The Daniel DanLoad 6000 is a powerful microcomputer-based batch delivery controller and liquid flow computer. It's ideal for applications like tanker vehicle loading, providing precise flow measurement and control for accurate liquid batch deliveries. The DanLoad 6000 simplifies batch delivery operations with intuitive commands and a graphic display showing the delivery progress.
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DanLoad 6000 (v6.00) __________________________________________________________
DANIEL M EASUREMENT AND CONTROL, INC. ("DANIEL") SHALL NOT BE LIABLE FOR TECHNICAL OR
EDITORIAL ERRORS IN THIS M ANUAL OR OM ISSIONS FROM THIS M ANU AL. D A NIEL M AKES NO
W ARRANTIES, EXPRESSED O R IM P LIED, INCLUDING TH E IM PLIED W A RRANTIES O F
M ERCHANTABILITY AND FITNESS FOR A PARTICULAR P U R PO SE W ITH RESPECT TO THIS
M A N U A L A ND, IN NO EVENT, SHALL DANIEL BE LIABLE FOR ANY INCIDENTAL, PUNITIV E,
SPECIAL O R CO NSEQUENTIAL DA M AGES INCLUDING, BUT NO T LIM ITED TO , LO SS O F
PRODUCTION, LOSS OF PROFITS, LOSS O F REVENUE O R USE AND COSTS INCURRED INCLUDING
W ITH OUT LIM ITATION FO R CAPITAL, FUEL AND PO W ER, AND CLAIM S OF THIRD PARTIES.
PRODUCT NAM ES USED HEREIN ARE FOR M ANUFACTURER OR SUPPLIER IDENTIFICATION ONLY
AND M AY BE TRADEM ARKS/REGISTERED TRADEM ARKS OF THESE COM PANIES.
THE CONTENTS OF THIS PUBLICATION ARE PRESENTED FOR INFORM ATIONAL PURPOSES ONLY, AND
W HILE EVERY EFFORT HAS BE EN M ADE TO ENSURE THEIR ACCURACY, THEY ARE NOT TO BE
CONSTRUED AS W ARRANTIES OR GUARANTEES, EX PRESSED OR IM PLIED, REGARDING THE
PRODUCTS OR SERVICES DESCRIBED HEREIN OR THEIR USE OR APPLICABILITY . ALL SALES ARE
GOVERNED BY DANIEL’S TERM S AND CONDITIONS, W HICH ARE AVAILABLE UPO N REQUEST. W E
RESERVE THE RIGHT TO MODIFY OR IMPROVE THE DESIGNS OR SPECIFICATIONS OF SUCH PRODUCTS
AT ANY TIM E.
DANIEL DOES NOT ASSUM E RESPONSIBILITY FOR T HE SELECTION, USE OR M AINTENANCE OF ANY
PROD U CT . RESPONSIBILITY FOR PROPER SELECTION, USE AND M AINTENANCE OF ANY DANIEL
PRODUCT REM AINS SOLELY W ITH THE PURCHASER AND END-USER.
DANIEL AND THE DANIEL LOGO ARE REGISTERED T RADEM ARKS OF DANIEL INDUSTRIES, INC. THE
EMERSON LOGO IS A TRADEM ARK AND SERVICE M ARK OF EM ERSON ELECTRIC CO.
COPYRIGHT © 2006
BY DANIEL MEASUREMENT AND CONTROL, INC.
HOUSTON, TEXAS, U.S.A.
All rights reserved. No part of this work may be reproduced or copied in any form or by any means - graphic, electronic or mechanical - without first receiving the written permission of
Daniel Measurement and Control, Inc., Houston, Texas, U.S.A.
Preface i
_________________________________________________________ DanLoad 6000 (v6.00)
1. LIM ITED W ARRANTY: Subject to the limitations contained in Section 2 herein and except as otherwise expressly provided herein, Daniel M easurement and Control, Inc. ("Daniel") warrants that the firmware will execute the programming instructions provided by Daniel, and that the Goods manufactured or Services provided by Daniel will be free from defects in materials or workmanship under normal use and care until the expiration of the applicable warranty period. Goods are warranted for twelve (12) months from the date of initial installation or eighteen (18) months from the date of shipment by Daniel, whichever period expires first. Consumables and Services are warranted for a period of 90 days from the date of shipment or completion of the Services. Products purchased by Daniel from a third party for resale to Buyer ("Resale Products") shall carry only the warranty extended by the original manufacturer. Buyer agrees that Daniel has no liability for Resale Products beyond making a reasonable commercial effort to arrange for procurement and shipping of the Resale Products. If Buyer discovers any warranty defects and notifies Daniel thereof in writing during the applicable warranty period, D aniel shall, at its option, promptly correct any errors that are found by Daniel in the firmware or Services, or repair or replace F.O.B. point of manufacture that portion of the Goods or firmware found by
Daniel to be defective, or refund the purchase price of the defective portion of the Goods/Services. All replacements or repairs necessitated by inadequate maintenance, normal wear and usage, unsuitable power sources, unsuitable environmental conditions, accident, misuse, improper installation, modification, repair, storage or handling, or any other cause not the fault of Daniel are not covered by this limited warranty, and shall be at Buyer's expense. Daniel shall not be obligated to pay any costs or charges incurred by Buyer or any other party except as may be agreed upon in writing in advance by an authorized Daniel representative. All costs of dismantling, reinstallation and freight and the time and expenses of Daniel's personnel for site travel and diagnosis under this warranty clause shall be borne by Buyer unless accepted in writing by Daniel. Goods repaired and parts replaced during the warranty period shall be in warranty for the remainder of the original warranty period or ninety (90) days, whichever is longer. This limited warranty is the only warranty made by Daniel and can be amended only in a writing signed by an authorized representative of Daniel. Except as otherwise expressly provided in the Agreement, T HERE ARE NO REPRESENTATIONS OR W ARRANTIES OF
ANY KIND, EXPRESSED OR IMPLIED, AS TO MERCHANTABILITY, FITNESS FOR PARTICULAR PURPOSE,
OR ANY OTHER MATTER W ITH RESPECT TO ANY OF THE GOODS OR SERVICES.
