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Issue: 5

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December 2010

BA458C

Intrinsically safe

Panel mounting

Batch Controller

Issue 5

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Summary of Contents for BA458C

Page 1: ...Issue 5 1st December 2010 BA458C Intrinsically safe Panel mounting Batch Controller Issue 5 ...

Page 2: ...6 4 15 User screens 6 4 16 Display 6 4 17 Output options 6 4 16 1 Control 2 6 4 16 2 Control 3 6 4 16 3 Flow alarm 6 4 16 4 Reset status 6 4 16 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 ...

Page 3: ...or selects via the front panel push buttons 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 a programmable volume before the batch setpoint is reached when Control 1 is also de energised By operating a small bypa...

Page 4: ... dispensed Operating the Start pushbutton will reset the batch controller and start another batch See section 6 4 7 Auto Restart enables the batch controller to run continuously At the end of each batch the controller waits for a programmable time before automatically resetting and starting another batch This sequence will continue until a programmable number of batches has been completed or the S...

Page 5: ... in any of the European Economic Area EEA member countries i e Austria Belgium Denmark Finland France Germany Greece Ireland Italy Luxembourg The Netherlands Portugal Spain Sweden and the United Kingdom ATEX certificates are also accepted in Norway Iceland Liechtenstein Switzerland and The Czech Republic This instruction manual describes installations which conform with BS EN60079 Part14 Electrica...

Page 6: ...contacts a proximity detector or a photodetector Input 2 terminals 13 14 15 16 17 complies with the requirements for simple apparatus and is for the connection of devices having a voltage or current output such as a magnetic 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 param...

Page 7: ...e apparatus 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 s...

Page 8: ...x ia IIC by an EEC approved certification body may be used providing that the safety parameters are within the limits specified by the BA458C EC Examination Certificate Only one polarity of Zener barrier i e positive or negative may be used with each BA458C batch controller installation To assist with system design the Zener barrier System Certificate specifies the safety description of barriers t...

Page 9: ...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 relays us...

Page 10: ...obably the simplest intrinsically safe interface as they provide isolation and do not require a high integrity earth connection Any galvanic isolator certified EEx ia IIC by an EEC approved certification 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 as...

Page 11: ...the hazardous 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 the same as described in section 4 2 4 Only when the switch output is required in the safe area is a galvanic isolator required A wide variety of switch transfer isolators are available with ...

Page 12: ... 6 Security link Access to the configuration menus is only available when terminals 18 19 are linked together see section 6 1 These terminals may only be linked together at the instrument or connected to a hazardous area mechanically operated switch having IP20 protection and able to withstand an ac test voltage of 500V to earth for one minute See section 3 7 5 INSTALLATION 5 1 Location The BA458C...

Page 13: ...and the panel c Connect the panel wiring to the rear terminal block s as shown in Fig 10 To simplify installation the terminals are removable so that panel wiring can be completed before the instrument is installed 5 3 EMC The BA458C complies with the requirements of the European EMC Directive 89 336 EEC For specified immunity all wiring should be in screened twisted pairs To prevent circulating c...

Page 14: ... and legends 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 button...

Page 15: ...Restart 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 9999999...

Page 16: ...16 Fig 11 System Settings ...

Page 17: ...rately 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 cali...

Page 18: ...n Note Two 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 BA458C 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 A...

Page 19: ...y A 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 bein...

Page 20: ...dicated output that is 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 T...

Page 21: ...21 BLANK PAGE ...

Page 22: ...22 Fig 14 Batch Settings ...

Page 23: ...lses 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 displa...

Page 24: ...ys 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 BA458C rate display represents litres per second but the total batched display is required in UK gallons Scale Factor Units of batched display Unit...

Page 25: ...tion 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 setpoi...

Page 26: ...ge 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 wi...

Page 27: ...27 BLANK PAGE ...

Page 28: ...28 Fig 16 Rate Settings ...

Page 29: ...play 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 ent...

Page 30: ... Smoothing 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 BA458C 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 inc...

Page 31: ...wards 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...

Page 32: ...ume 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 ...

Page 33: ... 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 been correctly configured 8 2 Fault finding after commissioning ENSURE PLANT SAFETY BEFORE ST...

Page 34: ...ulse 4 2 2 3 Installation procedure 5 2 Intrinsic safety 3 Language 6 4 1 Lineariser 6 4 6 Location 5 1 Subject Section Maintenance 8 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 Control 2 6 4 17 1 Control 3 6 4 17 2 F...

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Page 37: ...37 APPENDIX 2 Information menu ...

Page 38: ...wnloaded from www beka co uk A4 1 Intrinsic safety approval The BA458C batch 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 BA458C batch controller is also approved to the FM Class 3610 Nonincendive Standard an...

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