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BEKA BA454D, Manual

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Issue:    12

29

th

 August 2014

BA454D

Intrinsically safe

Field mounting

Batch Controller

Issue 12

Summary of Contents for BA454D

Page 1: ...Issue 12 29th August 2014 BA454D Intrinsically safe Field mounting Batch Controller Issue 12 ...

Page 2: ...4 17 Output options 6 4 17 1 Control 2 6 4 17 2 Control 3 6 4 17 3 Flow alarm 6 4 17 4 Reset status 6 4 17 5 Batch status 6 4 17 6 Pulse output 6 5 Batch settings 6 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 Legend 6 5 7 Batch Limit 6 5 8 Batch Names 6 5 9 Batch S...

Page 3: ...mable input scaling so that the total and rate displays may be in any engineering units such as litres or gallons The operator enters or selects via the pushbuttons the setpoint which is the required volume to be dispensed Control 1 is energised immediately the Start push button is operated followed by Control 2 after a programmable time delay Towards the end of the batch Control 2 is de energised...

Page 4: ...ed and Complete will be displayed on the screen RESET After completion of a batch the batch controller must be reset before the next batch can be started After resetting the screen displays Ready Input signals are ignored until the Start button is operated Note Two selectable options modify the reset function Quick Restart eliminates the need to manually reset the BA454D at the end of each batch W...

Page 5: ...ame state when power is restored 3 INTRINSIC SAFETY CERTIFICATION 3 1 ATEX certificate The BA454D has been issued with an EC Type Examination Certificate by Notified Body Intertek Testing Services ITS confirming compliance with the European ATEX Directive 94 9 EC for Group II Category 1 gas and dust atmospheres Ex ia IIC T5 equipment The instrument bears the Community Mark and subject to local cod...

Page 6: ...gnetic pickup or an analogue 4 20mA current Note Inputs 1 and 2 can not be used simultaneously 3 4 1 Input 1 Terminals 11 and 12 may be connected to any transducer having input parameters equal to or greater than Ui 10 6V dc Ii 20mA dc Pi 0 05W The terminals may also be connected to any device such as a switch contact complying with the requirements for simple apparatus as specified in Clause 5 7 ...

Page 7: ...ratus i e they must have IP20 protection and be capable of withstanding a 500V rms insulation test to earth for one minute Most industrial push buttons satisfy these requirements The total maximum permitted cable parameters for all the cables connected to terminals S1 to S7 in a IIC hydrogen gas are Co 0 15 µF Lo 0 48mH These are not restrictive and allow a significant distance between the switche...

Page 8: ...er certified Ex ia IIC by a Notified Body may be used providing that the safety parameters are within the limits specified by the BA454D EC Type Examination Certificate Only one polarity of Zener barrier i e positive or negative may be used with each BA454D batch controller installation To assist with system design the Zener barrier System Certificate specifies the safety description of barriers t...

Page 9: ...kHz 16 15 Low voltage pulse 1V 3V 5kHz 16 14 High voltage pulse 3V 10V 5kHz 16 13 Note Only one input may be used at a time 4 2 2 1 Switch contact input Any mechanically activated switch contact located in the hazardous area may be connected directly to terminals 12 11 providing the switch has IP20 protection and can withstand a 500V rms insulation test to earth Most magnetically activated reed re...

Page 10: ...ors are probably the simplest intrinsically safe interface as they provide isolation and do not require a high integrity earth connection Any galvanic isolator certified Ex ia IIC by a Notified Body may be used providing that the safety parameters of the isolator terminals are compatible with the safety parameters of the batch controller terminals to which the isolator is connected To assist with ...

Page 11: ...uired type of input into the hazardous area 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 WARNING These switch outputs should not be used for critical safety applications When the batch controller is powered from a galvanic isolator the switch outputs remain ...

Page 12: ...ore Zener barriers can not be used Fig 8 shows how external Stop buttons may be located in the safe and hazardous areas Fig 8 Stop buttons in hazardous safe areas 4 5 Inhibit link Linking terminals 18 and 20 together inhibits the batch controller input If linked during a batch dispensing will continue but the batched total will not be incremented or decremented if counting down These terminals may...

