517 549 581 613 645 677 709 741 Alarm PWM Output Floating Pt 486 518 550 582 614 646 678 710 742 487 519 551 583 615 647 679 711 743 Alarm PID Set Pt Floating Pt 488 520 552 584 616 648 680 712 744 489 521 553 585 617 649 681 713 745 Alarm PID KP Setting Integer 490 522 554 586 618 650 682 714 746 Alarm PID KI Setting Integer...

Страница 51: ...ation mode Floating Point 762 763 Analog Channel 7 Engineering Value Rate value during integration mode Floating Point 764 765 Analog Channel 8 Engineering Value Rate value during integration mode Floating Point 766 769 Flow Meter Rate 1 Floating Point 770 771 Flow Meter Total 1 Floating Point 772 773 Flow Meter Rate 2 Floating Point 774 775 Flow Meter Total 2 Floating Point 776 777 Flow Meter Rat...

Страница 52: ...screen instructions Using ConsoliDator Monitor Software Launch the program from the Start menu or desktop shortcut Make sure you are using the correct version of the software for the number of channels your model has 4 or 8 Verify the controller is powered up and properly connected before proceeding From the drop down menu in the bottom left of the screen select the Modbus ID that matches the same...

Страница 53: ...ction is limited to serving as an overview of programming through software because the parameters in the software menus correspond to the parameters on the controller s setup screens You will need to follow the Setup and Programming section page 21 to understand these parameters Settings programmed through software will automatically be updated to the controller and be visible and accessible in th...

Страница 54: ...l 54 OVERALL DIMENSIONS 3 0 76mm 8 0 203mm 8 75 222mm Figure 22 PD980 PD940 Overall Dimensions 9 36 238mm 7 16 182mm 7 86 200mm 3 10 79mm 8 66 220mm Figure 23 PD981 PD941 Overall Dimensions www calcert com sales calcert com 1 800 544 2843 0 5 10 15 20 25 30 ...

Страница 55: ...ding is inadequate or not connected Check earth ground continuity NO SENSORS FOUND is displayed but sensors are connected and transmitting Allow controller to warm up for 10 or more minutes If sensors still not detected cycle the power to reboot Display response seems slower than normal Ambient temperature is too cold Consider installing a heater with the instrument Display locks up or the instrum...

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