BEKA BA454D User manual

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

1. Description
2. Operation
2.1 Operator controls
2.2 Power supply failure
3. Intrinsic Safety Certification
3.1 ATEX certificate
3.2 Zones, gas groups & T rating
3.3 Power supply
3.4 Inputs
3.4.1 Input 1
3.4.2 Input 2
3.5 Switch outputs
3.6 External switches
3.7 Inhibit & security links
3.8 Certification label information
4. System Design for Hazardous Area
4.1 System certificates
4.2 Use with Zener barriers
4.2.1 Power supply
4.2.2 Pulse inputs
4.2.2.1Switch contact
4.2.2.2Proximity detector
4.2.2.3Voltage pulse
4.2.3 4/20mA analogue input
4.2.4 Switch outputs
4.3 Use with galvanic isolators
4.3.1 Power supply
4.3.2 Inputs
4.3.3 Switch outputs
4.4 External switches
4.5 Inhibit link
4.6 Security link
5. Installation
5.1 Location
5.2 Installation procedure
5.3 EMC
6. Configuration Menus
6.1 Security
6.2 Navigation
6.3 Default configuration
6.4 System settings
6.4.1 Language
6.4.2 User controls
6.4.3 Signal input
6.4.4 4mA calibration
6.4.5 20mA calibration
6.4.6 Lineariser
6.4.7 Restart
6.4.8 Output 2
6.4.9 Output 3
6.4.10 Optional outputs 4, 5 & 6
6.4.11 Pulse output
6.4.12 Clear grand total
6.4.13 Defaults
6.4.14 Security
6.4.15 Operator screens
6.4.16 Display
6.4.17 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 Size
6.5.10 Select Batch
6.5.11 Batch History
6.5.12 CONTROL2delay
6.5.13 CONTROL2stop
6.5.14 CONTROL3delay
6.5.15 CONTROL3stop
6.5.16 Count Mode
6.5.17 Overrun Compensation
6.5.18 Batch Cycles
6.5.19 Restart Delay
6.6 Rate settings
6.6.1 Rate Scaling (Pulse inputs)
6.6.2 Rate D.P. (Pulse inputs)
6.6.3 20mA Display (4/20mA input)
6.6.4 Rate Legend
6.6.5 Timebase
6.6.6 Rate Filter
6.6.7 Flow Alarm
6.6.8 Clip-Off
7. Calibration Examples
8. Maintenance
8.1 Fault finding during commissioning
8.2 Fault finding after commissioning
8.3 Servicing
8.4 Routine maintenance
8.5 Guarantee
8.6 Customer comments
9. Accessories
9.1 Tag number
9.2 Pipe mounting kits
10. Index
Appendix 1 User Screens
Appendix 2 Diagnostic information menu
Appendix 3 ATEX dust certification
Appendix 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. DESCRIPTION
The BA454D is a field mounting intrinsically
safe batch controller primarily intended to
control the dispensing of liquids, solids or
components in a hazardous area. It is a
second-generation instrument that replaces
field mounting applications of the BA350BP
and the BA350BC.
Although incorporating sophisticated control
functions, the BA454D is easy to operate and
configure. Batch status and the function of the
push-buttons are shown on the backlit graphic
display which is visible in all lighting conditions.
The instrument can provide single, dual or
three stage control and may be used with both
pulse and 4/20mA analogue output flowmeters.
The BA454D has been issued with an ATEX
EC-Type Examination Certificate by Notified
Body Intertek Testing & Certification which has
been used to confirm compliance with the
European ATEX Directive for use in explosive
gas and combustible dust atmospheres.
Dust certification is an option, see Appendix 3.
The BA454D is also FM approved for use in
the USA and cFM approved for use in Canada,
these approvals are described in Appendix 4.
Housed in a robust IP66 glass reinforced
polyester (GRP) enclosure with an armoured
glass window, the BA454D is surface
mounting, or may be pipe mounted using one
of the accessory kits.
2. OPERATION
Fig 1 shows a typical BA454D dispensing
application. The BA454D controller
incorporates programmable 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 a programmable
volume before the batch setpoint is reached
when Control 1 is also de-energised.
By operating a small bypass valve from Control
1 and the main control valve from Output 2, the
flow can be started and stopped slowly thus
reducing batching errors and flow surges. If
less accuracy is required, single stage control
can be accomplished using just Control 1 and
one control valve.
Control 1 is a dedicated output, but Outputs 2
and 3 may be configured as control, pulse or
batch status outputs.
Fig 1 Typical batch control application
If additional outputs are required, three more
may be added as a factory installed option.
The BA454D incorporates a selection of
operator display screens allowing the installer
to choose a display which only present
essential information to the operator.
To prevent accidental or unauthorised
adjustments, the operator and configuration
menus may be protected by separate security
codes. The configuration menu is also
protected by a security link between terminals
18 and 19. This link may be hard-wired, or
connected to an external key-switch when
frequent changes are required.
Fig 2 shows a simplified block diagram of the
controller.
3

