Issue: 1229th August 2014

BA454DIntrinsically safeField mounting

Batch ControllerIssue 12

1. Description

2. Operation2.1 Operator controls2.2 Power supply failure

3. Intrinsic Safety Certification3.1 ATEX certificate3.2 Zones, gas groups & T rating3.3 Power supply3.4 Inputs

3.4.1 Input 13.4.2 Input 2

3.5 Switch outputs3.6 External switches3.7 Inhibit & security links3.8 Certification label information

4. System Design for Hazardous Area4.1 System certificates 4.2 Use with Zener barriers

4.2.1 Power supply4.2.2 Pulse inputs

4.2.2.1 Switch contact 4.2.2.2 Proximity detector4.2.2.3 Voltage pulse

4.2.3 4/20mA analogue input4.2.4 Switch outputs

4.3 Use with galvanic isolators4.3.1 Power supply4.3.2 Inputs4.3.3 Switch outputs

4.4 External switches4.5 Inhibit link4.6 Security link

5. Installation5.1 Location5.2 Installation procedure5.3 EMC

6. Configuration Menus6.1 Security6.2 Navigation6.3 Default configuration6.4 System settings

6.4.1 Language6.4.2 User controls6.4.3 Signal input6.4.4 4mA calibration6.4.5 20mA calibration6.4.6 Lineariser6.4.7 Restart6.4.8 Output 26.4.9 Output 36.4.10 Optional outputs 4, 5 & 66.4.11 Pulse output6.4.12 Clear grand total6.4.13 Defaults6.4.14 Security6.4.15 Operator screens6.4.16 Display

6.4.17 Output options6.4.17.1 Control 26.4.17.2 Control 36.4.17.3 Flow alarm6.4.17.4 Reset status6.4.17.5 Batch status6.4.17.6 Pulse output

6.5 Batch settings6.5.1 Scale Points (Non-linear pulse inputs)6.5.2 Scale Factors (Non-linear pulse inputs)6.5.3 Scale Factor (Linear pulse

inputs)6.5.4 Scaling (4/20mA input)6.5.5 Batch D.P.6.5.6 Batch Legend6.5.7 Batch Limit6.5.8 Batch Names6.5.9 Batch Size6.5.10 Select Batch6.5.11 Batch History6.5.12 CONTROL2delay6.5.13 CONTROL2stop6.5.14 CONTROL3delay6.5.15 CONTROL3stop6.5.16 Count Mode6.5.17 Overrun Compensation6.5.18 Batch Cycles6.5.19 Restart Delay

6.6 Rate settings6.6.1 Rate Scaling (Pulse inputs)6.6.2 Rate D.P. (Pulse inputs)6.6.3 20mA Display (4/20mA input)6.6.4 Rate Legend6.6.5 Timebase6.6.6 Rate Filter6.6.7 Flow Alarm6.6.8 Clip-Off

7. Calibration Examples

8. Maintenance8.1 Fault finding during commissioning8.2 Fault finding after commissioning8.3 Servicing8.4 Routine maintenance8.5 Guarantee8.6 Customer comments

9. Accessories9.1 Tag number9.2 Pipe mounting kits

10. Index

Appendix 1 User ScreensAppendix 2 Diagnostic information menuAppendix 3 ATEX dust certificationAppendix 4 FM & cFM Approval for use in

USA and Canada.

2222222

The BA454D is CE marked to show compliance with the European Explosive Atmospheres Directive 94/9/EC

and the European EMC Directive 2004/108/EC

CONTENTS

1. DESCRIPTIONThe BA454D is a field mounting intrinsicallysafe batch controller primarily intended tocontrol the dispensing of liquids, solids orcomponents in a hazardous area. It is asecond-generation instrument that replacesfield mounting applications of the BA350BPand the BA350BC.

Although incorporating sophisticated controlfunctions, the BA454D is easy to operate andconfigure. Batch status and the function of thepush-buttons are shown on the backlit graphicdisplay which is visible in all lighting conditions.The instrument can provide single, dual orthree stage control and may be used with bothpulse and 4/20mA analogue output flowmeters.

The BA454D has been issued with an ATEXEC-Type Examination Certificate by NotifiedBody Intertek Testing & Certification which hasbeen used to confirm compliance with theEuropean ATEX Directive for use in explosivegas and combustible dust atmospheres.

Dust certification is an option, see Appendix 3.

The BA454D is also FM approved for use inthe USA and cFM approved for use in Canada,these approvals are described in Appendix 4.

Housed in a robust IP66 glass reinforcedpolyester (GRP) enclosure with an armouredglass window, the BA454D is surfacemounting, or may be pipe mounted using oneof the accessory kits.

2. OPERATIONFig 1 shows a typical BA454D dispensingapplication. The BA454D controllerincorporates programmable input scaling sothat the total and rate displays may be in anyengineering units such as litres or gallons.

The operator enters or selects, via thepushbuttons, the setpoint which is the requiredvolume to be dispensed. Control 1 is energisedimmediately the Start push-button is operated,followed by Control 2 after a programmabletime delay. Towards the end of the batch,Control 2 is de-energised a programmablevolume before the batch setpoint is reachedwhen Control 1 is also de-energised.

By operating a small bypass valve from Control1 and the main control valve from Output 2, theflow can be started and stopped slowly thusreducing batching errors and flow surges. Ifless accuracy is required, single stage controlcan be accomplished using just Control 1 andone control valve.

Control 1 is a dedicated output, but Outputs 2and 3 may be configured as control, pulse orbatch status outputs.

Fig 1 Typical batch control application

If additional outputs are required, three moremay be added as a factory installed option.

The BA454D incorporates a selection ofoperator display screens allowing the installerto choose a display which only presentessential information to the operator.

To prevent accidental or unauthorisedadjustments, the operator and configurationmenus may be protected by separate securitycodes. The configuration menu is alsoprotected by a security link between terminals18 and 19. This link may be hard-wired, orconnected to an external key-switch whenfrequent changes are required.

Fig 2 shows a simplified block diagram of thecontroller.

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Fig 2 Simplified block diagram of BA454D

2.1 Operator ControlsThe BA454D batch controller may beconfigured with one of six suites of operatordisplay screens containing differentcombinations of information as shown inAppendix 1. The function of each push-buttonis shown immediately above the button at thebottom of the screen. Buttons that are notidentified on the screen are not functional.The Down, Up, P and E identifications printedonto the push-buttons only apply when theinstrument is being configured.

The operator functions are:

START Causes Control 1 to be energisedwhich will start the batch. The screenwill display ‘Running’ until the batchis completed, or the STOP push-button is operated.

STOP Operating this button during a batchimmediately de-energises Control 1and Control Outputs 2 & 3 if they areused, causing the batch to pause.‘Paused’ will be displayed on thescreen. During a pause any inputsignal continues to be counted.

The batch may be resumed at anytime by pressing the Start button, or itmay be aborted by operating theReset button.At the end of each batch the ControlOutput(s) will be de-energised and‘Complete’ will be displayed on thescreen.

RESET After completion of a batch the batchcontroller must be reset before thenext batch can be started.After resetting the screen displays‘Ready’. Input signals are ignoreduntil the Start button is operated. Note: Two selectable optionsmodify the reset function.

Quick Restart eliminates the need tomanually reset the BA454D at theend of each batch. When a batch iscomplete the batch controller willdisplay the volume that has beendispensed. Operating the Startpushbutton will reset the batchcontroller and start another batch.See section 6.4.7

Auto Restart enables the batchcontroller to run continuously. At theend of each batch the controller waitsfor a programmable time beforeautomatically resetting and startinganother batch. This sequence willcontinue until a programmablenumber of batches has beencompleted or the Stop button isoperated. See section 6.4.7

MENU Operating this button gives access tothe Operator Menu that may beprotected by a four digit securitycode. This menu may be configuredto give the operator access to any, ornone of the following functions:

Select Batch Select 1 of 9 pre-entered setpoints

Batch Size Adjust 1 or all 9 setpoints.

Batch History Show size of last 10 batches.

Configure Full access to the instruments configuration menu.

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If no items are contained in the menuthe operator can only start, pauseand stop a batch. Inclusion of theSelect Batch function allows theoperator to select the batch setpointfrom one of nine pre-entered values.To aid identification, each setpointmay be identified by a name havingup to sixteen digits.

If included in the menu, the BatchSize function allows the adjustmentof the pre-entered batch setpoints.

Batch History shows the size of thelast ten batches which have beencompleted.

The Configure function providesoperator access to the batchcontroller configuration menusdescribed in section 6. Entry tothese menus is protected by anexternal security link betweenterminals 18 and 19 and an optionalfour digit security code.

