The BA454D from BEKA associates is a second-generation intrinsically safe field-mounting batch controller designed for dispensing liquids, solids, or components directly within hazardous areas — eliminating the need for a separate safe-area controller and long interconnecting cable runs. Certified for ATEX Zone 0 (gas: Ex ia IIC T5 Ga) and Zone 20 (dust: Ex ia IIIC T80°C Da IP66), plus UKEX, FM (USA), and cFM (Canada), it can be installed at the point of use in chemical, pharmaceutical, petrochemical, and grain handling facilities.

How does three-stage batch control improve dispensing accuracy?

The BA454D supports single, dual, or three-stage batch control with independently configurable flow alarm. In three-stage mode, the controller reduces flow through progressively smaller valve openings as the batch total approaches the setpoint, minimising overshoot. An overrun compensation function learns the system's actuator delay and automatically adjusts the cut-off point to compensate for valve closure time, pump coast-down, or product in flight. Nine user-configurable batch setpoints — each with a 16-character alphanumeric name — can be stored, and the Quick Restart function eliminates manual reset between identical batches. Auto Restart with a programmable 1-second to 24-hour delay supports repeat dosing cycles in continuous processes.

What input signal types can the BA454D accept?

The controller provides two input channels. Input 1 (terminals 11 & 12) accepts switch contacts (up to 100 Hz), 2-wire NAMUR proximity detectors (up to 5 kHz), or open collector signals (up to 5 kHz). Input 2 (terminals 13–17) adds support for magnetic pickups (40 mV p-p minimum, up to 5 kHz), low-voltage pulses (<1 V / >3 V thresholds), high-voltage pulses (<3 V / >10 V), and a 4–20 mA analogue input with ±0.3% of span accuracy and built-in 16-point lineariser and square root extraction for flow measurement. A security link and optional 4-digit code protect configuration parameters from unauthorised changes.

What installation and power supply arrangements are required?

The BA454D is housed in an IP66 glass-reinforced polyester (GRP) enclosure with an armoured glass window, weighing 1.6 kg. It mounts on a surface or pipe using BA392D/BA393 accessory kits. Power is supplied via a certified Zener barrier or galvanic isolator located in the safe area; the controller requires a minimum of 11 V DC at terminals 1 and 2, drawing approximately 33 mA at 24 V through a 28 V / 300 Ω barrier. A separate terminal compartment with screw clamps for 0.5–1.5 mm² conductors maintains the IP66 seal during field wiring. The LCD is annotatable in English, French, or German, with six operator-selectable display screens including batch status, dispensed quantity, setpoint, flow rate, output status, and a bargraph.