Fig 2 Simplified block diagram of BA454D
2.1 Operator Controls
The BA454D batch controller may be
configured with one of six suites of operator
display screens containing different
combinations of information as shown in
Appendix 1. The function of each push-button
is shown immediately above the button at the
bottom of the screen. Buttons that are not
identified on the screen are not functional.
The Down, Up, P and Eidentifications printed
onto the push-buttons only apply when the
instrument is being configured.
The operator functions are:
START Causes Control 1 to be energised
which will start the batch. The screen
will display ‘Running’ until the batch
is completed, or the STOP push-
button is operated.
STOP Operating this button during a batch
immediately de-energises Control 1
and Control Outputs 2 & 3 if they are
used, causing the batch to pause.
‘Paused’ will be displayed on the
screen. During a pause any input
signal continues to be counted.
The batch may be resumed at any
time by pressing the Start button, or it
may be aborted by operating the
Reset button.
At the end of each batch the Control
Output(s) will be de-energised 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. When a batch is
complete the batch controller will
display the volume that has been
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 Stop button is
operated. See section 6.4.7
MENU Operating this button gives access to
the Operator Menu that may be
protected by a four digit security
code. This menu may be configured
to give the operator access to any, or
none 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.
4

If no items are contained in the menu
the operator can only start, pause
and stop a batch. Inclusion of the
Select Batch function allows the
operator to select the batch setpoint
from one of nine pre-entered values.
To aid identification, each setpoint
may be identified by a name having
up to sixteen digits.
If included in the menu, the Batch
Size function allows the adjustment
of the pre-entered batch setpoints.
Batch History shows the size of the
last ten batches which have been
completed.
The Configure function provides
operator access to the batch
controller configuration menus
described in section 6. Entry to
these menus is protected by an
external security link between
terminals 18 and 19 and an optional
four digit security code.
2.2 Power supply failure
If the power supply for the BA454D fails during
a batch, the instrument will remember the
amount of product dispensed when the supply
failed, together with the number of cycle
completed if autostart is being used. When
power is restored, the batch controller will
return in the Paused condition displaying the
amount of product dispensed prior to the
failure. Operating the Start pushbutton will
complete the batch.
If the supply failure occurs when the batch
controller is in the Ready or Complete state,
the controller will return in the same 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 codes of practice, may be
installed in any of the European Economic
Area (EEA) member countries. ATEX
certificates are also acceptable for installations
in Switzerland.
This instruction manual describes installations
in explosive gas atmospheres which conform
with EN 60079:Part14 Electrical Installation in
Hazardous Areas. When designing systems
for installation outside the UK, the local Code
of Practice should be consulted.
For the use in the presence of combustible
dust, please refer to Appendix 3.
3.2 Zones, gas groups and T rating
The BA454D has been issued with EC Type
Examination certificate ITS03ATEX21378
confirming that it complies with the
requirements for Group II Category 1 G
equipment; Ex ia IIC T5 Ga (Tamb –40 to
60oC). When connected to a suitable system
the BA454D may be installed in:
Zone 0 explosive gas air mixture
continuously present.
Zone 1 explosive gas air mixture
likely to occur in normal
operation.
Zone 2 explosive gas air mixture not
likely to occur, and if it does
will only exist for a short
time.
Be used with gases in groups:
Group A propane
Group B ethylene
Group C hydrogen
5