2.2 Power supply failureIf the power supply for the BA454D fails duringa batch, the instrument will remember theamount of product dispensed when the supplyfailed, together with the number of cyclecompleted if autostart is being used. Whenpower is restored, the batch controller willreturn in the Paused condition displaying theamount of product dispensed prior to thefailure. Operating the Start pushbutton willcomplete the batch.

If the supply failure occurs when the batchcontroller is in the Ready or Complete state,the controller will return in the same state whenpower is restored.

3. INTRINSIC SAFETY CERTIFICATION

3.1 ATEX certificateThe BA454D has been issued with an EC-Type Examination Certificate by Notified BodyIntertek Testing Services (ITS) confirmingcompliance with the European ATEX Directive94/9/EC for Group II, Category 1 gas and dustatmospheres, Ex ia IIC T5 equipment. Theinstrument bears the Community Mark and,subject to local codes of practice, may beinstalled in any of the European EconomicArea (EEA) member countries. ATEXcertificates are also acceptable for installationsin Switzerland.

This instruction manual describes installationsin explosive gas atmospheres which conformwith EN 60079:Part14 Electrical Installation inHazardous Areas. When designing systemsfor installation outside the UK, the local Codeof Practice should be consulted.

For the use in the presence of combustibledust, please refer to Appendix 3.

3.2 Zones, gas groups and T ratingThe BA454D has been issued with EC TypeExamination certificate ITS03ATEX21378confirming that it complies with therequirements for Group II Category 1 Gequipment; Ex ia IIC T5 Ga (Tamb –40 to60oC). When connected to a suitable systemthe BA454D may be installed in:

Zone 0 explosive gas air mixturecontinuously present.

Zone 1 explosive gas air mixture likely to occur in normal operation.

Zone 2 explosive gas air mixture notlikely to occur, and if it doeswill only exist for a shorttime.

Be used with gases in groups:Group A propaneGroup B ethyleneGroup C hydrogen

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Having a temperature classification of:

T1 450oC

T2 300oC

T3 200oC

T4 135oC

T5 100oC

At an ambient temperature between –40 and +60oC.

Note: the guaranteed operating temperature range of the batch controller is –20 to +60oC

This allows the BA454D to be installed in allZones and to be used with most commonindustrial gases.

3.3 Power supplyWhen installed in a hazardous area theBA454D must be powered from a EEx ia IICcertified Zener barrier or galvanic isolatorhaving output parameters equal to or less than:

Uo = 28.0V dcIo = 96mA dcPo = 0.84W

The maximum equivalent capacitance andinductance between power supply terminals 1and 2 is:

Ci = 0.015µFLi = 8µH

To determine the maximum permissible cableparameters, Ci and Li must be subtracted fromthe maximum cable capacitance andinductance specified by the certificate of thebarrier or isolator powering the batchcontroller.

3.4 InputsThe BA454D has two alternative inputs.

Input 1 (terminals 11 & 12) is for devices thatrequire powering by the batch controller suchas switch contacts, a proximity detector or aphotodetector. Input 2 (terminals 13, 14, 15,16 & 17) complies with the requirements forsimple apparatus and is for the connection ofdevices having a voltage or current outputsuch as a magnetic pickup or an analogue4/20mA current.

Note: Inputs 1 and 2 can not be usedsimultaneously.

3.4.1 Input 1Terminals 11 and 12 may be connected to anytransducer having input parameters equal to orgreater than:

Ui = 10.6V dcIi = 20mA dcPi = 0.05W

The terminals may also be connected to anydevice such as a switch contact complying withthe requirements for simple apparatus asspecified in Clause 5.7 of EN 60079-11.

The maximum permitted capacitance andinductance for the cable plus the transducerconnected to terminals 11 & 12 in a IIChydrogen gas are:

C cable + Ci transducer 2.3µF maxL cable + Li transducer 90mH max

See system certificates for maximum limits forIIB and IIA gases.

3.4.2 Input 2Terminals 13, 14, 15, 16 and 17 comply withthe requirements for Simple Apparatusallowing any device certified Ex ia IIC withoutput parameters equal to or less than:

Uo 28V dcIo 100mA dcPo 0.66W

to be connected.

This allows devices with a certified voltagepulse output or a certified 4/20mA analoguecurrent output to be connected directly to thebatch controller.

The maximum equivalent capacitance Ci andinductance Li of terminals 13 to 17 is:

Ci = 0.018µFLi = 0.02mH

To determine the maximum permissible cableparameters, Ci and Li must be subtracted fromthe maximum permissible cable capacitanceand inductance specified by the certificate forthe device connected to input 2.

See system certificates for maximum limits forIIB and IIA gases.

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3.5 Switch outputsControl 1 and Outputs 2 & 3 are separategalvanically isolated solid state switches. TheEC-Type Examination Certificate specifies thatunder fault conditions the voltage, current andpower at each switch output will not exceedthose specified for simple apparatus in Clause5.4 of EN50020:2002. This allows each of theBA454D switch outputs to be connected to anyintrinsically safe circuit protected by a certifiedZener barrier or galvanic isolator providing thatthe output parameters of each circuit are lessthan:

Uo 28V dcIo 200mAPo 0.85W

The maximum equivalent capacitance andinductance of each BA454D switch output are:

Ci = 0.04µFLi = 0.02mH

To determine the maximum permissible cableparameters, Ci and Li must be subtracted fromthe maximum cable capacitance andinductance specified by the certificate of thebarrier or isolator connected to the switch.

3.6 External switchesFor applications requiring the batch controllerto be operated via large industrial push-buttons, terminals S1 to S7 may be connectedto four external switches.

Terminals S1 to S7 have the followingcombined output safety parameters:

Uo = 14.7V dcIo = 99mA dcPo = 0.6W

The switches and associated wiring connectedto the terminals must comply with therequirements for simple apparatus. i.e. theymust have IP20 protection and be capable ofwithstanding a 500V rms insulation test toearth for one minute. Most industrial push-buttons satisfy these requirements

The total maximum permitted cableparameters for all the cables connected toterminals S1 to S7 in a IIC hydrogen gas are:

Co 0.15 µFLo 0.48mH

These are not restrictive and allow a significantdistance between the switches and the instrument.

3.7 Inhibit and Security LinksThe inhibit and security links have the followingcombined output safety parameters:

Uo = 11.7V dcIo = 2.4mA dcPo = 7mW

A wire link may be connected between theterminals, or if frequent changes are requiredswitches may be used. These switches andassociated wiring must comply with therequirements for simple apparatus. i.e. theymust be mechanically activated, have IP20protection and be capable of withstanding a500V rms insulation test to earth for oneminute.

The total maximum permitted cableparameters for all the cables connected toterminals 18, 19 & 20 in a IIC hydrogen gasare:

Co 1.5µFLo 1H

These are not restrictive and do not limit theseparation between the batch controller andthe switches.

3.8 Certification Label InformationThe certification label is fitted in a recess onthe top outer surface of the enclosure. Itshows the ATEX certification information plusBEKA associates name and address. Theinstrument serial number and year ofmanufacture are shown on a separate labelwithin the terminal compartment.

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4. SYSTEM DESIGN FOR HAZARDOUS AREAS

4.1 System CertificatesIn addition to the EC-Type ExaminationCertificate, ITS issued two System Certificatesfor the BA454D batch controller. One defineshow the BA454D may be used with Zenerbarriers and the other with galvanic isolators.Both are divided into two sections to coverinput signal sources in the hazardous and thesafe area.

Interface Certificate No.Zener barriers Ex03E21380Galvanic isolators Ex03E21381

System Certificates are Certificates ofConformity, which were primarily issued forinstallation guidance in the UK. They do notform part of the ATEX certification.

4.2 Use with Zener barriersZener barriers are the least expensiveintrinsically safe interface between a safe andhazardous area. However they do not provideisolation and require a high integrity earthconnection that may be expensive to install.For a single BA454D batch controllerinstallation it may be less expensive andcomplicated to use galvanic isolators when ahigh integrity earth connection is not alreadyavailable.

Any Zener barrier certified Ex ia IIC by aNotified Body may be used, providing that thesafety parameters are within the limitsspecified by the BA454D EC-TypeExamination Certificate. Only one polarity ofZener barrier, i.e. positive or negative, may beused with each BA454D batch controllerinstallation.

To assist with system design, the Zener barrierSystem Certificate specifies the safetydescription of barriers that may be used andlists the maximum permitted cable parameters.

Fig 3 illustrates the basic circuit that is used forall BA454D installations protected by Zenerbarriers. Although the BA454D batchcontroller will operate from a wide range ofinput sources, only one source may beconnected at any time.