Buyer acknowledges and agrees that corrosion or erosion of materials is not covered by this warranty.
2. LIM ITATION O F REM EDY AND LIABILITY: DANIEL SHALL NOT BE LIABLE FOR DAMAGES
CAUSED BY DELAY IN P ERFORMANCE. THE SOLE AND EXCLUSIVE REMEDY FOR BREACH OF
W ARRANTY HEREUNDER SHALL BE LIM ITED TO REPAIR, CORRECTION, REPLACEMENT OR REFUND
OF PURCHASE PRICE UNDER THE LIMITED W ARRANTY CLAUSE IN SECTION 1 HEREIN. IN NO EVENT,
REGARDLESS OF THE FORM OF THE CLAIM OR CAUSE OF ACTION (W HETHER BASED IN CONTRACT,
INFRINGEM ENT, NEGLIGENCE, STRICT LIABILITY, OTHER TORT OR OTHERW ISE), SHALL DANIEL'S
LIABILITY TO BUYER AND/OR ITS CUST OM ERS EXCEED THE PRICE TO BU Y ER OF THE SPECIFIC
GOODS M ANUFACTURED OR SERVICES PROVIDED BY DANIEL GIVING RISE TO THE CLAIM OR CAUSE
OF ACTION. BUYER AGREES THAT IN NO EVENT SHALL DANIEL'S LIABILITY TO BUYER AND/OR ITS
CUSTOM ERS EXTEND TO INCLUDE INCIDENTAL, CONSEQUENTIAL OR PUNITIVE DAM AGES. THE
TERM "CONSEQUENTIAL DAM AGES" SHALL INCLUDE, BUT NOT BE LIM ITED TO, LOSS OF
ANTICIPATED PROFITS, REVENUE OR USE, AND COSTS INCURRED INCLUDING W ITHOUT LIM ITATION
FOR CAPITAL, FUEL AND POW ER, AND CLAIM S OF BUYER’S CUSTOM ERS. ii Preface
1.1
1.2
1.3
2.1
2.2
2.2.1
2.2.2
2.3
2.4
2.4.1
2.4.2
2.4.2.1
2.4.2.2
2.4.3
2.5
2.5.1
2.5.2
2.5.3
2.5.4
3.1
3.2
3.2.1
DanLoad 6000 (v6.00) __________________________________________________________
Functional Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Hardware Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
General Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
DanLoad 6000 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Installation Planning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
Card Cage Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
DanLoad 6000 Board Description and Jumper Settings . . . . . . . . . . . . . 2-11
Mechanical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-35
Electrical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-38
General Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-38
Selection/Installation of Electrical Wire / Cable . . . . . . . . . . . . . . . . . 2-39
Input / Output Field Signal Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-41
Electrical Grounds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-41
Selection/Installation of Wire Conduit . . . . . . . . . . . . . . . . . . . . . . . . . 2-43
Installing the Secondary Keypad / Display . . . . . . . . . . . . . . . . . . . . . . . 2-44
Hardware Setup / Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-44
Software Setup / Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-44
Wiring Details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-45
Power Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-45
Overview of DanLoad 6000 Capabilities . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Operator Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Data Display Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Table of Contents iii
3.8
3.9
3.10
3.10.1
3.10.2
3.10.3
3.10.4
3.10.5
3.11
3.11.1
3.11.2
3.11.3
3.11.4
3.11.5
3.11.6
3.11.7
3.11.8
3.12
3.13
_________________________________________________________ DanLoad 6000 (v6.00)
3.6
3.6.1
3.6.2
3.7
3.7.1
3.2.2
3.3
3.3.1
3.4
3.5
3.5.1
3.5.2
Keypad Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Initial Setup Procedure Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
Data Entry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
Initial Setup Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
Process I/O Signal Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24
Physical I/O Signal Assignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25
Inverted Discrete Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27
Product Delivery and Blending . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-70
Sequential Blending . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-70
In-Line Blending . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-71
Temperature and Pressure Compensation . . . . . . . . . . . . . . . . . . . . . . 3-78
Temperature Correction to a Non-Standard
Reference Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-83
Mass Loading Using a Mass Flow Meter . . . . . . . . . . . . . . . . . . . . . . . . 3-86
Mass Loading Using a Volumetric Flow Meter . . . . . . . . . . . . . . . . . . . 3-87
Additive Injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-88
Additive Injection Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-92
Additive Injection Configuration (Typical Examples) . . . . . . . . . . . . . 3-99
Additive Meter Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-109
Multi-Stream Injection Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-112
Multi-Rate Additive Injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-119
Transaction Storage Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-121
Transaction Storage / Transaction Ticket
Setup Procedure (Example) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-122
Default Ticket Formats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-134
Transaction Data Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-136
Relation Between Batch Storage and
Transaction Storage Variables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-148
Relation Between Transaction Storage Codes /
Batch Storage Codes / Program Codes . . . . . . . . . . . . . . . . . . . . . . . . . 3-149
Transaction Ticket Configuration Overview . . . . . . . . . . . . . . . . . . . . 3-151
Transaction Ticket Layout Planning . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-152
Alarm BitMap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-156
Compartment Size Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-164
Cutoff (End of Day Processing) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-165 iv Table of Contents
DanLoad 6000 (v6.00) __________________________________________________________
3.14
3.15
3.16
Set Contrast / Backlighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-166
CALMON - Turbine Meter Calibration Monitoring for the
DanLoad 6000 Electronic Preset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-167
Configuration Parameter Groups . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-175
4.1
4.1.1
4.1.1.1
4.1.1.2
4.1.1.3
4.2
4.2.1
4.3
4.4
4.4.1
4.5
4.5.1
4.5.2
5.1
5.1.1
5.2
5.2.1
5.2.2
5.2.3
5.2.4
5.2.5
5.3
5.3.1
5.3.2
5.3.3
5.3.4
5.3.5
Physical Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Displays and Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
LED Status Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
LCD Alpha-Numeric / Graphic Data Display . . . . . . . . . . . . . . . . . . . . 4-5
Keypad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Batch Delivery Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Controlling the Batch Delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
Additive Injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
Data Logging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20
Example Data Logs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21
Alarm Analysis / Correction / Diagnostic Tests . . . . . . . . . . . . . . . . . . 4-30
Alarm Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-31
Diagnostic Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-50
General Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Initial Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17
Tank Prover Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21
Meter Proof RUN 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22
Meter Proof RUN 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23
Meter Proof RUN 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23
Meter Proof RUN 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-24
Meter Proofs for Component 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-24
Master Meter Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-28
Meter Proof RUN 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-29
Meter Proof RUN 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-30
Meter Proof RUN 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-31
Meter Proof RUN 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-31
Meter Proofs for Component 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-31
Table of Contents v
_________________________________________________________ DanLoad 6000 (v6.00)
6.1
6.2
6.15
6.16
6.17
6.18
6.11
6.12
6.13
6.14
6.7
6.8
6.9
6.10
6.3
6.4
6.5
6.6
6.19
6.20
6.20.1
6.21
Program Code Attributes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Program Code Groups . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
Security Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12
Unit Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16
