BEKA BA654D User manual

Issue: 4
1st December 2010
BA654D
Field mounting
Batch Controller
Issue 4

2
1. Description
2. Operation
2.1 Operator controls
3. System Design
3.1 Power supply
3.1.1 Power supply failure
3.2 Pulse inputs
3.2.1 Switch contact
3.2.2 Proximity detector
3.2.3 Voltage pulse
3.3 4/20mA analogue input
3.4 Switch outputs
3.5 External switches
3.6 Inhibit link
3.7 Security link
4. Installation
4.1 Location
4.2 Installation procedure
4.3 EMC
5. Configuration Menus
5.1 Security
5.2 Navigation
5.3 Default configuration
5.4 System settings
5.4.1 Language
5.4.2 User controls
5.4.3 Signal input
5.4.4 4mA calibration
5.4.5 20mA calibration
5.4.6 Lineariser
5.4.7 Restart
5.4.8 Output 2
5.4.9 Output 3
5.4.10 Optional outputs 4, 5 & 6
5.4.11 Pulse output
5.4.12 Clear grand total
5.4.13 Defaults
5.4.14 Security
5.4.15 Operator screens
5.4.16 Display
5.4.17 Output options
5.4.17.1 Control 2
5.4.17.2 Control 3
5.4.17.3 Flow alarm
5.4.17.4 Reset status
5.4.17.5 Batch status
6.4.17.6 Pulse output
5.5 Batch settings
5.5.1 Scale Points (Non-linear
pulse inputs)
5.5.2 Scale Factors (Non-linear
pulse inputs)
5.5.3 Scale Factor (Linear pulse
inputs)
5.5.4 Scaling (4/20mA input)
5.5.5 Batch D.P.
5.5.6 Batch Legend
5.5.7 Batch Limit
5.5.8 Batch Names
5.5.9 Batch Size
5.5.10 Select Batch
5.5.11 Batch History
5.5.12 CONTROL2delay
5.5.13 CONTROL2stop
5.5.14 CONTROL3delay
5.5.15 CONTROL3stop
5.5.16 Count Mode
5.5.17 Overrun Compensation
5.5.18 Batch Cycles
5.5.19 Restart Delay
5.6 Rate settings
5.6.1 Rate Scaling (Pulse inputs)
5.6.2 Rate D.P. (Pulse inputs)
5.6.3 20mA Display (4/20mA input)
5.6.4 Rate Legend
5.6.5 Timebase
5.6.6 Rate Filter
5.6.7 Flow Alarm
5.6.8 Clip-Off
6. Calibration Examples
7. Maintenance
7.1 Fault finding during commissioning
7.2 Fault finding after commissioning
7.3 Servicing
7.4 Routine maintenance
7.5 Guarantee
7.6 Customer comments
8. Accessories
8.1 Tag number
. 8.2 Pipe mounting kits
9. Index
Appendix 1 User Screens
Appendix 2 Diagnostic information menu
CONTENTS
The BA654D is CE marked to show compliance with
the European EMC Directive 89/336/EEC

3
1. DESCRIPTION
The BA654D is a field mounting batch
controller primarily intended to control the
dispensing of liquids, solids or components. It
is a second-generation instrument that
replaces field mounting applications of the
BA550BP and the BA550BC.
Although incorporating sophisticated control
functions, the BA654D 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.
Housed in a robust IP66 glass reinforced
polyester (GRP) enclosure with an armoured
glass window, the BA654D is surface
mounting, or may be pipe mounted using one
of the accessory kits.
2. OPERATION
Fig 1 shows a typical BA654D dispensing
application. The BA654D 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 that 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 Control 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 BA654D 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 & 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.

4
Fig 2 Simplified block diagram of BA654D
2.1 Operator Controls
The BA654D 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 BA654D 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 5.4.7
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
5.4.7
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.