Alternatively the input source may be locatedin the safe area. Fig 4 shows how anadditional Zener barrier may be used totransfer the signal from the safe area to thebatch controller in the hazardous area. Forswitch contact and open collector inputs theend-to-end resistance of the Zener barrier plus

the resistance of the input device must complywith the batch controllers input switchingthresholds.

Fig 3 Batch controller powered via a Zener barrier with input in hazardous area.

Fig 4 Batch controller powered by Zener barrier with Input in the safe area.

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4.2.1 Power supplyUsually a BA454D batch controller is poweredfrom the safe area via a positive polarity 28V300 Zener barrier which has a typical end-to-end resistance of 340. The BA454Dconsumes a maximum current of 33mA andrequires a minimum voltage of 11V betweenterminals 1 and 2. When powered from a28V 300 Zener barrier the supply voltage inthe safe area must be between 22.2V and themaximum working voltage of the barrier whichis usually about 26V.

CAUTIONThe safety components within the batchcontroller limit the voltage between terminals 1and 2 at 15V. If the batch controller is directlyconnected to a 15V or greater power supplywithout a Zener barrier or equivalent seriesresistor, the instrument will consume a largecurrent for a few seconds and then shut-downto prevent permanent damage. To test aBA454D batch controller in a safe areaworkshop, terminals 1 & 2 should beconnected to a 24V dc power supply via a330 resistor.

4.2.2 Pulse inputsAs shown in Figs 3 and 4 the BA454D batchcontroller may be connected to a wide varietyof pulse transducers and sources in thehazardous or safe area. Input 1 is for pulsesources that need powering by the batchcontroller such as switch contacts or a 2-wireproximity detector. Input 2 is for voltage pulseinputs such as the magnetic pickup in a turbineflowmeter, or a voltage pulse output from aflowmeter.

The following table shows the switchingthresholds for the various transducers, plus themaximum operating frequency and the inputterminal numbers. For reliable counting theinput signal must fall below the lower switchingthreshold and rise above the upper threshold.

Switchingthresholds

Freqmax

Inputterminals

Switch 100 1000 100Hz 12 & 11 +Proximitydetector

1.2mA 2.1mA 5 kHz 12 & 11 +

Opencollector

2k 10k 5kHz 12 & 11 +

Magneticpickup

10mV 30mV 5kHz 16 & 15 +

Lowvoltagepulse

1V 3V 5kHz 16 & 14 +

Highvoltagepulse

3V 10V 5kHz 16 & 13 +

Note: Only one input may be used at a time.

4.2.2.1 Switch contact inputAny mechanically activated switch contactlocated in the hazardous area may beconnected directly to terminals 12 & 11providing the switch has IP20 protection andcan withstand a 500V rms insulation test toearth. Most magnetically activated reed relaysused in turbine flowmeters comply.

The maximum operating frequency for a switchcontact input is 100Hz.

4.2.2.2 2-wire proximity detector inputAny Ex ia certified intrinsically safe 2-wireproximity detector complying with NAMURswitching thresholds may be used, providingthe input safety parameters of the proximitydetector are equal to or greater than:

Ui 10.6V dcIi 20mA dcPi 50mW

If located in the same hazardous area as thebatch controller the proximity detector may bedirectly connected to terminals 12 & 11

When programmed to operate with a proximitydetector, the maximum input frequency of theBA454D batch controller is 5kHz.

4.2.2.3 Voltage pulse input Voltage pulse sources may be connecteddirectly to input 2, the terminals used dependupon the input magnitude – see the table insection 4.2.2. All these terminals comply withthe requirements for simple apparatus andthey may be directly connected to any Ex iacertified intrinsically safe voltage source withinthe hazardous area. The source must be ableto withstand a 500V rms insulation test to earthfor one minute and have output parametersequal to or less than:

Uo 28V dcIo 100mA dcPo 0.66W

This enables the BA454D to be connecteddirectly to most flowmeters incorporating acertified intrinsically safe magnetic pickup, or acertified intrinsically safe amplifier producing ahigh level pulse output. The BA454D hasthree selectable voltage switching thresholds,for magnetic pickups, low voltage pulses andhigh voltage pulses.

When programmed to operate with a voltagepulse source, the maximum input frequency ofthe BA454D batch controller is 5kHz.

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4.2.3 4/20mA analogue inputThe BA454D can also accept an analogue4/20mA input from a current sourcerepresenting rate of flow, not a current sink.Loop powered flow transmitters require anadditional power supply. The analogue inputterminals comply with the requirements forsimple apparatus allowing almost anyintrinsically safe 4/20mA signal to beconnected directly to the batch controller.

Voltagedrop

Freq.Max.

Inputterminals

4/20mA 0.6V 2Hz 16 & 17+

4.2.4 Switch outputsEach of the three switch outputs is agalvanically isolated single pole solid stateswitch as shown in Fig 5.

Fig 5 Equivalent circuit of each switch output

The output is polarised so current will only flowin one direction. Terminals A1, A3 and A5should be connected to the positive side of thesupply. The ‘on’ and ‘off’ performance of eachswitch output is:

Ron = 5 + 0.7VRoff = greater than 1M

Any hazardous area intrinsically safe circuitmay be switched by one of these outputsproviding the output safety parameters of thecircuit are less than the maximum inputparameters of the switch. Alternatively theswitch contact may be transferred to the safearea via a Zener barrier which again must havesafety parameter less than the maximum inputsafety parameters of the switch.

Notes: Because of the series protectiondiode, some test meters may notdetect a closed switch output.

Terminals A7 to A12 are for optionalfactory fitted outputs 4, 5 and 6.

WARNINGThese switch outputs should not beused for critical safety applications.

When the BA454D power supply is turned offor disconnected, all BA454D switch outputs willopen.

4.3 Use with galvanic isolatorsGalvanic isolators are probably the simplestintrinsically safe interface as they provideisolation and do not require a high integrityearth connection.

Any galvanic isolator certified Ex ia IIC by aNotified Body may be used providing that thesafety parameters of the isolator terminals arecompatible with the safety parameters of thebatch controller terminals to which the isolatoris connected. To assist with system design, the galvanicisolator System Certificate specifies the safetydescription of the galvanic isolators that maybe used and lists the maximum permitted cableparameters.

Fig 6 illustrates the basic circuit that is used forall BA454D installations protected by galvanicisolators. Although the BA454D batchcontroller will operate from a wide range ofinput sources, only one source may beconnected at any time.

Alternatively the input source may be locatedin the safe area. Fig 7 shows how anadditional isolator may be used to transfer theinput signal from the safe area to the batchcontroller in the hazardous area.

4.3.1 Power supplyAny certified galvanic isolator may be used topower the BA454D providing the output safetyparameters are less than the maximumpermitted input safety parameters of terminals1 & 2. In addition to matching the safetyparameters, the isolator must be able to supplyat least 11V to terminals 1 & 2 at 33mA.

CAUTIONThe safety components within the batchcontroller limit the voltage between terminals 1and 2 at 15V. If the batch controller is directlyconnected to a 15V or greater power supplywithout a galvanic isolator or equivalent seriesresistor, the instrument will consume a largecurrent for a few seconds and then shut-downto prevent permanent damage. To test aBA454D batch controller in a safe areaworkshop, terminals 1 & 2 should beconnected to a 24V dc power supply via a330 resistor.

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4.3.2 InputsWhen the batch controller is powered from agalvanic isolator, the pulse and analogueinputs remain the same as described insections 4.2.2 and 4.2.3. Only when the inputtransducer or source is in the safe area, asshown in Fig 7, are galvanic isolators requiredin the input circuit.

Any Ex ia IIC certified galvanic isolator may beused providing that the safety parameters ofthe isolator terminals are compatible with thesafety parameters of the batch controller inputterminals to which it is connected. Thegalvanic isolator must also be able to transferthe required type of input into the hazardousarea.

Fig 6 Batch controller powered by a galvanic isolator with input in hazardous area.

Fig 7 Batch controller protected by galvanic isolators with input in the safe area.

4.3.3 Switch outputs

WARNINGThese switch outputs should not be used for critical safety applications.

When the batch controller is powered from agalvanic isolator, the switch outputs remain thesame as described in section 4.2.4 Only whenthe switch output is required in the safe area isa galvanic isolator required. A wide variety ofswitch transfer isolators are available with aselection of relay and solid state outputs. Againthe output parameters of the galvanic isolatormust be less than the maximum permittedinput parameters of the batch controller switch.

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4.4 External switchesFor applications requiring the batch controllerto be operated via large industrial push-buttons, four external switches may beconnected as shown in Fig 2. Each externalswitch has a dedicated operating andconfiguration function.