Valve Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-34
Meter Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-36
Component Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-39
Delivery Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-42
Digital Valve Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-50
Pulse Per Unit Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-54
Additive Delivery Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-58
Factors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-68
Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-77
I/O Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-112
Additive I/O Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-144
Component I/O Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-148
Temperature / Pressure / Density . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-158
Recipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-180
Data Communications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-186
Dynamic Data Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-190
Dynamic Data Display Data Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-195
Data Logging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-202 vi Table of Contents
C
D
A
A.7
A.8
A.9
A.10
A.11
A.12
A.13
A.14
A.15
A.1
A.2
A.3
A.4
A.5
A.6
A.16
A.17
A.18
A.19
A.20
B
DanLoad 6000 (v6.00) __________________________________________________________
6.22
6.23
6.24
6.25
6.26
6.27
6.28
Blending . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-208
Additive Pumps / Block Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-228
LPG / Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-230
Transaction Data Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-239
Transaction Ticket Format . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-248
Analog Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-254
CPU Version 2 Analog Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-257
Installation Worksheets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
Physical Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-4
Functional Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-7
General Configuration Parameters Setup (Table A-11) . . . . . . . . . . . . A-19
Flow Meter Parameters Setup (Table A-12) . . . . . . . . . . . . . . . . . . . . . A-22
Flow Control Valve Parameters Setup (Table A-13) . . . . . . . . . . . . . A-24
Component Parameters Setup (Table A-14) . . . . . . . . . . . . . . . . . . . . . A-26
Component Block Valve / Pump Parameters Setup (Table A-15) . . . . A-28
Delivery Parameters Setup (Table A-16) . . . . . . . . . . . . . . . . . . . . . . . A-30
Blending Parameters Setup (Table A-17) . . . . . . . . . . . . . . . . . . . . . . . A-33
Temperature Compensation Parameters Setup (Table A-18) . . . . . . . . A-35
Pressure Compensation Parameters Setup (Table A-19) . . . . . . . . . . . A-37
Density Compensation Parameters Setup (Table A-20) . . . . . . . . . . . A-38
Pulse Per Unit Output Parameters Setup (Table A-21) . . . . . . . . . . . . A-40
Additive Parameters Setup (Table A-22) . . . . . . . . . . . . . . . . . . . . . . A-41
LPG / Pressure Control Parameters Setup (Table A-23) . . . . . . . . . . . A-44
Dynamic Data Display Parameters Setup (Table A-24) . . . . . . . . . . . A-46
Communications / Data Logging Parameters Setup (Table A-25) . . . A-54
Transaction Storage Parameters Setup (Table A-26) . . . . . . . . . . . . . A-56
Transaction Ticket Parameters Setup (Table A-27) . . . . . . . . . . . . . . A-61
Alarm Parameters Setup (Table A-28) . . . . . . . . . . . . . . . . . . . . . . . . A-65
Configuration Record . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1
LPG Loading Configuration Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . C-1
Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-1
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3-2
3-3
3-4
3-5
3-6
3-7
3-8
3-9
3-10
3-11
3-12
1-1
2-9
2-10
2-11
2-12
2-13
2-14
2-15
2-16
2-1
2-2
2-3
2-4
2-5
2-6
2-7
2-8
2-17
2-18
2-19
2-20
2-21
_________________________________________________________ DanLoad 6000 (v6.00)
E
F
Field Wiring Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-1
Other Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-1
Typical Load Rack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Standard Enclosure Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Standard Enclosure Field Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Shallow Enclosure Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Shallow Enclosure Field Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Card Cage Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
DC Power Supply Voltage Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
AC Power Input Jumpers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
CPU Board - Jumpers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
CPU and Analog Inputs Board Combination Jumpers . . . . . . . . . . . . . . 2-13
CPU Board Jumpers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
CPU Analog Inputs Program Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
DUART Board Address Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
2-Ch. Meter Pulse Input Board Jumpers . . . . . . . . . . . . . . . . . . . . . . . 2-17
4-Ch. Meter Pulse Input Board Jumpers . . . . . . . . . . . . . . . . . . . . . . . 2-22
MPMC Version Comparisons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24
Version 1 AC I/O Board Jumpers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26
Version 2 AC I/O Board Jumpers . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26
Version 1 Enhanced (Additive Injector) I/O Board Jumpers . . . . . . . . 2-29
Version 2 Enhanced I/O Board Jumpers . . . . . . . . . . . . . . . . . . . . . . . 2-31
DC I/O Board Jumpers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-33
Secondary Keypad / Display Connections . . . . . . . . . . . . . . . . . . . . . . . 2-46
Menu Tree . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Program Code Groups . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
General Display Format . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Program Code View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Key Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
Alpha-Numeric Characters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
Basic Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24
Set Date and Time Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30
Alarm Action Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-47
Digital Flow Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-75
Two-Stage Flow Control Valve (w/o Stem Switches) . . . . . . . . . . . . 3-76
Transaction Ticket (Typical) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-126 viii Table of Contents
DanLoad 6000 (v6.00) __________________________________________________________
4-1
4-2
4-3
4-4
4-5
4-6
4-7
4-8
4-9
3-13
3-14
3-15
3-16
5-1
5-2
5-3
6-1
6-2
6-3
Transaction Record / Ticket Worksheet (Example) . . . . . . . . . . . . . . . 3-127
Batch Record / Ticket Worksheet (Example) . . . . . . . . . . . . . . . . . . . . 3-128
DanLoad Default Ticket Formats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-135
Set Contrast / Backlighting Display . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-166
Keypad Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Key Functions (Batch Delivery) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Recipe Selection Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Additive Selection Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
Loading Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
Diagnostic Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-50
Input / Outputs Diagnostic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-52
DUART Ports Diagnostic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-54
LAN Port Diagnostic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-54
Prover / Meter Volume Relationship . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
Meter Proving Report For Tank Prover Method . . . . . . . . . . . . . . . . . 5-39
Meter Proving Report For Master Meter Method . . . . . . . . . . . . . . . . 5-40
Master Meter Meter-Factors Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-41
Menu Tree . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
Parameters List Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
CPU v2 Analog Calibration Set Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-262
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x Table of Contents
_________________________________________________________ DanLoad 6000 (v6.00)
This manual contains information on the installation, setup, and operation of the DanLoad 6000.