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 all
Zones and to be used with most common
industrial gases.
3.3 Power supply
When installed in a hazardous area the
BA454D must be powered from a EEx ia IIC
certified Zener barrier or galvanic isolator
having output parameters equal to or less than:
Uo = 28.0V dc
Io = 96mA dc
Po = 0.84W
The maximum equivalent capacitance and
inductance between power supply terminals 1
and 2 is: Ci = 0.015µF
Li = 8µH
To determine the maximum permissible cable
parameters, Ci and Li must be subtracted from
the maximum cable capacitance and
inductance specified by the certificate of the
barrier or isolator powering the batch
controller.
3.4 Inputs
The BA454D has two alternative inputs.
Input 1 (terminals 11 & 12) is for devices that
require powering by the batch controller such
as switch 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 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 of EN 60079-11.
The maximum permitted capacitance and
inductance for the cable plus the transducer
connected to terminals 11 & 12 in a IIC
hydrogen gas are:
C cable + Ci transducer 2.3µF max
L cable + Li transducer 90mH max
See system certificates for maximum limits for
IIB and IIA gases.
3.4.2 Input 2
Terminals 13, 14, 15, 16 and 17 comply with
the requirements for Simple Apparatus
allowing any device certified Ex ia IIC with
output parameters equal to or less than:
Uo 28V dc
Io 100mA dc
Po 0.66W
to be connected.
This allows devices with a certified voltage
pulse output or a certified 4/20mA analogue
current output to be connected directly to the
batch controller.
The maximum equivalent capacitance Ci and
inductance Li of terminals 13 to 17 is:
Ci = 0.018µF
Li = 0.02mH
To determine the maximum permissible cable
parameters, Ci and Li must be subtracted from
the maximum permissible cable capacitance
and inductance specified by the certificate for
the device connected to input 2.
See system certificates for maximum limits for
IIB and IIA gases.
6

3.5 Switch outputs
Control 1 and Outputs 2 & 3 are separate
galvanically isolated solid state switches. The
EC-Type Examination Certificate specifies that
under fault conditions the voltage, current and
power at each switch output will not exceed
those specified for simple apparatus in Clause
5.4 of EN50020:2002. This allows each of the
BA454D switch outputs to be connected to any
intrinsically safe circuit protected by a certified
Zener barrier or galvanic isolator providing that
the output parameters of each circuit are less
than: Uo 28V dc
Io 200mA
Po 0.85W
The maximum equivalent capacitance and
inductance of each BA454D switch output are:
Ci = 0.04µF
Li = 0.02mH
To determine the maximum permissible cable
parameters, Ci and Li must be subtracted from
the maximum cable capacitance and
inductance specified by the certificate of the
barrier or isolator connected to the switch.
3.6 External switches
For applications requiring the batch controller
to be operated via large industrial push-
buttons, terminals S1 to S7 may be connected
to four external switches.
Terminals S1 to S7 have the following
combined output safety parameters:
Uo = 14.7V dc
Io = 99mA dc
Po = 0.6W
The switches and associated wiring connected
to the terminals must comply with the
requirements for simple 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 switches and the
instrument.
3.7 Inhibit and Security Links
The inhibit and security links have the following
combined output safety parameters:
Uo = 11.7V dc
Io = 2.4mA dc
Po = 7mW
A wire link may be connected between the
terminals, or if frequent changes are required
switches may be used. These switches and
associated wiring must comply with the
requirements for simple apparatus. i.e. they
must be mechanically activated, have IP20
protection and be capable of withstanding a
500V rms insulation test to earth for one
minute.
The total maximum permitted cable
parameters for all the cables connected to
terminals 18, 19 & 20 in a IIC hydrogen gas
are: Co 1.5µF
Lo 1H
These are not restrictive and do not limit the
separation between the batch controller and
the switches.
3.8 Certification Label Information
The certification label is fitted in a recess on
the top outer surface of the enclosure. It
shows the ATEX certification information plus
BEKA associates name and address. The
instrument serial number and year of
manufacture are shown on a separate label
within the terminal compartment.
7