Switchnumber

Switch function when Operating Configuring

S1 Start DownS2 Stop UpS3 Reset PS4 Menu E

Section 3.6 describes the use of externalswitches in the hazardous area, but they mayalso be located in the safe area.

A certified intrinsically safe relay or a galvanicisolator with a switch contact output is requiredto transfer the switch contact from the safe tothe hazardous area. The combined permittedinput safety parameters for batch controllerterminals S1 to S7 are zero, therefore Zenerbarriers can not be used.

Fig 8 shows how external Stop buttons may belocated in the safe and hazardous areas.

Fig 8 Stop buttons in hazardous & safe areas

4.5 Inhibit linkLinking terminals 18 and 20 together inhibitsthe batch controller input. If linked during abatch, dispensing will continue but the batchedtotal will not be incremented, or decremented ifcounting down. These terminals may only beconnected to a hazardous area mechanicallyoperated switch having IP20 protection andable to withstand an ac test voltage of 500V toearth for one minute. See section 3.7.

4.6 Security linkAccess to the configuration menus is onlyavailable when terminals 18 & 19 are linkedtogether – see section 6.1. These terminalsmay only be lined together at the instrument, orconnected to a hazardous area mechanicallyoperated switch having IP20 protection andable to withstand an ac test voltage of 500V toearth for one minute. See section 3.7.

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5. INSTALLATION

5.1 Location The BA454D batch controller is housed in arobust IP66 glass reinforced polyester (GRP)enclosure incorporating an armoured glasswindow and stainless steel fitting. It is suitablefor exterior mounting in most industrialenvironments, including off-shore and wastewater treatment installations. Please consultBEKA associates if high vibration isanticipated.

The BA454D enclosure is surface mounting.Accessory kits described in sections 9.2 of thismanual enable the instrument to be mountedonto a vertical or horizontal pipe.

The field terminals and the two mounting holesare located in a separate compartment with asealed cover allowing the instrument to beinstalled without exposing the displayassembly.

The BA454D earth terminal is connected to theinternal EMC filters. For maximum radiofrequency interference rejection this terminalshould be connected to a local earth, or to acable screen which is earthed in the safe area.The BA454D enclosure is supplied with abonding plate to ensure electrical continuitybetween the three conduit / cable entries.

5.2 Installation ProcedureFig 9 illustrates the instrument installationprocedure.

a. Remove the instrument terminal cover byunscrewing the two captive 'A' screws.

b. Mount the instrument on a flat surfaceand secure with two M6 screws throughthe 'B' holes. Alternatively use one of themounting kits described in section 9.2

c. Remove the temporary hole plug andinstall an appropriate IP rated cablegland or conduit entry. If more than oneentry is required, one or both of the IP66stopping plugs may be replaced with anappropriated IP rated cable gland orconduit fitting.

d. Connect the field wiring to the terminalsas shown in Fig 10.

e. Replace the instrument terminal coverand evenly tighten the two 'A' screws.

Fig 9 BA454D installation procedure

5.3 EMC The BA454D complies with the requirements ofthe European EMC Directive 2004/108/EC.For specified immunity all wiring should be inscreened twisted pairs and the BA454D earthterminal should be locally earthed orconnected to a cable screen which is earthedin the safe area.

To prevent circulating currents, cable screensshould only be earthed at one point in the safearea.

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Fig 10 Dimensions and terminal connections

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6. CONFIGURATION MENUSThe BA454D batch controller is configured viathe front panel pushbuttons. Configurationfunctions are contained in three easy to usesub-menus, ‘System Settings’, ‘Batch Settings’and ‘Rate Settings’. A fourth sub-menu‘Information’ shows how the instrument hasbeen configured.

Although the BA458 batch controller containsmany sophisticated functions, it remains simpleto operate and configure. Menu navigation isexplained in section 6.2. Guided by on-screenprompts, the use of the configuration functionsis intuitive, but all the functions are fullydescribed in this manual.

6.1 SecurityTo prevent unauthorised or accidentaladjustment, the configuration menus can onlybe accessed when an external link is fittedbetween terminals 18 and 19 as shown below.

Terminals Access to18 and 19 configuration menus

Linked YesNot linked No

When authorised personnel need to makefrequent configuration adjustments, thesecurity link terminals may be wired to a keyswitch located in the hazardous area.

The configuration menus may also beprotected by a user selectable four digitsecurity code.

A separate four digit user selectable securitycode may be applied to the operator menu.

6.2 NavigationThe BA454D is configured via the four frontpanel push-buttons which are identified with aprinted legend.

This manual contains simplified drawings ofthe batch controller display screens associatedwith most functions. Although some screensmay consist of multiple pages that areautomatically accessed by scrolling throughthe options, in this manual they are shown onone page with the default option in bold.

Within this manual push-buttons are shown initalics e.g. P or Up push-button and legendsdisplayed by the batch controller are shownwithin inverted commas e.g. 'Running'.

When the batch controller is displaying ‘Ready’access to the main configuration menu isobtained by pressing the P and E buttons

simultaneously or, if enabled, via the OperatorMenu. The configuration menu can not beaccessed while the batch controller is running.

Once within the main menu the Up and Downbuttons move the highlight bar between sub-menus. When the required option has beenhighlighted, operating the P button will accessthe sub-menu.

The highlight bar is static when indicating amenu or sub-menu. When indicating an optionwhich has to be selected, or a variable that hasto be entered, the highlight bar flashes on andoff.

The configuration main menu comprises foursub-menus:

System Settings Defines function of batch controller including outputs & display screen.See Fig 11 & section 6.4

Batch Settings Defines batch parameters.See Fig 14 & section 6.5

Rate Settings Defines rate parameters.See Fig 16 & section 6.6

Information Lists all the batch controller settings and allows the Grand Total to be read.See Appendix 2

Highlighting the required function within thesub-menu and operating the P pushbutton willenter the function menu. Functions offer achoice of options or an invitation to enter avariable.

To select an option in a function menuPress the Up or Down button to move theflashing display highlight bar to therequired option, operating the E button willthen store the selected option and movethe display up one level to the sub-menu.

To enter a variableVariables are entered digit by digit, theflashing digit being adjusted using the Upor Down button. When a digit is set asrequired operating the P button willtransfer control to the next digit. When allthe digits have been adjusted, operatingthe E button will store the variable andmove the display up one level to the sub-menu.

15

When navigating through the menus the push-button(s) should be held until the requiredscreen is displayed.

Note:Functions that are dependent on a higher leveloption are automatically removed from the sub-menu when the higher level option is notselected. e.g. If the batch controller isconfigured for a pulse input, all the calibrationfunctions associated with a 4/20mA input willbe automatically removed from the menus.

6.3 Default configurationUnless otherwise requested at the time ofordering, BA454D batch controllers will besupplied configured as follows:

System SettingsLanguage EnglishOperator control Both Local &

Remote.Signal Input Open CollectorLineariser OffRestart NormalOutput 2 UnusedOutput 3 UnusedOptional outputs 4, 5 & 6 UnusedPulse Output Display / 1Grand Total Cleared Security

Config. Code 0000Operator Code 0000Operator Menu

Batch Sizing OnBatch Select OnHistory OnConfig. Menu On

Operator Screens Screen 1

Batch SettingsScale factor (Linear pulse) 000001.Scaling (4/20mA input) 000001.Batch D.P. 00000000.Batch Legend No legendBatch Limit 99999999Batch Names Batch 1Batch Size 00000000.Select Batch Batch 1CONTROL2delay 0000CONTROL2stop 00000000.CONTROL3delay 0000CONTROL3stop 00000000.Count Mode UpOverrun Comp OffBatch Cycles 1Restart Delay 00 : 00 : 00

Rate SettingsRate Scaling 000001.Rate D.P. 00000.020mA Display 00100.0Rate Legend No legendTimebase SecondsRate Filter

Smoothing 2Jump-Out 4

Flow Alarm 00000.0Inhibit Time 0000Clip-Off 00000.0

Default parameters may be globally restoredsee section 6.4.13

16

17

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18

Fig 11 System Settings

Fig 11 System Settings

6.4 SYSTEM SETTINGSSee Fig 11.

6.4.1 LanguageThe BA454D can display operating messagesand menus in three different languages:

DeutschEnglish Francais

Set Language

Highlight the required language and press E toenter the selection.

6.4.2 User ControlsThe BA454D batch controller may becontrolled by the front panel pushbuttons, byremote switches or by both the front panelswitches and the remote switches.

LocalRemoteBoth

Set User Controls

Highlight the required option and press E toenter the selection.

6.4.3 Signal InputA wide variety of analogue and digitaltransduces and sources may be connected tothe batch controller.

Open CollectorProx DetectorSwitch ContactMagnetic pickupVoltage Pulse

4/20mA4/20mA Sq. Law

Set Input Type

Notes: Input terminals vary depending uponthe type of input, see sections 4.2.2and 4.2.3.