The DanLoad 6000 is a versatile microcomputer based batch delivery controller and liquid flow computer. This type of instrument is commonly referred to as a Preset in the tanker vehicle loading industry. The DanLoad 6000 is easy to setup on-site for utilization in virtually any application that requires precise flow measurement and control of liquid batch deliveries. Batch delivery operations are easily conducted in a logical manner. A batch delivery can be setup and started with several intuitive commands. The instrument provides a graphic display of the progress of the batch delivery.
Notes
This manual covers the DanLoad 6000 software version 5.74 released in July, 2001. The
DanLoad 6000 software version number is displayed during the startup sequence after power is applied to the instrument and in the diagnostics menu. This software version is compatible with both the original CPU board and the new version 2 CPU (CPU v2) board.
How to use the Manual
#
#
The information contained in this manual is intended for use by operators, shift supervisors, instrument technicians, process engineers, and terminal / plant managers. To the extent that is practical, each section of the manual is designed as a stand alone document. The last section,
Section 6, contains a reference for the function of all program codes (parameters) that define the operation of the DanLoad 6000. Each program code is identified by a three-digit number between
001 and 991. Program codes are shown in the following forms in this text.
001 Passcode
052 / 055 / 058 / 061 Valve to be controlled
Unique program code.
Sequence of four similar three-digit program codes. Each three-digit number applies to one flow meter.
Program code sequence is in flow meter sequence in numerical order (1 to 4).
Introduction ____________________________________________________________ 1 - 1
DanLoad 6000 (v6.00) __________________________________________________________
# 481 / ... / 655 Name Sequence of similar three-digit program code numbers is too long to list all numbers. The ellipsis (...) is a place holder for additional program code numbers. In this example, the ellipsis represent 28 additional recipe name program code numbers.
Information applicable to new installations is located in the following sections.
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#
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Section 1 - Introduction
Section 2 - Installation
Section 3 - Setup
Section 6 - Program Code Definitions
Information applicable to operation of an existing system is located in the following sections.
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#
Section 4 - Operation
Section 5 - Flow Meter Proving
The individual sections contain the following information.
#
(this section)
This section contains an overview of the capabilities of the DanLoad 6000. A glossary of terms used throughout the manual is located at the rear of this section.
#
#
This section contains information on installation planning, mechanical installation, and electrical installation of the DanLoad 6000. Design considerations for on-site placement, mounting, and wiring methods are included in this section. Also read Section 3, Section 6,
Appendix A, Appendix B, and Appendix C before installing the instrument.
This section contains information on the initial setup (functional configuration) and modification of setup parameters stored in the DanLoad 6000. The DanLoad 6000 retains setup information in non-volatile memory. Therefore, the initial setup can be performed in a shop or office, before on-site physical installation of the instrument. Also read Section 2,
Section 6, Appendix A, Appendix B, and Appendix C before installing the instrument.
1 - 2 ____________________________________________________________ Introduction
_________________________________________________________ DanLoad 6000 (v6.00)
#
#
#
#
#
#
#
#
#
This section contains detailed information on local operation of the DanLoad 6000. Single product delivery, multi-component blending, and additive injection procedures are covered.
Information on data logs and fault analysis and correction is also located in this section.
This section contains information on operator directed, manual flow meter proving using the
DanLoad 6000. The instrument can monitor and perform flow meter proofs using tank meter provers, master flow meters, or mechanical displacement pipe provers.
This section contains reference information for all program codes (parameters) which determine the functional configuration of the DanLoad 6000.
This appendix contains several tables that can be photocopied and used as an aid in configuration of the DanLoad 6000 and interconnect wiring. The information in this appendix is related to the information in Section 2 - Installation and Section 3 - Setup.
This appendix contains a table that can be copied to provide a place to document the configuration of an installation.
This appendix contains instructions and listings that can be copied to provide a place to document LPG loading configurations.
This appendix contains lists of recommended DanLoad 6000 spare parts.
This appendix contains drawings that are relevant to the set up and operation of the DanLoad
6000 installation in the field.
This appendix contains other drawings that may be helpful for configuring and operating the
DanLoad 6000.
Introduction ____________________________________________________________ 1 - 3
DanLoad 6000 (v6.00) __________________________________________________________
Overview
The DanLoad 6000 can be operated in an independent stand-alone mode with batch delivery operations monitored and controlled from the operator control panel located on front of the DanLoad
6000. The DanLoad 6000 can also function as a slave unit in a terminal automation system network.
The information contained in this manual covers local operation of the DanLoad 6000 in the Stand-
alone Mode. The DanLoad 6000 accepts process input signals from and provides process control signals to the common instruments and devices used in liquid batch delivery systems. These instruments / devices include: liquid flow meters (turbine and positive displacement type), solenoid controlled digital flow control valves, additive injectors, security devices for verifying electrical ground connections and compartment overfills, electric motor driven pumps, and motor operated block valves. The DanLoad 6000 can be easily setup (configured) to deliver single component liquids or to blend up to four liquid components in precise ratios, with or without additive injection.