4. SYSTEM DESIGN FOR HAZARDOUS
AREAS
4.1 System Certificates
In addition to the EC-Type Examination
Certificate, ITS issued two System Certificates
for the BA454D batch controller. One defines
how the BA454D may be used with Zener
barriers and the other with galvanic isolators.
Both are divided into two sections to cover
input signal sources in the hazardous and the
safe area.
Interface Certificate No.
Zener barriers Ex03E21380
Galvanic isolators Ex03E21381
System Certificates are Certificates of
Conformity, which were primarily issued for
installation guidance in the UK. They do not
form part of the ATEX certification.
4.2 Use with Zener barriers
Zener barriers are the least expensive
intrinsically safe interface between a safe and
hazardous area. However they do not provide
isolation and require a high integrity earth
connection that may be expensive to install.
For a single BA454D batch controller
installation it may be less expensive and
complicated to use galvanic isolators when a
high integrity earth connection is not already
available.
Any Zener barrier 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 that may be used and
lists the maximum permitted cable parameters.
Fig 3 illustrates the basic circuit that is used for
all BA454D installations protected by Zener
barriers. Although the BA454D batch
controller will operate from a wide range of
input sources, only one source may be
connected at any time.
Alternatively the input source may be located
in the safe area. Fig 4 shows how an
additional Zener barrier may be used to
transfer the signal from the safe area to the
batch controller in the hazardous area. For
switch contact and open collector inputs the
end-to-end resistance of the Zener barrier plus
the resistance of the input device must comply
with the batch controllers input switching
thresholds.
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.
8

4.2.1 Power supply
Usually a BA454D batch controller is powered
from the safe area via a positive polarity 28V
300Zener barrier which has a typical end-to-
end resistance of 340. The BA454D
consumes a maximum current of 33mA and
requires a minimum voltage of 11V between
terminals 1 and 2. When powered from a
28V 300Zener barrier the supply voltage in
the safe area must be between 22.2V and the
maximum working voltage of the barrier which
is usually about 26V.
CAUTION
The safety components within the batch
controller limit the voltage between terminals 1
and 2 at 15V. If the batch controller is directly
connected to a 15V or greater power supply
without a Zener barrier or equivalent series
resistor, the instrument will consume a large
current for a few seconds and then shut-down
to prevent permanent damage. To test a
BA454D batch controller in a safe area
workshop, terminals 1 & 2 should be
connected to a 24V dc power supply via a
330resistor.
4.2.2 Pulse inputs
As shown in Figs 3 and 4 the BA454D batch
controller may be connected to a wide variety
of pulse transducers and sources in the
hazardous or safe area. Input 1 is for pulse
sources that need powering by the batch
controller such as switch contacts or a 2-wire
proximity detector. Input 2 is for voltage pulse
inputs such as the magnetic pickup in a turbine
flowmeter, or a voltage pulse output from a
flowmeter.
The following table shows the switching
thresholds for the various transducers, plus the
maximum operating frequency and the input
terminal numbers. For reliable counting the
input signal must fall below the lower switching
threshold and rise above the upper threshold.
Switching
thresholds Freq max Input terminals
Switch 1001000100Hz 12 & 11 +
Proximity
detector 1.2mA 2.1mA 5 kHz 12 & 11 +
Open
collector 2k10k5kHz 12 & 11 +
Magnetic
pickup 10mV 30mV 5kHz 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 relays
used in turbine flowmeters comply.
The maximum operating frequency for a switch
contact input is 100Hz.
4.2.2.2 2-wire proximity detector input
Any Ex ia certified intrinsically safe 2-wire
proximity detector complying with NAMUR
switching thresholds may be used, providing
the input safety parameters of the proximity
detector are equal to or greater than:
Ui 10.6V dc
Ii 20mA dc
Pi 50mW
If located in the same hazardous area as the
batch controller the proximity detector may be
directly connected to terminals 12 & 11
When programmed to operate with a proximity
detector, the maximum input frequency of the
BA454D batch controller is 5kHz.
4.2.2.3 Voltage pulse input
Voltage pulse sources may be connected
directly to input 2, the terminals used depend
upon the input magnitude – see the table in
section 4.2.2. All these terminals comply with
the requirements for simple apparatus and
they may be directly connected to any Ex ia
certified intrinsically safe voltage source within
the hazardous area. The source must be able
to withstand a 500V rms insulation test to earth
for one minute and have output parameters
equal to or less than:
Uo 28V dc
Io 100mA dc
Po 0.66W
This enables the BA454D to be connected
directly to most flowmeters incorporating a
certified intrinsically safe magnetic pickup, or a
certified intrinsically safe amplifier producing a
high level pulse output. The BA454D has
three selectable voltage switching thresholds,
for magnetic pickups, low voltage pulses and
high voltage pulses.
When programmed to operate with a voltage
pulse source, the maximum input frequency of
the BA454D batch controller is 5kHz.
9

