How to Use a Batch Controller

Batch Controller | FlowmetricsA batch controller calculates the number of items or the volume of things that are being processed at any given time. If these are solid objects, they work in the form of counters to calculate individual things, but when it comes to gas or liquid, these batches need to be counted by other means. Liquids and gasses pass through tubes when they are transferred and the volume of material must be communicated in the form of velocity, such as through rate per minute. A flow meter deals with volume and the batch controller displays the amount of liquid and gas that is passing through the tanks to the tubes.

When looking for a batch controller, you may select one that accepts pulses per second and gives rates and total readings for batching functions. You should also see hardware and software features and clear monitoring that is accurate and easy to read. You could find a controller that can monitor remotely or up close and can print out results as needed.

Batch Controller Features

Batch controller features usually include a scaling factor of five digits and programmable features for the output in the total. You should be aware of pulse capacity and familiarize yourself with various panels and inputs. You should be able to measure the rates as well as the grand total and switch it on and off as needed. There are also buttons for various situations and lockout features to prevent unauthorized access.

How to Mount the Batch Controller

The batch controller should be mounted with a gasket that has a tight seal. You should find brackets that will hold the panel tightly in place. The body should be slated through the gaskets and then inserted into the handle. Place the screws behind the brackets and tighten them, but not excessively. If the panel is not thick, you might have to watch out for flexing, and this could result in a misshapen unit that could threaten the seal.

A Word About Wires

The terminal has several areas for screwing on the wires. Keep in mind that the batch controller is powered by a microprocessor that is sensitive to interferences. Therefore, when you connect the wires, make sure they do not interfere with the connection of motors and pumps that can throw off the signal. The controller should not be affected by voltages, but if the voltage is very strong and fluctuates frequently, be on the lookout for irregularity. Keep the wires away from a clean power source and stay clear of input power lines because of the heavy electrical loads that they carry. In the case of electrical noise, shield your cable with a protective unit and hook it to the DC ground terminal for the instrument. The power should be connected only after other connections are completed; avoid touching live power terminals. Consult the diagram for proper wiring and make sure that everything is connected correctly.

Operating the Batch Controller

When you are beginning to use the batch controller, it will be reset at zero. After pressing the start button, it will count automatically with the right signals. If you choose the pre-set button, it will be indicated when the account reaches the program number. The reset or stop button can be activated at any time while it is functioning. You will see a row of buttons including one for entering and one which allows you to put in a code to unlock the panel. Another button is preset for programming things at a certain time and a button that will display program choices. The view button will show you the rate and the total, and the start button is self-explanatory. You can preset a number of functions including batch total, grand total, pre-warn delay, and lock.

You are able to program scale factors with five digit codes. These skills can affect flow batching, conveyor, and other features. You can also regulate the rate of work and time. Familiarize yourself with the list of other input commands you can use during operation. For instant paper feedback, you need to hook up the batch controller with the printer. It is useful to first connect the controller to a computer to receive data, transmit data, and print it.


You may have followed the instructions on installation and operating your batch controller but may be facing some problems. If the power does not light up, you may have an issue with the wiring. If the control is functioning properly most of the time but sometimes skips and jump, it may be facing interference because of line noise caused by a problem with the power supply. If the controller is otherwise working but the count is not correct, check wiring, scale factors, and the transmitting device. If instead of numbers you see FFFFFF, it could be that the number the controller is attempting to display is too large or too small. In this case, you should check the scaling factors that were programmed into the controller. For other problems, you can contact the company that sold you the controller and see if there is a more serious problem with your device.

Batch Controller Success

It is not difficult to install and program a batch controller. Having the right kind of device can help you properly measure the flow of your liquids and gasses and help you produce materials more efficiently. An interruption of flow can be due to a leak or some other type of interference, and the controller can identify problems early on. Purchase your controller from a reliable company that has significant experience with this kind of machinery and can offer a warranty for all of the devices that are sold. They should also be available for questions and comments and be able to guide you through any problems you may be having with that controller. Once installed and working, your device should faithfully and accurately calculate the flow of all gasses and liquids for efficient feedback and elimination of wasted resources. A quality controller will help you keep track of your resources and keep them moving in the right direction.

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