The various possible delivery and blending functions of the DanLoad 6000 are controlled by operator selectable recipes (predefined delivery control procedures). Additive injection is controlled by manual selection, recipe selection, or automatic selection from a terminal automation system. These features allow one DanLoad 6000 and the associated liquid delivery equipment to deliver many different combinations of liquid products, based on requirements of the client or receiver of the delivered product.
One common application for a DanLoad 6000 is as an on-site controller for delivering refined hydrocarbon liquid products from loading terminal storage tanks to mobile tanks, such as tanker trucks, rail tank cars, and tank barges. Some other applications include liquid component blending and / or additive injection in refinery or chemical plant processes. In addition, liquid components can be blended with or without additive injection into flowing pipelines or into storage tanks. A typical load rack installation with a DanLoad 6000 and associated equipment is shown in Figure 1 -
1.
1 - 4 ____________________________________________________________ Introduction
_________________________________________________________ DanLoad 6000 (v6.00)
Figure 1-1
Introduction ____________________________________________________________ 1 - 5
DanLoad 6000 (v6.00) __________________________________________________________
1.1
Functional Characteristics
The functional characteristics and capabilities of the DanLoad 6000 are presented in this section.
These functional characteristics and capabilities are closely related to the hardware configuration of the instrument. Section 1.2 - Hardware Configuration, contains general information on the hardware configuration of the DanLoad 6000. The DanLoad 6000 is delivered from the factory with several basic electronic modules and other optional modules to accommodate process input / output signals. The required process input / output signal boards are determined by the loading system configuration and should be specified when the DanLoad 6000 is purchased. The mix of process input / output signal boards and communications modules is field reconfigurable. The hardware configuration determines the input / output process signal handling capacity and the data logging / data communications capability of the instrument. The flow measurement and logical functions listed below are available in all hardware configurations of the DanLoad 6000. However, each unique installation requires a specific complement of process input / output signal boards, based on the actual devices that are monitored and controlled in the system.
The DanLoad 6000 can monitor and control operation of up to four flow meters, up to four flow control valves, delivery of up to four products, and up to six additive injectors and additive meters simultaneously. The minimum configuration consists of one flow meter measuring one component
(liquid product). Two high resolution pulse per unit volume outputs are provided for use by external equipment, such as meter prover counters. Product deliveries and component blending deliveries are selected by up to thirty configurable recipes (batch delivery / blending control procedures) and automatic or manual selection of additive injection. Any additive(s) can be associated with any recipe(s). The actual implementation of the various possible process operations are covered in detail in other sections of this manual.
# Batch Delivery
The DanLoad 6000 can automatically measure and control quantity-based preset batch delivery of one product or a blend of two to four liquid components. During blending operations, one to four flow meter streams are controlled independently from the other flow meter streams. Any combination of pulse output type flow meters of different sizes and flow handling capacities can be monitored and controlled by one DanLoad 6000. Each flow meter stream can have unique characteristics for the liquid component. For accounting and tracking purposes a batch delivery or group of consecutive batch deliveries can be combined to form one transaction.
In addition, the DanLoad 6000 can control batch loading of up to four independent loading arms, if only one loading arm is in use at any one time.
1 - 6 ____________________________________________________________ Introduction
_________________________________________________________ DanLoad 6000 (v6.00)
# Blending
#
#
#
#
#
The DanLoad 6000 can automatically measure and control gross or standard quantity based blending of several liquid components. Component blending can be performed by one of the following selectable methods.
Sequential, automatic block valve control
Sequential, manual block valve control
In-line, proportional
In-line, non-proportional
“Side” Stream Blending
Sequential blending is the mixing of two, three, or four components or transfers, one component at a time to the receiving tank by using block valves, either automatically or manually controlled.
Components are delivered in a time sequence through one flow meter / flow control valve stream.
In-line blending is the mixing of two, three, or four components simultaneously measured by individual flow meters / flow control valves, into one composite delivery stream. The blend ratio is precisely maintained during in-line proportional blending. The blend ratio is roughly maintained during in-line non-proportional blending. However, the blend ratio of a completed batch load is precise after the batch has been completely loaded.
"Side" stream blending is similar to in-line blending except one product component is delivered upstream to another product component. "Side" stream blending is typically used to inject ethanol into gasoline. Ethanol is injected into the gasoline stream and the blend is measured by the custody transfer meter.
The DanLoad 6000, Version 6.0 provides the ability of ethanol blending with gasoline. To accomplish this, an ethanol meter can be added and ethanol will be injected upstream into the gasoline product stream. When ethanol is injected into the gasoline stream the gasoline meter now will measure the blended product and cannot account for just the gasoline component. Also when ethanol is blended with gasoline, the gross volume of the blend changes due to the expansion of the mix. To accurately measure the gasoline-ethanol blend it is important to measure the blended product. This configuration provides the ability of ethanol blending with gasoline. This type of mixing is termed as "Side" Stream Blending.
Introduction ____________________________________________________________ 1 - 7
DanLoad 6000 (v6.00) __________________________________________________________
# Additive Injection
The DanLoad 6000's additive control functionality is designed with the following objectives:
# Allows direct control of additive injection (for up to 6 physical additives) via an
"additive panel" (additive meter and on/off valve), thus making so-called "smart" additive injectors obsolete. This also makes the DanLoad 6000 a more attractive economical solution for load rack automation when additive injection is required.
# Allows different injection methods (additive injector types) for each logical additive so that old and new additive injection equipment can be mixed on a single loading arm, e.g. mix other units and additive panels on the same loading arm.
# Provides multiple injection rates (concentrations) per additive via the "Multi Rate" additive selection method.
# Provides recipe gross and standard running totalizers and additive running totalizers to facilitate product and additive inventory management.
# Provides (functional) backward compatibility with previous DanLoad 6000 versions, though actual program codes may be different.
# Provides reporting (data logging) capabilities to facilitate product and additive inventory management and configuration.
Additive volume is measured via a K-factor per additive which is used for both authorized and unauthorized additive flow. The “Multi Rate” additive selection method allows multiple additive ratios (concentrations of additive) to be configured per additive by configuring an additive ratio per recipe. The DanLoad 6000 runs a cutoff (end of day processing) every 24 hours based on the configured cutoff hour. The totalizer and throughput data logs can be reprinted using the “Reprint cutoff” option in the program mode menu. Recipe and additive running totalizers allow product and additive throughput for a particular customer to be monitored. The configuration summary data log can be printed from the diagnostics menu in the manual operating mode.