4.2.3 4/20mA analogue input
The BA454D can also accept an analogue
4/20mA input from a current source
representing rate of flow, not a current sink.
Loop powered flow transmitters require an
additional power supply. The analogue input
terminals comply with the requirements for
simple apparatus allowing almost any
intrinsically safe 4/20mA signal to be
connected directly to the batch controller.
Voltage
drop Freq. Max. Input terminals
4/20mA 0.6V 2Hz 16 & 17+
4.2.4 Switch outputs
Each of the three switch outputs is a
galvanically isolated single pole solid state
switch as shown in Fig 5.
Fig 5 Equivalent circuit of each switch output
The output is polarised so current will only flow
in one direction. Terminals A1, A3 and A5
should be connected to the positive side of the
supply. The ‘on’ and ‘off’ performance of each
switch output is:
Ron = 5+ 0.7V
Roff = greater than 1M
Any hazardous area intrinsically safe circuit
may be switched by one of these outputs
providing the output safety parameters of the
circuit are less than the maximum input
parameters of the switch. Alternatively the
switch contact may be transferred to the safe
area via a Zener barrier which again must have
safety parameter less than the maximum input
safety parameters of the switch.
Notes: Because of the series protection
diode, some test meters may not
detect a closed switch output.
Terminals A7 to A12 are for optional
factory fitted outputs 4, 5 and 6.
WARNING
These switch outputs should not be
used for critical safety applications.
When the BA454D power supply is turned off
or disconnected, all BA454D switch outputs will
open.
4.3 Use with galvanic isolators
Galvanic isolators 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 system design, the galvanic
isolator System Certificate specifies the safety
description of the galvanic isolators that may
be used and lists the maximum permitted cable
parameters.
Fig 6 illustrates the basic circuit that is used for
all BA454D installations protected by galvanic
isolators. Although the BA454D batch
controller will operate from a wide range of
input sources, only one source may be
connected at any time.
Alternatively the input source may be located
in the safe area. Fig 7 shows how an
additional isolator may be used to transfer the
input signal from the safe area to the batch
controller in the hazardous area.
4.3.1 Power supply
Any certified galvanic isolator may be used to
power the BA454D providing the output safety
parameters are less than the maximum
permitted input safety parameters of terminals
1 & 2. In addition to matching the safety
parameters, the isolator must be able to supply
at least 11V to terminals 1 & 2 at 33mA.
CAUTION
The safety components within the batch
controller limit the voltage between terminals 1
and 2 at 15V. If the batch controller is directly
connected to a 15V or greater power supply
without a galvanic isolator or equivalent series
resistor, the instrument will consume a large
current for a few seconds and then shut-down
to prevent permanent damage. To test a
BA454D batch controller in a safe area
workshop, terminals 1 & 2 should be
connected to a 24V dc power supply via a
330resistor.
10