The brilliance of the display backlightis reduced when open collector,proximity detector or switch contactinputs are selected.

6.4.4 4mA CalibrationNote: Only necessary when 4/20mA input is

used When the BA454D batch controller is suppliedthe analogue current input will have beenaccurately factory calibrated, it is onlynecessary to perform this calibration as part ofroutine maintenance.

To perform the calibration connect a 4 to 20mAcurrent source to batch controller terminals 16& 17(+) and adjust the input current to exactly4mA. To achieve maximum batch controllerperformance, the accuracy of the currentsource should be greater than 0.025% (4uA).

To prevent the batch controller calibrationbeing accidentally corrupted the instruction hasto be confirmed before it will be executed.

CalibrateCancel

CAL. (Inject 4mA)

Highlight the ‘Calibrate’ option and operate theE pushbutton, which will result in theconfirmation screen being displayed. Toperform the calibration highlight ‘Continue’ andpress E , after a few seconds the display willreturn to the System setting menu.

ContinueCancel

Are you sure?

6.4.5 20mA CalibrationThis function is identical to the 4mA calibrationdescribed in the previous section 6.4.4, but a20mA input current should be used.

6.4.6 Lineariser (Pulse inputs)The 16 point straight line lineariser willcompensate for k-factor non-linearity in turbineflowmeters.

This function turns the lineariser on and off,calibration parameters are entered in the BatchSetting menu – See sections 6.5.1 and 6.5.2 .

On Off

Set Lineariser

Highlight the required setting and press E toenter the selection.

19

6.4.7 RestartThis function determines what happens at theend of each batch. There are three options:

Normal: The display screen shows thevolume that has beendispensed. Before anotherbatch can be started the Resetpush-button must be operated.The screen will then display‘Ready’.

Quick: The display screen shows thevolume that has beendispensed. Operating theStart pushbutton will reset thebatch controller and startanother batch.

Auto restart: The display screen shows thevolume that has beendispensed. After a configurablerestart delay (See 6.5.19) thebatch controller automaticallyresets and starts another batch.The number of batch cycles tobe performed is defined by theBatch Cycle function, which iscontained in the Batch Settingmenu. See 6.5.18

NormalQuick Auto

Set Batch Restart

Highlight the required option and press E toenter the selection.

6.4.8 Output 2Output 2 is an isolated single pole solid stateswitch contact that is connected to terminalsA3 and A4. It may be configured to output anyone of six different signals, or may be unused.

UnusedControl 2Control 3

Flow alarmReset statusBatch statusPulse Output

Set O/P 2 Function

Highlight the required option and press E toenter the selection.Note: Two or more of the outputs may be

configured to output the same function.

6.4.9 Output 3As Output 2 except terminals are A5 and A6.

6.4.10 Optional outputs 4, 5 and 6Only available when factory fitted option isinstalled in the BA454D batch controller.Configuration is the same as for Output 2,except terminal numbers are:

Output Terminal numbers4 A7 & A85 A9 & A106 A11 & A12

6.4.11 Pulse OutputAny of the batch controller outputs may beconfigured as a pulse output. The number ofoutput pulses is proportional to the totalvolume dispensed by the batch controller.This Pulse Output function enables the pulseoutput frequency to be reduced by one of fivedividing factors between 10 and 100,000.

Display / 1Display / 10

Display / 100Display / 1000Display / 10000Display / 100000

Set Output Rate

Highlight the required option and press E toenter the selection.

Note: Maximum output frequency is 4 Hz.

6.4.12 Clear Grand TotalThe Grand Total is a record of the totalquantity of product dispensed since the GrandTotal was last reset to zero. It must be zeroedevery time the batch controller scaling ischanged The Grand Total can be viewed in theInformation section of the System Menu – seesection 6.2 and Appendix 2.

CAUTIONAfter zeroing the old grand total

can not be recovered

To prevent the Grand Total being accidentallyzeroed, the clear instruction has to beconfirmed before it will be executed.

Clear G TotalCancel

Clear Grand Total

20

If ‘Clear G Total’ is highlighted and the Epushbutton operated, a second screen will bepresented. To confirm that the Grand Total isto be zeroed highlight ‘Continue’ and press Ewhich will result in the instruction beingexecuted.

ContinueCancel

Clear Grand Total

6.4.13 DefaultsThis function allows the configuration defaultslisted in section 6.3 to be globally restored.Although useful for defining a starting pointwhen commissioning a batch controller, thesettings overwritten by this command can notbe recovered

CAUTIONAfter restoring default configuration theprevious settings can not be recovered.

To prevent the default settings beingaccidentally restored, the instruction has to beconfirmed before it will be executed.

Restore DefaultsCancel

Restore Defaults

If ‘Restore Defaults’ is highlighted and the Epushbutton operated, a second screen will bepresented. To confirm that the defaults are tobe restored, highlight ‘Continue’ and press Ewhich will result in the instruction beingexecuted.

ContinueCancel

Restore Defaults

6.4.14 SecurityA summary of instrument security is containedin section 6.1 of this manual.

This security function enables the four digitsecurity codes protecting the configuration andoperator menus to be defined. It also allowsthe contents of the operator menu to beselected.

Config CodeOperator CodeOperator Menu

Security

Highlighting the required function and pressingP will result in a selection menu beingdisplayed.

Each of the two security codes is entered digitby digit, when all four digits have been set,pressing E will enter the code and return thedisplay the security menu.

0000

Set Config Code

Notes: Default code 0000 disables thesecurity function and allowsunrestricted access to the menu.

Access to the Configuration Menus isalso protected by an external link asdescribed in section 6.1.

Contents of the Operator Menu are defined bytoggling the ‘On / Off’ box associated witheach item. To make the selection, highlight theitem to be changed and operate the P button.The item may then be turned ‘On’ or ‘Off’ usingthe Up or Down push-buttons.

Batch Sizing: OnBatch Select: On

History OnConfig Menu: On

Set Operator Menu

Pressing E will enter the selection, anotheritem may then be selected or the displayreturned to the Security menu by pressing Eagain.

21

6.4.15 Operator ScreensThe user screen may be selected from sixdifferent formats that are shown in Appendix 1.

They show different information and havedifferent display sizes so that the operator isonly presented with the essential informationnecessary to operate the batching system.Some screens include graphical informationallowing batch progress to be rapidlyassessed.

Screen 6 is intended for commissioning andshows all engineering information includingoutput status and flow rate.

SCREEN 1SCREEN 2

toSCREEN 6

Set User Screen

Highlight the required option and press E toenter the selection.

6.4.16 DisplayThe display contrast and backlight brillianceare adjustable using this function. The twoadjustments are made with the Up and Downbuttons, the amplitude of each being shown ona horizontal bargraph. Control is transferredbetween brilliance and contrast by operatingthe P pushbutton.

After adjustment pressing E enters thechanges and returns the display to the SystemMenu.

6.4.17 Output optionsControl 1 is a dedicated output that is alwaysconnected to terminals A1 and A2. Control 1is energised immediately the Start button isoperated and de-energised when the batchedvolume equals the batch setpoint. Outputs 2 and 3 may be configured to outputsix different signals or they may be unused asdescribed in sections 6.4.8 & 9. The followingsections describe each of these selectablesignals.

6.4.17.1 Control 2This output is similar to Control 1. It isenergised a configurable timeCONTROL2delay after Control 1 is energisedand de-energised a configurable batchedvolume CONTROL2stop before Control 1 isde-energised. Fig. 1 shows the operationdiagrammatically.

6.4.17.2 Control 3This output is identical to Control 2 exceptdelays are defined by CONTROL3delay andCONTROL3stop.

6.4.17.3 Flow alarmThis output is described in section 6.6.7

6.4.17.4 Reset statusThe reset status output indicates when thebatch has been started and when the controllerhas been reset and is ready to start anotherbatch. See Fig 12.

Fig 12 Reset status timing

6.4.17.5 Batch statusThe batch status output is the inverse ofControl 1 except that it does not close if apause is initiated during a batch. See Fig 13.

Fig 13 Batch status timing

6.4.17.6 Pulse outputThis output is described in section 6.4.11

22

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24

Fig 14 Batch Settings

6.5 BATCH SETTINGSSee Fig 14.

6.5.1 Scale Points (Non-linear pulse inputs)This and the following Scale Factors functiondescribed in section 6.5.2 are used to calibratethe 16 point lineariser. The lineariser isactivated from the System Menu - see section6.4.6.