# Meter Proving
The DanLoad 6000 can be used to perform manual flow meter proofs. Tank provers, master meters, or mechanical displacement meter proves can be used for flow meter proving.
# Transaction Storage / User Defined Transaction Ticket
Various data accumulated during each batch delivery and groups of batch deliveries (transaction) can be selected for storage in non-volatile memory. This data can be acquired by a terminal automation system and / or printed on user defined pre-printed transaction tickets. Ticket formats can be designed to meet the user's requirements.
1 - 8 ____________________________________________________________ Introduction
_________________________________________________________ DanLoad 6000 (v6.00)
# LPG / Pressure Control
LPG (liquid petroleum gas) can be measured (temperature and pressure corrected) and the flow control valve can be automatically controlled to maintain the minimum back pressure. Other features include Mercaptan vessel fill and display of external faults. Appendix C provides a LPG
Loading Configuration Checklist.
# Calibration Monitoring
Preliminary support of calibration monitoring is provided in the form of a “Calibration failure” alarm per meter and a “CALMON status” screen in the program mode. Section 3.9.3 Additive Meter
Calibration and CALMON provides a brief summary of the CALMON program codes.
1.2
Hardware Configuration
The DanLoad 6000 contains electronic modules in the form of plug-in printed circuit boards. The basic hardware configuration of the instrument is required for normal operation. In many cases, the instrument in the basic hardware configuration has the capacity to monitor and control the batch delivery installation. In other cases, additional process input / output signal expansion printed circuit boards and / or data communications modules may be required. Flow calculations and logical control capabilities of the DanLoad 6000 in the basic hardware configuration and the fully expanded configuration are identical. Hardware expansion of the instrument only increases the process signal handling capacity and / or provides data signal handling capability. Information on hardware configuration is contained in Section 2 - Installation. The basic configuration of a DanLoad 6000 is described below.
# Integral text / graphics display and operator keypad mounted in a rugged weatherproof case, designed for outside installation in NEC Class 1, Group D, Division 1 hazardous atmosphere environments.
# One DC Voltage power supply with factory selectable power input of 115 Vac or 230 Vac,
47 to 63 Hertz.
#
#
One main processor (CPU version 1) board with two micro-controllers, shared memory, non-volatile memory, and other related logic and process signal circuitry. Two swing arm status inputs. And optionally (requires addition of a module to the version 1 main processor board):
# One RS-485 port and one RS-232 port OR two RS-485 ports.
One flow meter pulse input board, able to process two flow meter pulse inputs (two flow meters or IP-252 pulse integrity from one flow meter) and provide two discrete DC Voltage control outputs.
# One discrete AC input / output board, able to process two status inputs and eight control outputs (90 to 230 Vac).
Introduction ____________________________________________________________ 1 - 9
DanLoad 6000 (v6.00) __________________________________________________________
1.3
General Terminology
The terminology used throughout this manual is defined in the table below. Section 6 - Program
Code Definitions contains additional information which helps clarify these terms. Some of the definitions are based on information contained in American Petroleum Institute (API) standards and industry accepted use. Other national standards use similar terminology.
Term Definition additive A liquid that is injected into a primary liquid component in relatively small quantities, usually less than four percent of the delivered volume total.
Additives are injected into the primary liquid component by an injector mechanism which places a known, fixed volume of the additive into the primary liquid component stream for each injector pulse received from the
DanLoad 6000.
arm (also: swing arm, loading arm) A movable pipe / hose assembly used at a tanker truck loading island. The arm can be designed for either top loading or bottom loading to the tanker compartments. A swing arm can be positioned to load at either side of the loading island or the parked state.
batch blend stream
A preset, quantity-based product delivery or blended component delivery of a single recipe.
Blend stream is the blended product stream and is a mix of both gasoline and ethanol.
blending component
The process of mixing two or more liquid components to form a composite delivered stream. The DanLoad 6000 can control blending based on a predetermined recipe by the sequential (automatic or manual) or the in-line
(proportional or non-proportional) methods. The quantity of each component in a blend is typically greater than two to four percent of the blended product.
Injection of very small quantities of liquids, less than four percent of the blended product, is usually controlled by the additive injection process.
Any liquid metered and controlled by the DanLoad 6000. Liquid hydrocarbons refined from crude oil and LPG’s (such as propane) are usually referred to as products. Components are base products or tank products stored at a distribution terminal. The component is measured before being blended with other components. Additives may be injected before (upstream of) or after (downstream of) the component meter.
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Term Definition of the flow meter at a specific flow rate.
Calculation: gross quantity = indicated quantity times meter factor indicated quantity The change in the flow meter reading that occurs during a product flow measurement operation. (Not displayed by the DanLoad 6000)
Calculation: indicated quantity = end reading minus start reading
IP-252 Institute of Petroleum standard 252. A British standard for pulse fidelity and security for pulse output type flow meters. Program codes 233 and 234 define the operation of this function. (Note: Equivalent standard is API
Manual of Petroleum Measurement Standards / Chapter 5 - Metering /
Section 5 - Fidelity and Security of Flow Measurement Pulsed-Data
Transmission Systems.)
K-factor (system factor)
The pulses per unit quantity generated by a pulse output type flow meter. The
K-factor is also called the system factor. The nominal value is determined by flow meter design and factory water flow calibration. The “average” Kfactors for the flow meters are usually indicated on the flow meter nameplates.
load [Sequential blending] In multi-component blending, a load is the completed delivery of one component of a batch. The completion of loading all components in the batch completes the batch delivery. If the recipe only loads one component, a load corresponds to a batch delivery.
[In-line blending] Each component of the blend is loaded simultaneously.
Depending on the blend ratio, the low-proportion components are loaded completely during the time that the high proportion component(s) are being loaded. After loading of the highest proportion component has been terminated, all component loads and the batch delivery are complete.
loading island loading riser
(also loading rack) An installation of one or more loading arms or risers used to deliver liquid components to a tanker vehicle located on one or both sides of the island, depending on the design of the island.
