A&D AD-4402 Batch Weighing Controller

Overview

The A&D AD-4402 Batch Weighing Controller is an industrial-grade, microprocessor-based weighing and process control system engineered for high-accuracy material dispensing in multi-ingredient batching, mixing, and filling applications. Designed and manufactured in Japan, the AD-4402 implements precision load cell signal conditioning via a 24-bit sigma-delta A/D converter with real-time digital filtering, delivering stable weight acquisition at 100 samples per second. Its core architecture supports deterministic control logic execution synchronized with weight measurement cycles, enabling tight integration between gravimetric feedback and actuator sequencing—critical for maintaining batch consistency in regulated manufacturing environments such as food processing, pharmaceutical excipient blending, chemical compounding, and additive manufacturing feedstock preparation.

Key Features

• High-fidelity analog signal processing: 0.3 µV/d input sensitivity and 1-part-in-1,000,000 internal resolution ensure minimal quantization error across wide dynamic ranges (typical scale capacities from 1 kg to 5,000 kg)
• IP65-rated front-panel enclosure with high-brightness fluorescent display and tactile numeric keypad—optimized for readability and operability in dusty, humid, or vibration-prone production areas
• Configurable I/O architecture: 11 programmable digital inputs and 11 outputs support flexible mapping to valves, solenoids, motor starters, limit switches, and status indicators; 50 predefined function codes enable rapid commissioning without custom firmware
• Digital calibration suite including automatic zero tracking, span adjustment, and location-specific gravity compensation—eliminates reliance on physical test weights during field installation or relocation
• Eight independent alarm outputs assignable to over/under-fill, timeout, sensor fault, hopper blockage, communication loss, or recipe validation failure—each triggering hardwired interlocks to halt downstream equipment
• Modular communication expansion: Optional interface boards support native integration into major industrial networks including CC-Link (IE Control), DeviceNet (CIP), and PROFIBUS DP—ensuring compatibility with PLC-based MES and SCADA systems

Sample Compatibility & Compliance

The AD-4402 is compatible with standard 4-wire and 6-wire analog load cells meeting OIML R60 C3/C4 accuracy classes and compliant with EN 61000-6-2 (EMC immunity) and EN 61000-6-4 (EMC emissions). It meets CE marking requirements for machinery safety (2006/42/EC) and electromagnetic compatibility (2014/30/EU). While not certified for SIL-rated safety functions, its deterministic scan cycle and watchdog timer architecture support implementation within Safety Integrity Level 1 (SIL 1) subsystems under IEC 61508 when deployed with appropriate external safety relays. The controller’s data logging and audit trail capabilities—including timestamped recipe execution logs, calibration history, and alarm event records—align with Good Manufacturing Practice (GMP) documentation expectations for traceability in FDA-regulated industries.

Software & Data Management

The AD-4402 operates autonomously without host PC dependency; all configuration, recipe management, and diagnostics are performed locally via the front-panel interface. Recipes and material definitions are stored in non-volatile EEPROM with checksum verification to prevent corruption during power interruption. Optional PC configuration software (A&D WinBatch Pro, sold separately) enables offline recipe development, batch report generation (CSV/Excel export), and firmware updates via RS-232 or USB-to-serial adapter. All parameter changes, recipe loads, and calibration actions are logged with date/time stamps and user ID fields—supporting 21 CFR Part 11 compliance when used with validated electronic signature workflows and access-controlled networked PCs.

Applications

• Multi-component dry blending systems requiring precise mass-based ratio control (e.g., polymer masterbatch formulation, nutraceutical premixes)
• Gravimetric liquid filling lines where density variation precludes volumetric metering (e.g., syrups, suspensions, viscous coatings)
• Automated powder dispensing for tablet press feeders with real-time loss-in-weight monitoring
• Batch reactor charge control integrating weigh data with agitator speed ramping and temperature interlocks
• Recycling operations managing mixed-material feedstocks via weight-proportional sorting algorithms

FAQ

Does the AD-4402 support NIST-traceable calibration?
Yes—when used with NIST-traceable reference weights and following A&D’s documented calibration procedure (P/N MA-AD4402-CAL), the unit achieves metrological traceability per ISO/IEC 17025 requirements.
Can recipes be edited remotely via PLC?
No—recipe editing requires local front-panel access or offline PC configuration. However, recipe selection and start/stop commands can be triggered via discrete I/O or Modbus RTU commands.
Is gravity compensation required for every installation site?
Gravity compensation is recommended for installations where local gravitational acceleration deviates by more than ±0.05% from nominal (9.80665 m/s²), particularly above 1,000 m elevation or near geological anomalies.
What is the maximum cable length for RS-485 communication?
Up to 1,200 meters at 9.6 kbps, provided shielded twisted-pair cabling (AWG 24 or heavier) and proper termination resistors are used per EIA/TIA-485-A specifications.
Are firmware updates backward-compatible with existing recipes?
Yes—A&D maintains strict binary compatibility across firmware revisions; previously saved recipes and configurations remain fully functional after update.