5
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 all 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 5. Entry to
these menus is protected by an
external security link between
terminals 18 and 19 and an optional
four digit security code.
3. SYSTEM DESIGN
The BA654D is a versatile instrument that may
be used with most flowmeters having a pulse
or 4/20mA output. Fig 3 illustrates the basic
circuit that is used for all installations.
Although the BA654D batch controller will
operate from a wide range of input sources,
only one source or transducer may be
connected at any time.
Fig 3 Basic batch controller circuit
3.1 Power supply
Any dc power supply having an output
between 20 and 36 volts that is capable of
supplying 95mA may be used to power the
BA654D. The output ripple must not cause the
instantaneous voltage to drop below 20V.
The batch controller inputs and outputs are
galvanically isolated thus allowing multiple
batch controllers to be operated from a
common power supply. Similarly, if required
the power supply may be earthed. If a
common or earthed supply is used, the batch
controller inhibit and security link terminals,
and the optional external switch terminals
should only be connected to electrically
isolated switch contacts. i.e. they should not
be earthed or connected to other circuits.

6
3.1.1 Power supply failure
If the power supply for the BA654D 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.
3.2 Pulse inputs
As shown in Fig 3 the BA654D batch controller
may be connected to a wide variety of pulse
transducers and sources. 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 100Ω1000Ω100Hz 12 & 11 +
Proximity
detector 1.2m A2.1mA 5 kHz 12 & 11 +
Open
collector 2kΩ10kΩ5kHz 12 & 11 +
Magnetic
pickup 10m V30mV 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.
3.2.1 Switch contact input
Any switch contact may be connected directly
to terminals 12 & 11. Most magnetically
activated reed relays used in turbine
flowmeters may be used.
The maximum operating frequency for a switch
contact input is 100Hz.
3.2.2 2-wire proximity detector input
Any 2-wire proximity detector complying with
NAMUR switching thresholds (1.2mA and
2.1mA) may be connected to terminals 12 and
11.
When programmed to operate with a proximity
detector, the maximum input frequency of the
BA654D batch controller is 5kHz.
3.2.3 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 3.2.
This enables the BA654D to be connected
directly to most flowmeters incorporating a
magnetic pickup, or an amplifier producing a
high level pulse output.
When conditioned to operate with a voltage
pulse source, the maximum input frequency of
the BA654D batch controller is 5kHz.
3.3 4/20mA analogue input
The BA654D can also accept an analogue
4/20mA input representing rate of flow from a
current source, not a current sink. Loop
powered flow transmitters require an additional
power supply. The batch controller input is
galvanically isolated and only introduces a
0.6V drop into the 4/20mA loop. It may
therefore be connected into to almost any
flowmeter loop.
Voltage
drop Freq. Max. Input terminals
4/20mA 0.6V 2Hz 16 & 17+
3.4 Switch outputs
The BA654D batch controller has three single
pole relay outputs which may be used for
switching valves, actuators or contactors.
Output Terminals
Control 1 A1 & A2
Output 2
May be configured
to output one of six
different signals.
A3 & A4
Output 3
May be configured
to output one of six
different signals.
A5 & A6