Fig 15 shows the relationship between inputfrequency and Scale Factor for a lineariserusing three breakpoints. Up to sixteenbreakpoints may be used, the input frequencyfor any breakpoints that are not requiredshould be set to zero.

Fig 15 Three point lineariser

The Scale Factor at input frequencies belowthe lowest Scaling Point is the same as thatentered for the lowest Scaling Point.

The Scale Factor for input frequencies abovethe highest Scaling Point is the same as thatentered for the highest Scaling point.

The Scale Factor at input frequencies betweentwo Scaling Points is calculated according to astraight line between the Scale Factors at thetwo points.

The input frequency at which each breakpointis require should be set using this function.

Point 01: XXXX.X to

Point 16: XXXX.X

Select Scaling Point / Set Frequency

6.5.2 Scale Factors (Non-linear pulse inputs)The k factor of a flowmeter is the number ofoutput pulses that it produces per unit volumee.g. 70 pulses per litre.

The batch controller’s Scale Factor is adividing factor adjustable between 0.001 and999999, which is used to convert the outputpulses from the flowmeter into a volumedisplay in engineering units.

Volume displayed = Number of input pulses Scale Factor If the Scale Factor is set to the flowmeter’s kfactor, the batch controller will display volumein the flowmeter’s engineering units.

e.g. For a flowmeter having a k factor of 70pulses per litre, the batch controller ScaleFactor may be selected to provide the requireddisplay

Scale Factor Least significant Display digit represents

Litres

0.7 Hundredths of a Litre7.0 Tenths of a Litre

70.0 Litres700.0 Tens of Litres

7000.0 Hundreds of Litres318.2 Gallons

(There are 4.54609 litres in a UK gallon)

This function sets the required Scale Factor ateach Scaling Point input frequency(breakpoint) defined in the Scaling Pointfunction described in section 6.5.1

XXXX.X: XXXXXX to

XXXX.X: XXXXXX

Select Frequency / Set Scale Factor

6.5.3 Scale Factor (For linear pulse inputs)The k factor of a flowmeter is the number ofoutput pulses that it produces per unit volumee.g. 70 pulses per litre.

The batch controller’s Scale Factor is adividing factor adjustable between 0.001 and999999, which is used to convert the outputpulses from the flowmeter into a volumedisplay in engineering units.

25

Volume displayed = Number of input pulses Scale Factor If the Scale Factor is set to the flowmeter’s kfactor, the batch controller will display volumein the flowmeter’s engineering units.

e.g. For a flowmeter having a k factor of 70,the Cal Value may be selected to provide therequired display

Scale Factor Least significant Display digit represents

Litres

0.7 Hundredths of a Litre7.0 Tenths of a Litre

70.0 Litres700.0 Hundreds of Litres318.2 Gallons

(There are 4.54609 litres in a UK gallon)

000001.

Set Scale Factor

6.5.4 Scaling (For 4/20mA input)The 4/20mA analogue output from a flowmeterrepresents the rate of flow, which may bedisplayed by the BA454D batch controller inany engineering units. See section 6.6.3

Total batched volume is calculated byintegrating the flow rate during the batchingperiod.

The batch controller Scale Factor, which is adividing factor that may be adjusted between0.001 and 999999, defines the arithmeticrelationship between the units of measurementof the rate and the total batched displays.

Scale Factor = Units of batched display Units of rate display

When calculating this Scale Factor, therequired units of measurement for the totalbatched display must be converted to thoseused for the rate display as shown in thefollowing example.

The BA454D rate display represents litres persecond but the total batched display is requiredin UK gallons.

Scale Factor = Units of batched display Units of rate display

= 1 gallon = 4.5461 litre 1 litre 1 litres

Scale Factor = 4.5461

If the rate display and the total batched displayare required in the same units ofmeasurement, the Scale Factor should be setto 1.0

000001.

Set Scale Factor

6.5.5 Batch D.P.The position of the decimal point in the batchdisplay, which determines the resolution of thedisplay, is set by this function. In operationleading zeros are suppressed

00000000.

Set Display D.P.

The function also determines the position ofthe decimal point in the Batch Size, Batch Limitand Pre-Stop functions.

6.5.6 Batch LegendThe units of measurement of the batchedvolume can be entered with this function. Upto six upper and lower case alphanumericcharacters may be used. Some of the operatorscreens will display this legend against thebatch display.

XXXXXX

Set Batch Legend

26

6.5.7 Batch LimitTo prevent accidental over-filling, the BatchLimit defines the maximum batch that may bedispensed. If a batch setpoint greater than theBatch Limit is entered, it will be accepted but awarning will appear on the screen. Theposition of the decimal point will be the sameas the batch display. See 6.5.5.

99999999

Set Batch Limit

6.5.8 Batch NamesThis function enables up to nine pre-enteredbatch setpoints to be identified with individualnames each having up to sixteen alphanumericcharacters. The name is displayed when theBatch Size setpoint is selected or adjusted seesections 6.5.9 and 6.5.10. Some of theoperator display screens also show thesetpoint name.

Batch 1

Set Batch Names

6.5.9 Batch SizeThe named batch setpoints can be assigned avalue with this function. The position of thedecimal point in all the setpoints will be asdefined by the Batch D.P. function. - See 6.5.5.

Batch 1Batch 2

ToBatch 9

00000000.

Set Batch Size

Note: May be included in Operator Menu.See 2.1

6.5.10 Select BatchThis allows the batch controller’s operatingsetpoint to be selected from the nine pre-entered setpoints. To select, highlight thename of the required setpoint and press E.The setpoint value will be shown at the bottomof the display screen.

Batch 1Batch 2

ToBatch 9

XXXXXXXX

Select Batch

Note: May be included in Operator Menu.See 2.1

6.5.11 Batch HistoryThe volume of product dispensed in theprevious nine batches is recorded by thisfunction.

Batch n: XXXXXXXn-1:n-2:ton-9:

Batch History

Note: May be included in Operator Menu.See 2.1

6.5.12 CONTROL2delay (Control 2 Start Delay)At the start of a batch, Control 1 is energisedimmediately the Start button is operated.Control 2 may be energised at the same time,or delayed for up to 3600 seconds by thisfunction.

0000

CTL2 Delay: Seconds

27

6.5.13 CONTROL2stop (Control 2 Pre-Stop)Control 1 is de-energised when the batchedtotal equals the batch setpoint. Control 2 maybe de-energised at the same time, or aprogrammable batch quantity before the batchsetpoint is reached. This quantity is defined byCONTROL2stop which is displayed in thesame units as the batched total.

00000000.

CTL2 Pre-Stop Counts

6.5.14 CONTROL3delay (Control 3 Start Delay)As Control 2 Start delay described in section6.5.12 except the delay applies to Control 3.

6.5.15 CONTROL3stop ( Control 3 Pre-Stop)As Control 2 Pre-Stop described in section6.5.13 except this function applies to Control 3.

6.5.16 Count ModeThis function determines whether the batchdisplay counts upwards from zero to the batchsize setpoint, or downwards from the batchsize setpoint to zero.

UpDown

Set Count Direction

Highlight the required option and press E toenter the selection.

6.5.17 Overrun CompensationOverrun compensation automatically correctsfor time delays in the batching system that maycause product dispensing to continue afterControl 1 has been de-energised. Theaverage overrun of the last three batches isused for the correction.

When overrun compensation is selected, theaverage amount of product dispensed betweenControl 1 being de-energised and the batchcontroller being reset is calculated. Thisquantity is automatically subtracted from thebatch setpoint for subsequent batches.

If the flow alarm has been assigned to one ofthe outputs, overrun compensation will becalculated using the product dispensedbetween Control 1 being de-energised and theflow alarm being activated or the batchcontroller being reset, whichever occurs first.

OnOff

Set Compensation

Highlight the required option and press E toenter the selection.

6.5.18 Batch CyclesWhen the ‘Restart’ function described insection 6.4.7 is set to ‘Auto Restart’, thisfunction defines the number of batches that areperformed. Any number of cycles up to10,000 may be entered.

00001

Set No. of Batches

Set the required number cycles digit by digitand press E to enter the value.

6.5.19 Restart DelayWhen the ‘Restart’ function described insection 6.4.7 is set to ‘Auto Restart’, thisfunction defines the delay between one batchfinishing and the next batch starting. Anydelay up to 24 hours may be set.

00 : 00 : 00

Restart: hh : mm : ss

Set the required delay time digit by digit andpress E to enter the value.

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30

Fig 16 Rate Settings

6.6 RATE SETTINGSSee Fig. 16

6.6.1 Rate Scaling (For pulse inputs)The Rate Scaling factor, which may beadjusted between 0.001 and 999999, definesthe arithmetic relationship between the units ofmeasurement of the batch display and the ratedisplay units of measurement.