4.3.2 Inputs
When the batch controller is powered from a
galvanic isolator, the pulse and analogue
inputs remain the same as described in
sections 4.2.2 and 4.2.3. Only when the input
transducer or source is in the safe area, as
shown in Fig 7, are galvanic isolators required
in the input circuit.
Any Ex ia IIC certified galvanic isolator may be
used providing that the safety parameters of
the isolator terminals are compatible with the
safety parameters of the batch controller input
terminals to which it is connected. The
galvanic isolator must also be able to transfer
the required 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 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 a
selection of relay and solid state outputs. Again
the output parameters of the galvanic isolator
must be less than the maximum permitted
input parameters of the batch controller switch.
11

4.4 External switches
For applications requiring the batch controller
to be operated via large industrial push-
buttons, four external switches may be
connected as shown in Fig 2. Each external
switch has a dedicated operating and
configuration function.
Switch
number Switch function when Operating Configuring
S1 Start Down
S2 Stop Up
S3 Reset P
S4 Menu E
Section 3.6 describes the use of external
switches in the hazardous area, but they may
also be located in the safe area.
A certified intrinsically safe relay or a galvanic
isolator with a switch contact output is required
to transfer the switch contact from the safe to
the hazardous area. The combined permitted
input safety parameters for batch controller
terminals S1 to S7 are zero, therefore 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 only be
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.
4.6 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 lined 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.
12

5. INSTALLATION
5.1 Location
The BA454D batch controller is housed in a
robust IP66 glass reinforced polyester (GRP)
enclosure incorporating an armoured glass
window and stainless steel fitting. It is suitable
for exterior mounting in most industrial
environments, including off-shore and waste
water treatment installations. Please consult
BEKA associates if high vibration is
anticipated.
The BA454D enclosure is surface mounting.
Accessory kits described in sections 9.2 of this
manual enable the instrument to be mounted
onto a vertical or horizontal pipe.
The field terminals and the two mounting holes
are located in a separate compartment with a
sealed cover allowing the instrument to be
installed without exposing the display
assembly.
The BA454D earth terminal is connected to the
internal EMC filters. For maximum radio
frequency interference rejection this terminal
should be connected to a local earth, or to a
cable screen which is earthed in the safe area.
The BA454D enclosure is supplied with a
bonding 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. Remove the temporary hole plug and
install an appropriate IP rated cable
gland or conduit entry. If more than one
entry is required, one or both of the IP66
stopping plugs may be replaced with an
appropriated IP rated cable gland or
conduit fitting.
d. Connect the field wiring to the terminals
as shown in Fig 10.
e. Replace the instrument terminal cover
and evenly tighten the two 'A' screws.
Fig 9 BA454D installation procedure
5.3 EMC
The BA454D complies with the requirements of
the European EMC Directive 2004/108/EC.
For specified immunity all wiring should be in
screened twisted pairs and the BA454D earth
terminal should be locally earthed or
connected to a cable screen which is earthed
in the safe area.
To prevent circulating currents, cable screens
should only be earthed at one point in the safe
area.
13