The related instruments and devices, located in a meter stream, that provide the liquid component loading capability to a mobile tanker vehicle. (Note:
The flow meter piping can also be installed horizontally, if desired.)
Introduction ____________________________________________________________ 1 - 11
DanLoad 6000 (v6.00) __________________________________________________________
Term Definition load spot meter factor
(also bay, lane) One side of a loading island, a position where a tanker vehicle parks for a loading operation. One load spot can have one or more loading arms.
A number obtained by dividing the actual volume of liquid passed through a flow meter during a meter proving operation by the volume registered by the flow meter. The meter factor is used in flow calculations to correct the
indicated volume (end flow meter registration minus start flow meter registration) to the observed gross volume (actual flow meter throughput at operating conditions)
Meter prover volume corrected to standard conditions
Meter factor = -----------------------------------------------------
Flow meter indicated vol corrected to std conditions meter proving permissive
A procedure used to determine the meter factor for a flow meter. The Kfactor (exact number of pulses per a volume unit that are generated by a flow meter) is determined at the factory. The K-factor is used to derive a mathematical factor, known as meter factor, that is used to adjust results of the internal flow calculations performed by the DanLoad 6000. (Note: The flow meter is not re-calibrated; determination of the meter factor allows the operator to manually re-calibrate the DanLoad 6000 so that the nonadjustable calibration characteristic [pulses per volume unit (K-factor)] of the flow meter is incorporated into the flow calculations.)
A discrete signal from a device that is input to a discrete input in the
DanLoad 6000. The signal is used by the DanLoad 6000 to allow a product delivery to be initiated or allow a product delivery to continue. Permissive contacts are CLOSED in the normal or safe state and OPEN in the abnormal or unsafe state.
preset A generic term that describes the functional instrument group of the DanLoad
6000. The term originated from mechanical and electrical preset counters.
The DanLoad 6000 provides much more versatility and capability compared to a simple mechanical or electrical preset counter.
primary blend stream component
A blended product measured by a primary blend stream meter is called a primary blend stream component.
1 - 12 ____________________________________________________________ Introduction
_________________________________________________________ DanLoad 6000 (v6.00)
Term Definition primary blend stream meter (sales meter)
A meter measuring the gasoline-ethanol blend is called a primary blend stream meter. program code One of approximately 1000 parameters that define the operation of the
DanLoad 6000. All program codes are defined in Section 6. quantity (example: gross standard quantity)
The resulting amount of product measured after compensation for operational temperature and pressure, indicated in one of the following corrected units: cubic meters, liters, barrels, gallons.
recipe A pre-entered delivery / blending / control description that allows the
DanLoad 6000 to automatically control the product quantity or total quantity based on percentages of multiple components during a batch delivery operation. Up to thirty recipes can be defined in the DanLoad 6000.
side stream Side stream is the controlled stream and is a term referred to the ethanol product. The ethanol product is metered and can be controlled and measured.
side stream component
A mix component measured by both a side stream meter and a primary blend stream meter is called a side stream component. Ethanol is referred as a side stream component. side stream meter A meter measuring the side component (ethanol) is called a side stream meter.
standard quantity
The gross quantity corrected to standard temperature and/or pressure. This is a quantity measurement.
Calculation: standard quantity = gross quantity times C
TLM
(correction factor for the effect of temperature on the liquid in the meter)
times C
PLM
(correction factor for the effect of pressure on the liquid in the meter) transaction Group of one or more consecutive batch deliveries for accounting purposes.
The batches that comprise a transaction always use one recipe, one additive selection, and one loading side. An example of a transaction is the delivery of multiple batches to different compartments in a single tanker vehicle.
Introduction ____________________________________________________________ 1 - 13
DanLoad 6000 (v6.00) __________________________________________________________
Term Definition volume (example: indicated volume; gross volume)
The actual space occupied by the product measured, indicated in one of the following actual units: cubic meters, liters, barrels, gallons.
wild stream Wild stream is the uncontrolled stream and is a term referred to the gasoline product. This is because the gasoline product cannot be exclusively metered, controlled or measured. wild stream component
A product component measured as part of (Primary Blend Stream Component
– Side Stream Component) a primary blend stream component by a primary blend stream meter is called a wild stream component. Gasoline is referred as wild stream component.
1 - 14 ____________________________________________________________ Introduction
_________________________________________________________ DanLoad 6000 (v6.00)
Note
Appendix A contains several tables with data on the physical and functional configuration of the DanLoad 6000. These tables can be photocopied and unique configuration data can be manually entered to provide a record of specific DanLoad 6000 installations.
This section contains DanLoad 6000 specifications and information on installation of the DanLoad
6000. Installation tasks should be performed in the following order.
#
#
#
#
Installation planning
Initial setup (described in Section 3 - Setup)
Mechanical (physical) installation
Electrical installation
The initial setup, described in Section 3 - Setup, must be performed before the DanLoad 6000 is placed in-service. The initial setup can be performed with only a 115 or 230 Vac power source connected to the instrument.
Mechanical and electrical installation recommendations for the DanLoad 6000 adhere to general industry standards for this type equipment and are covered in Section 2.3 - Mechanical Installation and Section 2.4 - Electrical Installation. The remaining part of Section 2 contains information on installation planning for the DanLoad 6000.
Installation ______________________________________________________________ 2 - 1
DanLoad 6000 (v6.00) __________________________________________________________
2.1
DanLoad 6000 Specifications
# Dimensions (approximate):
Standard The standard enclosure for the DanLoad 6000.
Remote / Secondary
The short enclosure contains the front panel display and keypad only. This enclosure is usually used as a remote operator station in a two side loading island.
