Contrec - 515-BA01 – Batch Additive Controller

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515-BA01 Batch Additive Controller

The 515-BA01 Batch Additive Controller is a standalone unit designed for precise batch control and additive injection in industrial flow applications. It efficiently manages both the main product line and additive dosing during transfer operations, using volumetric frequency flowmeters for accurate measurement.

Advanced Batch Control Modes

The 515-BA01 supports flexible operation with two key modes:

Preset Mode:
Provides full dual-stage batch control of the main product while accurately controlling additive dosing into the process stream.
Unload / Pacing Mode:
Works alongside an external batch or load controller, monitoring the main line flow signal to deliver precise additive injection in real time.

Intelligent Additive Dosing

Equipped with an advanced additive dosing algorithm, the 515-BA01 simplifies setup while ensuring dosing accuracy remains within specification. Key features include:

Automatic dose trimming and optimisation
Control based on target PPM (parts per million)
Adjustable dosing using time-based or quantity-based intervals
Reliable performance based on the nominal additive flow rate

Key Benefits

Accurate and repeatable batch and additive control
Seamless integration with industrial flow systems
Reduced programming complexity
High precision dosing for consistent product quality

Calculations

The total and flowrate are derived from accurately measured frequency and the number of received pulses.

volume = pulses / k-factor
volume flow = frequency / k-factor
Automatic overrun compensation calculates the new valve closure point to ensure correct delivery by averaging the overrun amount from
the last three complete batches.
The overrun compensation value is valid for a new preset value provided the stored overrun is less than 20% of the new preset.

Displayed Information

The front panel display shows the current values of the input variables and the results of the calculations. A list of the variables for this application and their type (total or rate) is shown at the end of this document.
The instrument can be supplied with a real-time clock for storage of up to 1000 transactions with time and date stamps.

Communications

There are two communication ports available as follows:
• COM-1 RS-232 port
• COM-2 RS-485 port (optional) or Ethernet (optional)
The ports are available for remote data reading, printouts and for initial application loading of the instrument.

Isolated Outputs

The opto-isolated outputs can be configured to retransmit any main menu variable or provide various error/control signals (flow error, pump control, end-of-batch, etc.). One output is standard, a second output is available as an option.

Relay Outputs

The relay outputs 1 and 2 are used to control the flow of product for each delivery. These contacts are normally open and can be used to drive external relays, valves, pump circuits etc. The advanced option provides another two relays that can be used as fully programmable alarms for any rate type variable.

Software Configuration

The instrument can be programmed to suit the particular application needs and the flexible I/O can be assigned as required. Program settings can be changed either via the front panel (depending on assigned access levels) or viathe 500 Series Program Manager (500-PM software).
The instrument stores all set-up parameters, totals and logged data in non-volatile memory with at least 30 years retention.

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