Fig 10 Dimensions and terminal connections
14

6. CONFIGURATION MENUS
The BA454D batch controller is configured via
the front panel pushbuttons. Configuration
functions are contained in three easy to use
sub-menus, ‘System Settings’, ‘Batch Settings’
and ‘Rate Settings’. A fourth sub-menu
‘Information’ shows how the instrument has
been configured.
Although the BA458 batch controller contains
many sophisticated functions, it remains simple
to operate and configure. Menu navigation is
explained in section 6.2. Guided by on-screen
prompts, the use of the configuration functions
is intuitive, but all the functions are fully
described in this manual.
6.1 Security
To prevent unauthorised or accidental
adjustment, the configuration menus can only
be accessed when an external link is fitted
between terminals 18 and 19 as shown below.
Terminals Access to
18 and 19 configuration menus
Linked Yes
Not linked No
When authorised personnel need to make
frequent configuration adjustments, the
security link terminals may be wired to a key
switch located in the hazardous area.
The configuration menus may also be
protected by a user selectable four digit
security code.
A separate four digit user selectable security
code may be applied to the operator menu.
6.2 Navigation
The BA454D is configured via the four front
panel push-buttons which are identified with a
printed legend.
This manual contains simplified drawings of
the batch controller display screens associated
with most functions. Although some screens
may consist of multiple pages that are
automatically accessed by scrolling through
the options, in this manual they are shown on
one page with the default option in bold.
Within this manual push-buttons are shown in
italics e.g. P or Up push-button 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 Pand Ebuttons
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 the highlight bar between sub-
menus. When the required option has been
highlighted, operating the Pbutton will access
the sub-menu.
The highlight bar is static when indicating a
menu or sub-menu. When indicating an option
which has to be selected, or a variable that has
to be entered, the highlight bar flashes on and
off.
The configuration main menu comprises four
sub-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 the
sub-menu and operating the Ppushbutton will
enter the function menu. Functions offer a
choice of options or an invitation to enter a
variable.
To select an option in a function menu
Press the Up or Down button to move the
flashing display highlight bar to the
required option, operating the E button will
then store the selected option and move
the display up one level to the sub-menu.
To enter a variable
Variables are entered digit by digit, the
flashing digit being adjusted using the Up
or Down button. When a digit is set as
required operating the Pbutton will
transfer control to the next digit. When all
the digits have been adjusted, operating
the E button will store the variable and
move the display up one level to the sub-
menu.
15

When navigating through the menus the push-
button(s) should be held until the required
screen is displayed.
Note:
Functions that are dependent on a higher level
option are automatically removed from the sub-
menu when the higher level option is not
selected. e.g. If the batch controller is
configured for a pulse input, all the calibration
functions associated with a 4/20mA input will
be automatically removed from the menus.
6.3 Default configuration
Unless otherwise requested at the time of
ordering, BA454D batch controllers will be
supplied configured as follows:
System Settings
Language English
Operator control Both Local &
Remote.
Signal Input Open Collector
Lineariser Off
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 99999999
Batch Names Batch 1
Batch Size 00000000.
Select Batch Batch 1
CONTROL2delay 0000
CONTROL2stop 00000000.
CONTROL3delay 0000
CONTROL3stop 00000000.
Count Mode Up
Overrun Comp Off
Batch Cycles 1
Restart Delay 00 : 00 : 00
Rate Settings
Rate Scaling 000001.
Rate D.P. 00000.0
20mA Display 00100.0
Rate Legend No legend
Timebase Seconds
Rate Filter
Smoothing 2
Jump-Out 4
Flow Alarm 00000.0
Inhibit Time 0000
Clip-Off 00000.0
Default parameters may be globally restored
see section 6.4.13
16