7
Each relay output has a maximum contact
rating of: 240V 5A 2kVA
30V 5A
When a reactive load is being switched by the
relay contact, it is essential that a suppressor
is fitted to prevent contact damage and radio
frequency interference. A 0.1µF capacitor in
series with a 100Ωresistor connected between
the relay contacts will usually provide
adequate suppression. Proprietary
encapsulated suppression assemblies can be
purchased from electrical suppliers. Please
note that BEKA associates’ guarantee
excludes relay contact damage.
WARNING
These switch outputs should not be
used for critical safety applications.
When the BA654D power supply is turned off
or disconnected, all BA654D switch outputs will
open.
Notes: For applications requiring change-over
contacts, the BA654D can be supplied
with just Control 1 and Output 2 each
having one change-over contact.
Three additional outputs, each of
which may be configured to output one
of six signals, are available as a
factory fitted option. Each output is a
single pole isolated solid state switch
capable of switching a 30V, 100mA dc
load.
3.5 External switches
For application requiring the batch controller to
be controlled by large industrial pushbuttons,
four external switches may be connected as
shown in Fig 2.
Switch
number Switch function when Operating Configuring
S1 Start Down
S2 Stop Up
S3 Reset P
S4 Menu E
3.6 Inhibit link
Linking terminals 18 and 20 together inhibits
the batch controller input. If linked during a
batch, none of the outputs will change so
dispensing will continue, but the volume
dispensed while the link is connected will not
be added to the batch display. This facility is
intended for applications requiring pre-batch
purging, or re-circulation during batching to
maintain temperature or good mixing.
3.7 Security link
Access to the configuration menus is only
available when terminals 18 & 19 are linked
together. This may be achieved with a wire
link, or a keyswitch when frequent security
changes are required.

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4. INSTALLATION
4.1 Location
The BA654D batch controller is housed in a
robust IP66 glass reinforced polyester (GRP)
enclosure incorporating an armoured glass
window and stainless steel fittings. 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 BA654D enclosure is surface mounting.
Accessory kits described in sections 8.2 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 BA654D 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 an
earthed cable screen.
The BA654D enclosure is supplied with a
bonding plate to ensure electrical continuity
between the three conduit / cable entries.
4.2 Installation Procedure
Fig 4 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 8.2
c. Remove the temporary dust seals from
the three cable entries and install the
required glands, conduit fittings or
blanking plugs.
Note: The temporary dust seals fitted for
transit do not maintain the IP66
protection of the BA654D enclosure.
d. Connect the field wiring to the terminals
as shown in Fig 5.
e. Replace the instrument terminal cover
and evenly tighten the two 'A' screws.
Fig 4 BA654D installation procedure
4.3 EMC
The BA654D complies with the requirements of
the European EMC Directive 89/336/EEC. For
specified immunity all wiring should be in
screened twisted pairs and the BA654D earth
terminal should be locally earthed or
connected to an earthed cable screen.
To prevent circulating currents, cable screens
should only be earthed at one point.

9
Fig 5 Dimensions and terminal connections

10
5. CONFIGURATION MENUS
The BA654D 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 BA654D batch controller contains
many sophisticated functions, it remains simple
to operate and configure. Menu navigation is
explained in section 5.2. Guided by on-screen
prompts, the use of the configuration functions
is intuitive, but all the functions are fully
described in this manual.
5.1 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 an
external key switch.
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.
5.2 Navigation
The BA654D is configured via the four front
panel push-buttons which are identified by 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 menus 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 6 & section 5.4
Batch Settings Defines batch
parameters.
See Fig 9 & section 5.5
Rate Settings Defines rate parameters.
See Fig 11 & section 5.6
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.

11
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.
5.3 Default configuration
Unless otherwise requested at the time of
ordering, BA654D 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 5.4.13

12
Fig 6 System Settings

13
5.4 SYSTEM SETTINGS
See Fig 6.
5.4.1 Language
The BA654D 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.
5.4.2 User Controls
The BA654D 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 Operator Controls
Highlight the required option and press Eto
enter the selection.
5.4.3 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 3.2
and 3.3
The brilliance of the display backlight
is reduced when open collector,
proximity detector or switch contact
inputs are selected.
5.4.4 4mA Calibration
Note: Only necessary when 4/20mA input is
used
When the BA654D 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?
5.4.5 20mA Calibration
This function is identical to the 4mA calibration
described in the previous section 5.4.4, but a
20mA input current should be used.
5.4.6 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 5.5.1 and 5.5.2 .
On
Off
Set Lineariser
Highlight the required setting and press Eto
enter the selection.