Rate Scaling Factor = Units of rate display Units of batch display

When calculating the Rate Scaling Factor, therequired units of measurement for the ratedisplay must be converted to those used forthe batch display as shown in the followingexample.

The BA454D batch display is in UK gallons butthe rate display is required in litres.

Rate Scaling Factor = Units of rate display Units of batch display

= 1 litre 1 gallon

= 1 litre 4.5461 litres

Rate Scaling Factor = 0.21997

If the rate display is required in the same unitsas the batch display, the Rate Scaling Factorshould be set to 1.0

000001.

Set Scale Factor

6.6.2 Rate D.P. (For pulse inputs)The position of the rate display decimal point,which determines the resolution of the display,is set by this function. In operation leadingzeros are suppressed

00000.0

Set Display D.P.

6.6.3 20mA Display (For 4/20mA input)The rate display at 20mA is set with thisfunction. The range of adjustment is between0.00001 and 999999

00100.0

Set 20mA Display

The display may represent flow per second,per minute or per hour. The units of time aredefined by the Timebase, which determineshow the measured rate is integrated toproduce the batch display. See 6.6.5

6.6.4 Rate LegendThis function enables the units of the ratedisplay to be entered. Up to six upper andlower case alphanumeric characters may beused. Some of the operator screens willdisplay this legend against the rate display.

XXXXXX

Set Rate Legend

6.6.5 TimebaseThe exact function of the timebase dependsupon whether the batch controller isconditioned to receive a pulse input or a4/20mA analogue input.

Pulse inputsNumber of pulses received is proportionalto volume dispensed.The timebase multiplies the rate display by60 if flow per minute is to be shown and by3,600 if flow per hour is to be shown.

4/20mA Analogue inputAmplitude of the input current isproportional to rate of dispensing (flow).The timebase does not affect the ratedisplay. If the rate display represents flowper minute, the batch display is divided by60, if the rate display represents flow perhour the batch display is divided by 3,600.

/Second/Minute/Hour

Set Rate TimeBase

Highlight the required option and press E toenter the selection.

31

6.6.6 Rate FilterThe BA454D contains a digital filter with twoindependent adjustable parameters enablingthe rate display frequency response to betailored for optimum performance.

SmoothingAmount of filtering applied (time constant).Adjustable between 0 and 9, where 0 is nofiltering and 9 is maximum filtering.

Smoothing Filter time constantseconds

0 01 1.32 4.33 6.54 8.75 11.36 15.77 20.98 25.29 31.5

Jump-OutDefines the deviation from the displayedrate at which the filter will be overriddenand the rate display will move rapidly tothe new value.

Jump-Out Magnitude of stepchange which willproduce a rapid

response0 Off1 1%2 2%3 4%4 8%5 12%6 16%7 24%8 32%9 64%

By careful adjustment of the two parameters astable display with an acceptable step inputresponse can be obtained for mostapplications.

During commissioning it is recommend thatinitially Jump-Out is set to 0 (off) andSmoothing is adjusted to provide acceptablerate display stability. Jump-Out should then beincreased until the selected step size is greaterthan the noise on the display signal, at whichsetting the rate display will again becomestable. These will be the optimum filterparameters for acceptable rate display stabilityand a fast response to a large rate signalchange.

Smoothing: 2Jump-Out: 4

1..9 = Light..Heavy / 1..9 = Fine..Coarse

6.6.7 Flow AlarmThe flow alarm may be assigned to any of thebatch controller outputs – See section 6.4.8When the flow rate falls below the flow alarmsetpoint, the assigned output will close, theBA454D will enter a pause condition and thedisplay will show ‘Paused – Low Flow’.

To prevent false alarms at the start of a batchwhile the flow rate increases, the flow alarmmay be inhibited for between 1 and 3,600seconds after the batch is started.

Low-Flow RateInhibit Time

Flow Alarm

Highlight the ‘Low-Flow Rate’ option andoperate the P pushbutton, which will result inthe ‘Set Low-Flow Rate’ screen beingdisplayed with the decimal point positioned asalready specified. Set the required alarmsetpoint digit by digit then press E to enter thevalue and return to the ‘Flow Alarm’ screen.

If the alarm is to be inhibited while the batch isstarting, highlight the ‘Inhibit Time’ option andoperate the P pushbutton which will result inthe ‘Inhibit: Seconds’ screen being displayed.Set the required inhibit time digit by digit andthen press E to enter the value and return tothe ‘Flow Alarm’ screen.

6.6.8 Clip-OffTo prevent the batch total being incrementedat very low flow rates where flowmeters maybe less accurate, the BA454D incorporates anadjustable clip-off function. At flow ratesbelow the adjustable clip-off threshold, the ratedisplay is forced to zero and the batch displayis not incremented.

00000.0

Set Clip-off Rate

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7. CALIBRATION EXAMPLE

In this example a BA454D batch controller isrequired to control the dispensing of a liquidinto a tank as shown in Fig. 17. It is a stand-alone system so galvanic isolators have beenused for the interface between the safe andhazardous area. The batch controller ispowered by an isolator with a 28V, 93mAoutput safety description. Two more identicaldevices are used to power the intrinsically safesolenoid valves that are controlled by Control 1and Output 2. Output 3, which is configuredas a flow alarm, is connected to a switchtransfer isolator which produces a switchcontact closure in the safe area.

The BA454D batch controller is required to:

Dispense 1,000 or 500 litres of product intoa tank having a maximum capacity of1,100 litres. Two volumes to be identifiedFull volume and Half volume respectively.

The flowmeter incorporates a proximitydetector and produces an output of 25pulses per litre.

Display the dispensed total with aresolution of 0.1 litres.

Batch Controller to count upwards fromzero to the batch setpoint.

Control two parallel valves (2 stagecontrol).

At start of the batch valve 2 is to open 10seconds after valve 1 and to close when50 litres of product remain to bedispensed.

Compensate for errors resulting fromactuator delays.

Initiate an alarm if the flow rate falls below0.2 litres per second. Alarm to beinhibited for the first 20 seconds of thebatch.

Operator needs to select the batch sizefrom the operator menu, but must not beable to adjust the two setpoints. Theoperator requires access to the history ofthe last ten batches but must not haveaccess to the configuration menus.

The process is to be controlled by thebatch controller’s front panel switches. TheReset function is not required.

The Operator Menu is not to be protected by asecurity code, but the Configuration Menus areto be protected by code 1209.

Fig 17 Liquid dispensing system

System Settings

Function SettingLanguage English

User Controls Local

Signal Input Prox Detector

Lineariser Off

Restart Quick

Output 2 Control 2

Output 3 Flow Alarm

Clear Grand Total Yes

SecurityConfig Code 1209Operator Code 0000Operator Menu Batch Sizing Off

Batch Select OnHistory OnConfig Menu Off

Operator Screens Screen 1

33

Batch Settings

Function SettingScale Factor 25Batch D.P. 0000000.0Batch Legend LitresBatch Limit 1050.0Batch Names Batch 1 Full Volume

Batch 2 Half VolumeBatch Size Full Volume 1000.0

Half Volume 500.0CONTROL2delay 10 secondsCONTROL2stop 50.0Count Mode UpOverrun Comp On

Rate Settings

Function SettingRate Scaling 1.0Rate D.P. 00000.0Rate Legend L / sTimebase /SecondRate Filter Smoothing 2

Jump-Out 4Flow Alarm Low-Flow Rate 0.2Inhibit Time 0020Clip-Off 00000.0

34

8. MAINTENANCE

8.1 Fault finding during commissioningIf a BA454D fails to function duringcommissioning the following procedure shouldbe followed:

Symptom Cause Check:No Display No Power

Incorrect wiring

No Zener barrier,galvanic isolator

or resistor inseries with powersupply. See 4.2.1

That there is atleast 11 volts

between terminal1 and 2.

Terminal 1should bepositive.

Front panelpushbuttons do

not function.

Batch controllerconditioned tooperate with

remote switches.

User Controlsconfiguration.

BA454D will notcount inputpulses or

integrate 4/20mAinput.

Input notcorrectly

configured.

Input connectedto wrong

terminals orreversed.

Incorrectelectrical level

Signal inputconfiguration.

Input terminals

That pulse inputexceeds batch

controller’s inputswitching

thresholds.

4/20mA loop cantolerate 0.6V

drop introducedby the batchcontroller.

Control 1 is notenergised andscreen does notdisplay ‘Running’

when Startbutton isoperated.

Batch sizesetpoint not

entered.

Batch setpoint.Enter or select

the correct batchsetpoint.

BA454Dcontinues to

count after batchsize setpoint is

reached.