17
BLANK PAGE

18
Fig 11 System Settings
Fig 11 System Settings

6.4 SYSTEM SETTINGS
See Fig 11.
6.4.1 Language
The BA454D can display operating messages
and menus in three different languages:
Deutsch
English
Francais
Set Language
Highlight the required language and press Eto
enter the selection.
6.4.2 User Controls
The BA454D batch controller may be
controlled by the front panel pushbuttons, by
remote switches or by both the front panel
switches and the remote switches.
Local
Remote
Both
Set User Controls
Highlight the required option and press Eto
enter the selection.
6.4.3 Signal Input
A wide variety of analogue and digital
transduces and sources may be connected to
the batch controller.
Open Collector
Prox Detector
Switch Contact
Magnetic pickup
Voltage Pulse
4/20mA
4/20mA Sq. Law
Set Input Type
Notes: Input terminals vary depending upon
the type of input, see sections 4.2.2
and 4.2.3.
The brilliance of the display backlight
is reduced when open collector,
proximity detector or switch contact
inputs are selected.
6.4.4 4mA Calibration
Note: Only necessary when 4/20mA input is
used
When the BA454D batch controller is supplied
the analogue current input will have been
accurately 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 calibration
being accidentally corrupted the instruction has
to be confirmed before it will be executed.
Calibrate
Cancel
CAL. (Inject 4mA)
Highlight the ‘Calibrate’ option and operate the
E pushbutton, which will result in the
confirmation screen being displayed. To
perform the calibration highlight ‘Continue’ and
press E, after a few seconds the display will
return to the System setting menu.
Continue
Cancel
Are you sure?
6.4.5 20mA Calibration
This function is identical to the 4mA calibration
described in the previous section 6.4.4, but a
20mA input current should be used.
6.4.6 Lineariser (Pulse inputs)
The 16 point straight line lineariser will
compensate for k-factor non-linearity in turbine
flowmeters.
This function turns the lineariser on and off,
calibration parameters are entered in the Batch
Setting menu – See sections 6.5.1 and 6.5.2 .
On
Off
Set Lineariser
Highlight the required setting and press Eto
enter the selection.
19

6.4.7 Restart
This function determines what happens at the
end of each batch. There are three options:
Normal: The display screen shows the
volume that has been
dispensed. Before another
batch can be started the Reset
push-button must be operated.
The screen will then display
‘Ready’.
Quick: The display screen shows the
volume that has been
dispensed. Operating the
Start pushbutton will reset the
batch controller and start
another batch.
Auto restart: The display screen shows the
volume that has been
dispensed. After a configurable
restart delay (See 6.5.19) the
batch controller automatically
resets and starts another batch.
The number of batch cycles to
be performed is defined by the
Batch Cycle function, which is
contained in the Batch Setting
menu. See 6.5.18
Normal
Quick
Auto
Set Batch Restart
Highlight the required option and press Eto
enter the selection.
6.4.8 Output 2
Output 2 is an isolated single pole solid state
switch contact that is connected to terminals
A3 and A4. It may be configured to output any
one of six different signals, or may be unused.
Unused
Control 2
Control 3
Flow alarm
Reset status
Batch status
Pulse Output
Set O/P 2 Function
Highlight the required option and press Eto
enter the selection.
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 BA454D batch controller.
Configuration is the same as for Output 2,
except terminal numbers are:
Output Terminal numbers
4A7&A8
5 A9 & A10
6 A11 & A12
6.4.11 Pulse Output
Any of the batch controller outputs may be
configured as a pulse output. The number of
output pulses is proportional to the total
volume dispensed by the batch controller.
This Pulse Output function enables the pulse
output frequency to be reduced by one of five
dividing factors between 10 and 100,000.
Display / 1
Display / 10
Display / 100
Display / 1000
Display / 10000
Display / 100000
Set Output Rate
Highlight the required option and press Eto
enter the selection.
Note: Maximum output frequency is 4 Hz.
6.4.12 Clear Grand Total
The Grand Total is a record of the total
quantity of product dispensed since the Grand
Total was last reset to zero. It must be zeroed
every time the batch controller scaling is
changed
The Grand Total can be viewed in the
Information section of the System Menu – see
section 6.2 and Appendix 2.
CAUTION
After zeroing the old grand total
can not be recovered
To prevent the Grand Total being accidentally
zeroed, the clear instruction has to be
confirmed before it will be executed.
Clear G Total
Cancel
Clear Grand Total
20