14
5.4.7 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 5.5.19) 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 5.5.18
Normal
Quick
Auto
Set Batch Restart
Highlight the required option and press Eto
enter the selection.
5.4.8 Output 2
Output 2 is a single pole relay 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.
5.4.9 Output 3
As Output 2 except terminals are A5 and A6.
5.4.10 Optional outputs 4, 5 and 6
Only available when factory fitted option is
installed in the BA654D 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
and outputs are single pole solid state.
See 3.4.
5.4.11 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.
5.4.12 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 5.2 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

15
If ‘Clear G Total’ is highlighted and the E
pushbutton operated, a second screen will be
presented. To confirm that the Grand Total is
to be zeroed highlight ‘Continue’ and press E
which will result in the instruction being
executed.
Continue
Cancel
Clear Grand Total
5.4.13 Defaults
This function allows the configuration defaults
listed in section 5.3 to be globally restored.
Although useful for defining a starting point
when commissioning a batch controller, the
settings overwritten by this command can not
be recovered
CAUTION
After restoring default configuration the
previous settings can not be recovered.
To prevent the default settings being
accidentally restored, the instruction has to be
confirmed before it will be executed.
Restore Defaults
Cancel
Restore Defaults
If ‘Restore Defaults’ is highlighted and the E
pushbutton operated, a second screen will be
presented. To confirm that the defaults are to
be restored, highlight ‘Continue’ and press E
which will result in the instruction being
executed.
Continue
Cancel
Restore Defaults
5.4.14 Security
A summary of instrument security is contained
in section 5.1 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
Pwill result in a selection menu being
displayed.
Each of the two security codes is entered digit
by digit, when all four digits have been set,
pressing Ewill enter the code and return the
display the security menu.
0000
Set Config Code
Note: Default code 0000 disables the security
function and allows unrestricted access
to the menu.
Access to the Configuration Menus is
also protected by an external link as
described in section 5.1.
Contents of the Operator Menu are defined by
toggling the ‘On / Off’ box associated with
each item. To make the selection, highlight
the item to be changed and operate the P
button. The item may then be turned ‘On’ or
‘Off’ using the Up or Down push-buttons.
Batch Sizing: On
Batch Select: On
History On
Config Menu: On
Set Operator Menu
Pressing Ewill enter the selection, another
item may then be selected or the display
returned to the Security menu by pressing E
again.

16
5.4.15 Operator Screens
The user screen may be selected from six
different formats that are shown in Appendix 1.
They show different information and have
different display sizes so that the operator is
only presented with the essential information
necessary to operate the batching system.
Some screens include graphical information
allowing batch progress to be rapidly
assessed.
Screen 6 is intended for commissioning and
shows all engineering information including
output status and flow rate.
SCREEN 1
SCREEN 2
to
SCREEN 6
Set User Screen
Highlight the required option and press Eto
enter the selection.
5.4.16 Display
The display contrast and backlight brilliance
are adjustable using this function. The two
adjustments are made with the Up and Down
buttons, the amplitude of each being shown on
a horizontal bargraph. Control is transferred
between brilliance and contrast by operating
the Ppushbutton.
After adjustment pressing Eenters the
changes and returns the display to the System
Menu.
5.4.17 Output options
Control 1 is a dedicated 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 5.4.8 & 9. The following
sections describe each of these selectable
signals.
5.4.17.1 Control 2
This output is similar to Control 1. It is
energised a configurable time
CONTROL2delay after Control 1 is energised
and de-energised a configurable batched
volume CONTROL2stop before Control 1 is
de-energised. Fig. 1 shows the operation
diagrammatically.
5.4.17.2 Control 3
This output is identical to Control 2 except
delays are defined by CONTROL3delay and
CONTROL3stop.
5.4.17.3 Flow alarm
This output is described in section 5.6.7
5.4.17.4 Reset status
The reset status output indicates when the
batch has been started and when the controller
has been reset and is ready to start another
batch. See Fig 7.
Fig 7 Reset status timing
5.4.17.5 Batch status
The batch status output is the inverse of
Control 1 except that it does not close when a
pause is initiated during a batch. See Fig 8.
Fig 8 Batch status timing
5.4.17.6 Pulse output
This output is described in section 5.4.11