Page 13: ... plate to ensure electrical continuity between the three conduit cable entries 5 2 Installation Procedure Fig 9 illustrates the instrument installation procedure a Remove the instrument terminal cover by unscrewing the two captive A screws b Mount the instrument on a flat surface and secure with two M6 screws through the B holes Alternatively use one of the mounting kits described in section 9 2 c...

Page 14: ...Fig 10 Dimensions and terminal connections 14 ...

Page 15: ...egends displayed by the batch controller are shown within inverted commas e g Running When the batch controller is displaying Ready access to the main configuration menu is obtained by pressing the P and E buttons simultaneously or if enabled via the Operator Menu The configuration menu can not be accessed while the batch controller is running Once within the main menu the Up and Down buttons move...

Page 16: ...tart Normal Output 2 Unused Output 3 Unused Optional outputs 4 5 6 Unused Pulse Output Display 1 Grand Total Cleared Security Config Code 0000 Operator Code 0000 Operator Menu Batch Sizing On Batch Select On History On Config Menu On Operator Screens Screen 1 Batch Settings Scale factor Linear pulse 000001 Scaling 4 20mA input 000001 Batch D P 00000000 Batch Legend No legend Batch Limit 99999999 B...

Page 17: ...17 BLANK PAGE ...

Page 18: ...18 Fig 11 System Settings Fig 11 System Settings ...

Page 19: ...tely factory calibrated it is only necessary to perform this calibration as part of routine maintenance To perform the calibration connect a 4 to 20mA current source to batch controller terminals 16 17 and adjust the input current to exactly 4mA To achieve maximum batch controller performance the accuracy of the current source should be greater than 0 025 4uA To prevent the batch controller calibr...

Page 20: ... or more of the outputs may be configured to output the same function 6 4 9 Output 3 As Output 2 except terminals are A5 and A6 6 4 10 Optional outputs 4 5 and 6 Only available when factory fitted option is installed in the BA454D batch controller Configuration is the same as for Output 2 except terminal numbers are Output Terminal numbers 4 A7 A8 5 A9 A10 6 A11 A12 6 4 11 Pulse Output Any of the ...

Page 21: ... summary of instrument security is contained in section 6 1 of this manual This security function enables the four digit security codes protecting the configuration and operator menus to be defined It also allows the contents of the operator menu to be selected Config Code Operator Code Operator Menu Security Highlighting the required function and pressing P will result in a selection menu being d...

Page 22: ...always connected to terminals A1 and A2 Control 1 is energised immediately the Start button is operated and de energised when the batched volume equals the batch setpoint Outputs 2 and 3 may be configured to output six different signals or they may be unused as described in sections 6 4 8 9 The following sections describe each of these selectable signals 6 4 17 1 Control 2 This output is similar t...

Page 23: ...23 BLANK PAGE ...

Page 24: ...24 Fig 14 Batch Settings ...

Page 25: ...s that it produces per unit volume e g 70 pulses per litre The batch controller s Scale Factor is a dividing factor adjustable between 0 001 and 999999 which is used to convert the output pulses from the flowmeter into a volume display in engineering units Volume displayed Number of input pulses Scale Factor If the Scale Factor is set to the flowmeter s k factor the batch controller will display v...

Page 26: ...Scale Factor Units of batched display Units of rate display When calculating this Scale Factor the required units of measurement for the total batched display must be converted to those used for the rate display as shown in the following example The BA454D rate display represents litres per second but the total batched display is required in UK gallons Scale Factor Units of batched display Units o...

Page 27: ...n of the decimal point in all the setpoints will be as defined by the Batch D P function See 6 5 5 Batch 1 Batch 2 To Batch 9 00000000 Set Batch Size Note May be included in Operator Menu See 2 1 6 5 10 Select Batch This allows the batch controller s operating setpoint to be selected from the nine pre entered setpoints To select highlight the name of the required setpoint and press E The setpoint ...

