Dosing Controllers Batching Master 110/110i/210/210i

The Batching Master series consists of compact, intrinsically safe batch controllers designed for precise and safe dosing and loading of liquids and gases in industrial environments.

• Batching Master 110/110i: Field-mounted housing (IP65), installed directly at the loading point. The 110i version is intrinsically safe for hazardous areas (ATEX Zone 1).

• Batching Master 210/210i: Panel-mounted version (front IP65, rear IP20), intended for integration into local control panels. The 210i version is also intrinsically safe (ATEX Zone 1).

All models feature a clear 2×16-character LCD display (with optional backlight), a membrane keyboard, PID flow control, pressure monitoring (especially for LPG with 25-point linearization), soft start/stop of valves (up to 5 steps), hydraulic shock prevention, additive injection, line flushing, and product selection (up to 3 products via F1–F3 keys). Communication with DCS/SCADA is possible via digital I/O or Modbus RTU/ASCII.

Operating Principle

The controller receives instantaneous flow, volume, or mass signals from primary measuring instruments (pulse or 4–20 mA inputs). It compares the delivered quantity with the preset batch value and generates control signals for pumps, valves, and shut-off devices to ensure exact dosing. Key functions include:

• Automatic error compensation (overrun, underfill, line break detection)

• PID-controlled flow regulation

• Pressure and temperature compensation (according to API, FAME, etc.)

• Soft valve opening/closing (up to 9999 s ramp time)

• Additive injection and line flushing sequences

• Emergency stop and clear-text fault messages

Up to 5 freely configurable digital inputs/outputs and one 4–20 mA analog output allow full process automation.

Technical Specifications

• Certification: ATEX 1Ex ib IIC T4 Gb (110i/210i), suitable for commercial custody transfer

• Protection class: IP65 (110/110i), IP65 front / IP20 rear (210/210i)

• Operating temperature: –20…+60 °C

• Power supply: 18–30 V DC (standard models), intrinsically safe 28.5 V DC (i-models)

• Inputs: – 2 pulse/frequency inputs (0–10 kHz, resolution ±1 pulse) – 3 analog inputs 4–20 mA – 5 digital inputs (active)

• Outputs: – 5 digital outputs (passive, optocouplers) – 1 analog output 4–20 mA – 2 × RS485 (Modbus RTU/ASCII, DIN 66348)

• Batch range: up to 9 999 999 units (ml, l, m³, g, kg, t)

• Accuracy: pulse ±1 pulse, analog signals ±0.03–0.05 %

• Dimensions & weight: – 110/110i: 240 × 240 × 120 mm, ≤ 4.3 kg – 210/210i: 144 × 144 × 130 mm, ≤ 1.3 kg

• Sealing capability for fiscal/custody transfer applications

Main Application Areas

• Petroleum and petrochemical industry (truck/railcar loading, pipeline batching)

• Chemical and pharmaceutical plants (reactor feeding, additive dosing)

• Food and beverage (alcohol, oils, ultrapure water systems)

• LPG and LNG loading stations (with pressure compensation)

• Custody-transfer loading of fuels, chemicals, and gases (OIML R117 / MI-005 compliant)

• Any process requiring precise, repeatable batching with documentation

Key Advantages of Batching Master 110/110i/210/210i

• Extremely high dosing accuracy and repeatability (±1 pulse, automatic overrun compensation)

• Intrinsically safe versions for Zone 1 without additional barriers

• Built-in PID controller and hydraulic shock elimination

• Full temperature/pressure/density compensation without external calculators

• Flexible additive injection and line flushing sequences

• Clear-text error messages and simple local operation

• Easy integration into existing DCS/SCADA via Modbus and digital I/O

• Compact design, low power consumption, and possibility of fiscal sealing

• One device covers virtually all liquid and gas batching tasks — from fuels and chemicals to ultrapure water and LPG