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18
Fig 9 Batch Settings

19
5.5 BATCH SETTINGS
See Fig 9.
5.5.1 Scale Points (Non-linear pulse inputs)
This and the following Scale Factors function
described in section 5.5.2 are used to calibrate
the 16 point lineariser. The lineariser is
activated from the System Menu - see section
5.4.6.
Fig 10 shows the relationship between input
frequency and Scale Factor for a lineariser
using three breakpoints. Up to sixteen
breakpoints may be used, the input frequency
for any breakpoints that are not required
should be set to zero.
Fig 10 Three point lineariser
The Scale Factor at input frequencies below
the lowest Scaling Point is the same as that
entered for the lowest Scaling Point.
The Scale Factor for input frequencies above
the highest Scaling Point is the same as that
entered for the highest Scaling point.
The Scale Factor at input frequencies between
two Scaling Points is calculated according to a
straight line between the Scale Factors at the
two points.
The input frequency at which each breakpoint
is require should be set using this function.
Point 01: XXXX.X
to
Point 16: XXXX.X
Select Scaling Point / Set Frequency
5.5.2 Scale Factors (Non-linear pulse
inputs)
The k factor of a flowmeter is the number of
output pulses 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 volume
in the flowmeter’s engineering units.
e.g. For a flowmeter having a k factor of 70
pulses per litre, the batch controller Scale
Factor may be selected to provide the required
display
Scale Factor Least significant
Display digit represents
Litres
0.7 Hundredths of a Litre
7.0 Tenths of a Litre
70.0 Litres
700.0 Tens of Litres
7000.0 Hundreds of Litres
318.2 Gallons
(There are 4.54609 litres in a UK gallon)
This function sets the required Scale Factor at
each Scaling Point input frequency
(breakpoint) defined in the Scaling Point
function described in section 5.5.1
XXXX.X: XXXXXX
to
XXXX.X: XXXXXX
Select Frequency / Set Scale Factor
5.5.3 Scale Factor (For linear pulse inputs)
The k factor of a flowmeter is the number of
output pulses 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.

20
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 volume
in the flowmeter’s engineering units.
e.g. For a flowmeter having a k factor of 70,
the Cal Value may be selected to provide the
required display
Scale Factor Least significant
Display digit represents
Litres
0.7 Hundredths of a Litre
7.0 Tenths of a Litre
70.0 Litres
700.0 Hundreds of Litres
318.2 Gallons
(There are 4.54609 litres in a UK gallon)
000001.
Set Scale Factor
5.5.4 Scaling (For 4/20mA input)
The 4/20mA analogue output from a flowmeter
represents the rate of flow, which may be
displayed by the BA654D batch controller in
any engineering units. See section 5.6.3
Total batched volume is calculated by
integrating the flow rate during the batching
period.
The batch controller Scale Factor, which is a
dividing factor that may be adjusted between
0.001 and 999999, defines the arithmetic
relationship between the units of measurement
of the rate and the total batched displays.
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 BA654D rate display represents litres per
second but the total batched display is
required in 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 display
are required in the same units of
measurement, the Scale Factor should be set
to 1.0
000001.
Set Scale Factor
5.5.5 Batch D.P.
The position of the decimal point in the batch
display, which determines the resolution of the
display, is set by this function. In operation
leading zeros are suppressed
00000000.
Set Display D.P.
The function also determines the position of
the decimal point in the Batch Size, Batch Limit
and Pre-Stop functions.
5.5.6 Batch Legend
The units of measurement of the batched
volume can be entered with this function. Up
to six upper and lower case alphanumeric
characters may be used. Some of the operator
screens will display this legend against the
batch display.
XXXXXX
Set Batch Legend