BEKA BA658C User manual

Issue: 4
1st December 2010
BA658C
Panel 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 2-wire 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 User 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
5.4.17.6 Pulse output
5.4.17.7
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
9. Index
Appendix 1 User Screens
Appendix 2 Diagnostic Information Menu
CONTENTS
The BA658C is CE marked to show compliance with the
European EMC Directive 89/336/EEC

3
1. DESCRIPTION
The BA658C is a panel mounting batch
controller primarily intended to control the
dispensing of liquids, solids or components. It
is a second-generation instrument that
replaces both the BA550BP and the
BA550BC.
Although incorporating sophisticated control
functions, the BA658C is easy to operate and
configure. Batch status and the function of the
front panel 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 72 x 144 panel mounting
DIN enclosure, the controller has an IP65 front
panel and is supplied with a gasket to seal the
joint between the instrument and the panel.
2. OPERATION
Fig 1 shows a typical BA658C dispensing
application. The BA658C 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 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 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 BA658C 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 may also be
protected by a security link connected
between terminals at the rear of the
instrument. This link may be hard-wired, or
connected to a panel mounting key-switch
when frequent changes are required.
Fig 2 shows a simplified block diagram of the
controller.
Fig 2 Simplified block diagram of BA658C

4
2.1 Operator Controls
The BA658C batch controller may be
configured with a variety of operator display
screens. Each set of screens provides a
different level of information, some including
graphical displays. All the screens identify the
function of the front panel push-buttons which
have the following functions.
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
BA658C 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.
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 link between terminals 18
and 19 and an optional four digit
security code.

5
3. SYSTEM DESIGN
The BA658C 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 BA658C 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
BA658C. The output ripple must not cause
the instantaneous voltage to fall 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 links, and the
optional external switches should only be
connected to electrically isolated switch
contacts. I.e. they should not be earthed or
connected to other circuits.
3.1.1 Power supply failure
If the power supply for the BA658C 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 BA658C batch controller
may be connected to a wide variety of pulse
transducers. 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 each type of input, 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 1.2mA 2.1mA 5 kHz 12 & 11 +
Open
collector 2kΩ10kΩ5kHz 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.
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 &
11
When conditioned to operate with a proximity
detector, the maximum input frequency of the
BA658C batch controller is 5kHz.

6
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 BA658C to be connected 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 BA658C batch controller is 5kHz.
3.3 4/20mA analogue input
The BA658C 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 to almost any
flowmeter loop.
Voltage
drop Freq. Max. Input terminals
4/20mA 0.6V 2Hz 16 & 17+
3.4 Switch outputs
The BA658C batch controller has three single
pole relay outputs which may be used for
switching valves, actuators or contactors in
high power applications.
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
The output relay contact rating must not be
exceeded. 240V 5A 1.25kVA
30V 5A 150W dc
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 BA658C power supply is turned off
or disconnected, all BA658C switch outputs
will open.
Notes: For applications requiring change-over
contacts, the BA658C can be supplied
with just Control 1 and Output 2 each
having change-over contacts
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 controlling 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. Unlike the front panel
pushbuttons, 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
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 at the rear of
the instrument are linked together. This may
be achieved with a wire link or a keyswitch
when frequent security changes are required.

7
4. INSTALLATION
4.1 Location
The BA658C is housed in a robust aluminium
enclosure with a toughened glass window
mounted in a Noryl bezel. The front of the
instrument provides IP65 protection and a
gasket seals the joint between the instrument
enclosure and the panel. The instrument may
be installed in any panel providing the
environmental limits shown in the specification
are not exceeded.
Fig 4 shows the overall dimensions of the
BA658C and the panel cut-out. To achieve an
IP65 seal between the instrument enclosure
and the panel, the smaller cut-out must be
used and the instrument secured with four
panel mounting clips.
The BA658C liquid crystal display has
maximum contrast when viewed from directly
ahead and slightly below the centre line of the
instrument.
Fig 4 BA658C dimensions
4.2 Installation Procedure
a. Insert the BA658C into the instrument
panel cut-out from the front of the
panel.
b. Fix panel mounting clips to opposite
sides of the instrument and tighten until
the instrument is secure as shown in
Fig 5. Four clips are required to
achieve an IP65 seal between the
instrument enclosure and the panel.
c. Connect the panel wiring to the rear
terminal block(s) as shown in Fig 5.
To simplify installation, the terminals
are removable so that panel wiring can
be completed before the instrument is
installed.
Fig 5 Installation and terminal connections

8
4.3 EMC
The BA658C 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 currents, cable screens
should only be earthed at one point.

9
5. CONFIGURATION MENUS
The BA658C 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 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 BA658C is configured via the front panel
pushbuttons which are soft-keys identified on
the display screen.
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, this manual shows them
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 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 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
access 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.

10
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, BA658C 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.
(RateUnits / BatchUnits)
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