The BA454D willonly stop

counting wheninput pulses stop,or 4/20mA inputcurrent falls to

4mA.

Note: The controlloop must be

closed so that thebatch controlleroutput(s) controlthe input signal.

Configurationmenus are not

accessible.

Security linkmissing and / orsecurity code not

entered.

That terminals 18& 19 are joined

together.

Enter four digitsecurity code.

Function missingfrom sub-menu.

Functionsdependent onhigher level

functions areremoved fromthe menu if the

higher levelfunction is not

selected.

That relatedhigher levelfunction has

been selected.

Batch controlleris not performingas anticipated.

Incorrectconfiguration.

Information menuthat lists all theconfiguration

settings.

The information sub-menu, which is described in section 6.2 and Appendix 2, lists all the batch controller configuration settings. This provides a rapid way of checking that the instrument has been correctly configures.

8.2 Fault finding after commissioning

ENSURE PLANT SAFETY BEFORESTARTING MAINTENANCE

Live maintenance is permitted onintrinsically safe equipment installedin a hazardous area, but only certifiedtest equipment should be used unlessa gas clearance certificate is available.

If a BA454D fails after it has been functioningcorrectly, the table shown in section 8.1 mayhelp to identify the cause of the failure.

If this procedure does not reveal the cause ofthe fault, please contact BEKA or our localagent.

8.3 ServicingWe recommend that faulty BA454D batchcontrollers are returned to BEKA associates orto our local agent for repair.

8.4 Routine maintenanceThe mechanical and electrical condition of theinstrument should be regularly checked.Initially annual inspections are recommended,but the inspection frequency should beadjusted to suit the environmental conditions.

See sections 6.4.4 and 6.4.5 if the batchcontroller’s 4/20mA input is being used.

8.5 GuaranteeInstruments which fail within the guaranteeperiod should be returned to BEKA associatesor our local agent. It is helpful if a briefdescription of the fault symptoms is provided.

8.6 Customer commentsBEKA associates is always pleased to receivecomments from customers about our productsand services. All communications areacknowledged and whenever possible,suggestions are implemented.

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9. ACCESSORIES

9.1 Tag numberThe BA454D can be supplied with a blank orcustom engraved stainless steel plate securedby two screws to the side of the instrumentenclosure. This plate can accommodate:

1 row of 9 alphanumeric characters 10mmhigh.

or 1 row of 11 alphanumeric characters 7mmhigh.

or 2 rows of 18 alphanumeric characters5mm high.

9.2 Pipe mounting kitsTwo pipe mounting kits are available forsecuring the BA454D batch controller to ahorizontal or vertical pipe.

BA392D Stainless steel bracket secured bytwo worm drive hose clips for 60 to80mm outside diameter pipe.

BA393 Heavy duty stainless steel bracketsecured by a single ‘V’ bolt. Willclamp to any pipe with an outsidediameter between 40 and 80mm.

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10. INDEX

Subject Section

ATEX Directive 3.1, 3.8Dust certification Appendix 3

Backlight 6.4.3Batch

Cycles 6.5.18Decimal point D.P. 6.5.5History 6.5.11Legend 6.5.6Limit 6.5.7Names 6.5.8Select 6.5.10Size 6.5.9

Calibration4mA 6.4.420mA 6.4.5Example 7.

CertificatesEC Type-Examination 3.1System 4.1

Certification label 3.8cFM Approval Appendix 4Clip-off 6.6.8Configuration

Batch 6.5Default 6.3Rate 6.6System 6.4

CONTROL2delay 6.5.12CONTROL3delay 6.5.14CONTROL2stop 6.5.13CONTROL3stop 6.5.15Count mode 6.5.16

Dust certification Appendix 3

EMC 5.3External switches 3.6, 4.4

Flow alarm 6.6.7FM Approval Appendix 4

Galvanic isolators 4.3Gas groups 3.2Grand total 6.4.12

Appendix 2

Information sub-m Appendix 2Inhibit link 3.7, 4.5Inputs 3.4, 4.2.2, 4.3.2

Analogue 4/20mA 4.2.3Proximity detector 4.2.2.2Switch contact 4.2.2.1Voltage pulse 4.2.2.3

Installation procedure 5.2Intrinsic safety 3.

Language 6.4.1Lineariser 6.4.6Location 5.1

Subject Section

MenuBatch settings 6.5Configuration 6.Operator 2.1Rate settings 6.6System 6.4

Operator Controls 2.1Display 6.4.16Screens 6.4.15, Appendix 1

Output2 6.4.83 6.4.94, 5 & 6 (optional) 6.4.10Options 6.4.17

Batch status 6.4.17.5Control 2 6.4.17.1Control 3 6.4.17.2Flow alarm 6.4.17.3Reset status 6.4.17.4

Overrun compensation 6.5.17

Pipe mounting kits 9.2Power supply 3.3, 4.2.1, 4.3.1

Failure of 2.2Pulse output 6.4.11

Rate Decimal point D.P. 6.6.2Filter 6.6.6Legend 6.6.4Scaling (pulse input) 6.6.1Timebase 6.6.5

Reset pushbutton 2.1Restart 6.4.7

Delay 6.5.19

Security 6.1, 6.4.14Link 3.7, 4.6

Scale factors 6.5.2, 6.5.3Scale points 6.5.1Scaling 6.5.4

Signal input 6.4.3Start pushbutton 2.1Stop pushbutton 2.1Switch outputs 3.5, 4.2.4, 4.3.3

Tag number 9.1T rating 3.2

User controls 6.4.2

Zener barriers 4.2Zones 3.2

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Appendix 2 Information menu

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Appendix 3 ATEX dust certification

A3.0 ATEX dust certificationIn addition to ATEX certification permittinginstallation in explosive gas atmosphereswhich is described in the main section of thisinstruction manual, the BA454D is availableATEX certified for use in the presence ofcombustible dusts. If ATEX dust certificationis required it must be requested when theBA454D Batch Controller is purchased.

WARNINGBefore installing a BA454D BatchController in the presence of acombustible dust, ensure that thecertification information label whichis located on the top of theinstrument specifies dustcertification - see section A3.2

A3.1 Zones and Maximum Surface TemperatureThe BA454D has been ATEX dust certified asGroup II, Category 1 D Ex ia IIIC T80ºC Da(Tamb = -40ºC to +60ºC) IP66.

When installed as specified by EN 60079-14Electrical installations design, selection anderection, the Batch Controller may be installedin:

Zone 20 explosive atmosphere in the form of a cloud of combustible dust in air is continuously present, or forlong periods or frequently.

Zone 21 explosive atmosphere in the form of a cloud of combustible dust in air is likely to occur occasionallyin normal operation.

Zone 22 explosive atmosphere in the form of a cloud of combustible dust in air is not likely to occur in normaloperation, but if it does occur, will only persist for a short period.

Be used with dusts having a Minimum Ignition Temperature of:

Dust cloud 120oC

Dust layer on BA454D 155oCup to 5mm thick

Dust layer on BA454D Refer toover 5mm thick. EN 60079-14

At an ambient temperature between -40 and +60oC

A3.2 Certification Label InformationThe certification label is fitted in a recess onthe top outer surface of the enclosure. Itshows the ATEX dust certification informationincluding the maximum surface temperatureand ingress protection, plus the ATEX gascertification information. Non Europeaninformation may also be shown.

The instrument serial number and date ofmanufacture are recorded on a separate labelinside the terminal compartment.

A3.3 Calibration & maintenanceThe ATEX dust certification relies on the BatchController enclosure being dust-tight.Therefore the control and terminal coversshould only be removed when dust can notenter the instrument enclosure. Beforereplacing the control and terminal coversensure that the sealing gaskets areundamaged and are free from foreign bodies.

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Appendix 4 FM & cFM Approval for use in the USA &Canada.

A4.0 Factory Mutual ApprovalFor installation in the USA and Canada theBA454D has been approved intrinsically safeand nonincendive by FM Approvals, projectidentification 3033262. Copies of theCertificates of Compliance are available fromthe BEKA associates sales office, or may bedownloaded from www.beka.co.uk

A4.1 Intrinsic safety approvalThe BA454D batch controller is approved tothe FM Class 3600 intrinsic safety Standardand Canadian Standard C22.2. Installationsshould comply with BEKA associates ControlDrawing CI450-12 that is attached to thisappendix.

A4.2 Nonincendive approvalThe BA454D batch controller is also approvedto the FM Class 3610 Nonincendive Standardand Canadian Standard C22.2. Installationsshould comply with BEKA associates ControlDrawing CI450-13 that is attached to thisappendix.

Note:When powered from a 24V dc supply without aZener barrier or a galvanic isolator, a 330ohm1W resistor should be connected in series withterminal 1.

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