Page 28: ...e overrun of the last three batches is used for the correction When overrun compensation is selected the average amount of product dispensed between Control 1 being de energised and the batch controller being reset is calculated This quantity is automatically subtracted from the batch setpoint for subsequent batches If the flow alarm has been assigned to one of the outputs overrun compensation wil...

Page 29: ...29 BLANK PAGE ...

Page 30: ...30 Fig 16 Rate Settings ...

Page 31: ...y at 20mA is set with this function The range of adjustment is between 0 00001 and 999999 00100 0 Set 20mA Display The display may represent flow per second per minute or per hour The units of time are defined by the Timebase which determines how the measured rate is integrated to produce the batch display See 6 6 5 6 6 4 Rate Legend This function enables the units of the rate display to be entere...

Page 32: ...oothing 2 Jump Out 4 1 9 Light Heavy 1 9 Fine Coarse 6 6 7 Flow Alarm The flow alarm may be assigned to any of the batch controller outputs See section 6 4 8 When the flow rate falls below the flow alarm setpoint the assigned output will close the BA454D will enter a pause condition and the display will show Paused Low Flow To prevent false alarms at the start of a batch while the flow rate increa...

Page 33: ...s from zero to the batch setpoint Control two parallel valves 2 stage control At start of the batch valve 2 is to open 10 seconds after valve 1 and to close when 50 litres of product remain to be dispensed Compensate for errors resulting from actuator delays Initiate an alarm if the flow rate falls below 0 2 litres per second Alarm to be inhibited for the first 20 seconds of the batch Operator nee...

Page 34: ... Batch 2 Half Volume Batch Size Full Volume 1000 0 Half Volume 500 0 CONTROL2delay 10 seconds CONTROL2stop 50 0 Count Mode Up Overrun Comp On Rate Settings Function Setting Rate Scaling 1 0 Rate D P 00000 0 Rate Legend L s Timebase Second Rate Filter Smoothing 2 Jump Out 4 Flow Alarm Low Flow Rate 0 2 Inhibit Time 0020 Clip Off 00000 0 34 ...

Page 35: ...unction is not selected That related higher level function has been selected Batch controller is not performing as anticipated Incorrect configuration Information menu that lists all the configuration 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 ...

Page 36: ... alphanumeric characters 7mm high or 2 rows of 18 alphanumeric characters 5mm high 9 2 Pipe mounting kits Two pipe mounting kits are available for securing the BA454D batch controller to a horizontal or vertical pipe BA392D Stainless steel bracket secured by two worm drive hose clips for 60 to 80mm outside diameter pipe BA393 Heavy duty stainless steel bracket secured by a single V bolt Will clamp...

Page 37: ...ty detector 4 2 2 2 Switch contact 4 2 2 1 Voltage pulse 4 2 2 3 Installation procedure 5 2 Intrinsic safety 3 Language 6 4 1 Lineariser 6 4 6 Location 5 1 Subject Section Menu Batch settings 6 5 Configuration 6 Operator 2 1 Rate settings 6 6 System 6 4 Operator Controls 2 1 Display 6 4 16 Screens 6 4 15 Appendix 1 Output 2 6 4 8 3 6 4 9 4 5 6 optional 6 4 10 Options 6 4 17 Batch status 6 4 17 5 C...

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Page 40: ...Appendix 2 Information menu 40 ...

Page 41: ...orm of a cloud of combustible dust in air is likely to occur occasionally in normal operation Zone 22 explosive atmosphere in the form of a cloud of combustible dust in air is not likely to occur in normal operation but if it does occur will only persist for a short period Be used with dusts having a Minimum Ignition Temperature of Dust cloud 120o C Dust layer on BA454D 155o C up to 5mm thick Dust...

Page 42: ...h controller is approved to the FM Class 3600 intrinsic safety Standard and Canadian Standard C22 2 Installations should comply with BEKA associates Control Drawing CI450 12 that is attached to this appendix A4 2 Nonincendive approval The BA454D batch controller is also approved to the FM Class 3610 Nonincendive Standard and Canadian Standard C22 2 Installations should comply with BEKA associates ...

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