Cole-Parmer 05628-00 Batch Controller

Overview

The Cole-Parmer 05628-00 Batch Controller is a dedicated, microprocessor-based instrumentation device engineered for precise volumetric or mass-based batch dispensing control in industrial process environments. It operates on a deterministic logic architecture—accepting pulse inputs from flow sensors (e.g., turbine, paddlewheel, or ultrasonic transducers) to accumulate totalized counts, then executing discrete control actions upon reaching user-defined setpoints. Unlike general-purpose PLCs, the 05628-00 implements fixed-function batch sequencing logic optimized for repeatability, low-latency response, and minimal configuration overhead. Its design prioritizes functional safety in non-critical but operationally essential unit operations—such as chemical dosing, solvent transfer, intermediate filling, or raw material charging—where deterministic stop/start behavior, tamper-resistant parameter storage, and field-deployable physical interface are mandatory requirements.

Key Features

• Dual SPDT relays rated at 5 A @ 250 V AC / 30 V DC, supporting independent control of pumps, solenoid valves, or alarm circuits without external relay modules
• Non-isolated 4–20 mA analog output compliant with standard process current loop specifications, enabling direct integration with chart recorders, SCADA I/O modules, or DCS analog input cards
• EOB (End-of-Batch) pulse output with configurable polarity and duration, providing TTL- or opto-coupled compatibility for PLC-triggered sequence advancement or HMI-initiated batch restart
• Optically isolated frequency input (5–1000 Hz), rejecting common-mode noise and ensuring stable counting under variable signal amplitude or cable length conditions
• Backlit 2-line × 16-character alphanumeric LCD with bidirectional rotary thumbwheel (0–100% or 100–0% scaling), allowing intuitive local setpoint adjustment without menu navigation depth
• Four-button membrane keypad with password-protected access (user-configurable security code) to prevent unauthorized modification of batch targets, relay assignments, or scaling factors
• Non-volatile EEPROM retains all configuration parameters—including accumulated totals, relay states, and analog scaling coefficients—through power interruption, eliminating recalibration after outage
• Wide-input 12–24 V AC/DC power supply eliminates need for external transformers in mixed-voltage plant environments; meets UL 508 and CE low-voltage directive requirements

Sample Compatibility & Compliance

The 05628-00 is designed for integration with pulse-output flow sensors commonly deployed in liquid handling systems—including Cole-Parmer’s own series of turbine and gear-type flowmeters (e.g., models 05600-XX, 05610-XX). It does not perform fluid property measurement (e.g., density, viscosity, or temperature compensation); instead, it assumes linear pulse-to-volume correlation per sensor calibration certificate. The controller complies with electromagnetic compatibility standards per EN 61326-1 (industrial environment) and carries CE marking for use within the European Economic Area. While not SIL-certified, its deterministic relay timing (<10 ms actuation latency) and fail-safe relay de-energization on power loss align with good engineering practice for non-safety-critical batch termination per IEC 61511 Annex A guidelines. It supports audit-ready operation when paired with externally logged analog outputs and relay status traces.

Software & Data Management

The 05628-00 operates without embedded firmware updates or host PC software—configuration is performed exclusively via front-panel interface. However, its 4–20 mA output provides continuous real-time representation of accumulated volume (scaled linearly from 0 to full-scale setpoint), enabling third-party data historians (e.g., Ignition, WinCC, or LabVIEW DAQ systems) to reconstruct batch timelines and verify execution fidelity. The EOB pulse serves as a hardware-level trigger event, timestampable by external controllers to validate batch completion against target tolerance (±1 pulse count). Configuration changes are logged only via manual entry into maintenance logs; no electronic audit trail or 21 CFR Part 11 compliance is provided natively—users requiring electronic records must implement external validation protocols and metadata tagging at the supervisory system level.

Applications

• Pharmaceutical intermediate transfer where batch quantity accuracy must meet USP analytical instrument qualification thresholds for volumetric dispensing
• Food & beverage ingredient blending lines requiring repeatable fill volumes across shift changes, with operator-settable targets stored locally
• Chemical manufacturing catalyst charging stations where dual-relay interlock prevents simultaneous valve opening and ensures sequential purge-fill cycles
• Water treatment coagulant dosing skids integrating with existing 4–20 mA recorder infrastructure for regulatory reporting
• R&D pilot plants needing rapid deployment of deterministic batch logic without PLC programming resources or validation overhead

FAQ

Can the 05628-00 accept analog voltage inputs (e.g., 0–10 V)?
No. It accepts only pulse-frequency signals (5–1000 Hz) with optical isolation. Voltage inputs require external signal conditioning or a compatible pulse-output flow sensor.
Is the 4–20 mA output scalable to represent instantaneous flow rate?
No. The analog output is configured exclusively for totalized batch volume (0–100% of setpoint), not real-time flow rate.
Does the controller support Modbus or other digital communication protocols?
No. Communication is limited to hardwired pulse, relay, and analog I/O. Integration with higher-level networks requires external protocol converters.
What happens if power is lost mid-batch?
The accumulated pulse count and active setpoint are retained in non-volatile memory; upon power restoration, the controller resumes counting from the last valid value and triggers relays at the original target.
Can relay timing be delayed or dithered for pump soft-start?
No. Relay actuation is immediate and deterministic upon setpoint reach. External timers or VFDs must be used for controlled ramping.