Item
Height
Width
Depth
Weight
Standard
13-inches (330 mm)
14-inches (355 mm)
14-inches (355 mm)
75-pounds (34 kg)
Remote / Secondary
13-inches (330 mm)
14-inches (355 mm)
8-inches (200 mm)
45-pounds (20,5 kg)
#
#
Power requirements:
Standard Power Supply:
115 Vac (+ 10% / - 15%), 47 to 63 Hz, 1-phase
230 Vac (+/_ 15%), 47 to 63 Hertz, 1-phase
25 VA nominal
CE-Mark Power Supply - AC Line Input:
90-140 VAC, or 198-270 VAC, 47 to 63 Hz, single phase
Factory Selected with a single jumper (28 VA nominal)
Cable entry (USA version):
Center 2-inch female NPT, normally used for all DC signal (meter pulse, RTD, analog, status / control) cables
Left 1-inch female NPT, normally used for AC power input and AC status / control signals
Right (separate routing for low level signals and status / control signals):
1-inch female NPT, used for meter pulse and / or RTD and / or analog signals when separate signal routing is required
2 - 2 ______________________________________________________________ Installation
_________________________________________________________ DanLoad 6000 (v6.00)
#
#
#
#
#
Cable entry (metric version):
Center M50 x 1.5 mm, normally used for all DC signal (meter pulse, RTD, analog, status
/ control) cables
Left M25 x 1.5 mm, normally used for AC power input and AC status / control signals
Right (separate routing for low level signals and status / control signals):
M25 x 1.5 mm, used for meter pulse and / or RTD and / or analog signals when separate signal routing is required
Environment:
Temperature [operating with case heater installed]:
-40 to +140 degrees Fahrenheit (-40 to +60 degrees Celsius)
Temperature [storage (non-operating)]:
-4 to +158 degrees Fahrenheit (-20 to +70 degrees Celsius)
(Note: Storage temperature lower limit is due to fluid in the liquid crystal display (LCD) unit.)
Relative humidity: 5 to 95 percent (non-condensing)
Electromagnetic Compatibility (EMC):
Optionally CE-Mark Compliant
FCC Method - (CFR-47) Part 15 - Digital Devices
CCA LMB-EG-08 section 3.6.3.4
CISPR Methods: Radiated emissions from 30 MHz to 1000 MHz
Conducted emissions (mains disturbance) from 150 kHz to 30 MHz
Susceptibility - 10 volts/meter over the frequency range 30 MHz to 1000 MHz
Fast transients - Line power and I/O
Electrostatic Discharge
Mechanical shock:
Per S.A.M.A. PMC 31.1-1980, Section 5.3
Enclosure:
NEMA 4X weatherproof, corrosion resistant
NEMA 7 for Class I, Division 1, Groups C and D areas
EEx d IIB T6, IP65
Installation ______________________________________________________________ 2 - 3
DanLoad 6000 (v6.00) __________________________________________________________
# Fasteners:
Front cover hex drive bolts and case mounting bolts: M10 - 1.5 (metric)
Two front cover bolts are longer than the other front cover bolts. These two long bolts have holes near the end of the threaded end to allow placement of a Weight and
Measures seal wires. The seal wires prevent undetected access to the DanLoad 6000 electronic / field wiring compartment.
Depth of tapped mounting bolt holes: 0.50 inches (13 mm)
Front cover hex bolt wrench: 8-mm (or 5/16-inch) Allen wrench
Torque specification (all bolts): 18 to 21 foot-pounds-force
(24 to 29 Newton-meters)
2 - 4 ______________________________________________________________ Installation
_________________________________________________________ DanLoad 6000 (v6.00)
Standard Enclosure Dimensions
Figure 2 - 1
Installation ______________________________________________________________ 2 - 5
DanLoad 6000 (v6.00) __________________________________________________________
Standard Enclosure Field Mounting
Figure 2 - 2
2 - 6 ______________________________________________________________ Installation
_________________________________________________________ DanLoad 6000 (v6.00)
Shallow Enclosure Dimensions
Figure 2 - 3
Installation ______________________________________________________________ 2 - 7
DanLoad 6000 (v6.00) __________________________________________________________
Shallow Enclosure Field Mounting
Figure 2 - 4
2 - 8 ______________________________________________________________ Installation
_________________________________________________________ DanLoad 6000 (v6.00)
2.2
Installation Planning
Installation planning is very important due to the physical and functional reconfigurable capabilities of the instrument. Several worksheets are provided in Appendix A to aid in installation planning and system design. These worksheets are used in conjunction with the Setup Procedure described in
Section 3. Installation planning consists of the following three major tasks.
# Assure that the DanLoad 6000 contains the required number and type of process input / output signal boards for monitoring and controlling the other devices in the product delivery system.
# Determine the functions to be performed by the DanLoad 6000. These functions are selectively enabled during the setup procedure (logical configuration) of the instrument.
# Design the mechanical / electrical installation considering the safety and ease of use by the operator. Also consider the safety and ease of access to instruments and devices for maintenance technicians.
2.2.1
Card Cage Description
The DanLoad 6000 is constructed in a modular electronic and functional form. An electronic card cage is located inside the cast enclosure. The layout of the card cage is shown in Figure 2-5. The card cage contains a passive backplane with sockets for installation of a main processor board, a
DC power supply board, and one to seven process input / output signal boards. The function of each board is described in Section 2.2.2.
Installation ______________________________________________________________ 2 - 9
DanLoad 6000 (v6.00) __________________________________________________________
Card Cage Layout
Figure 2 - 5
Placement of I/O boards in card cage determines I/O assignments during start up. Please see section 3.5.1 for details.
2 - 10 ______________________________________________________________ Installation
_________________________________________________________ DanLoad 6000 (v6.00)
2.2.2
DanLoad 6000 Board Description and Jumper Settings
Note
Several of the electronic circuit boards contain jumpers that must be verified for correct configuration before installation of the instrument. Jumper configuration should be verified before the setup procedure is executed. Verify the following jumper configurations before applying any power or connecting any process input / output signals to the instrument. To identify pin 1 on any of the jumper selections, find the location on the back of the board where the jumper pins are soldered into place. The square solder pad will always be pin 1.
# Power Supply (DC Voltage)
Installed in the leftward vertical slot (J0) with component side facing right (toward the I/O card slots).
The DC power supply generates the following voltages for the following uses;
Voltage
+ 5 Vdc
+ 5 Vdc unregulated
+ 15 Vdc / - 15 Vdc
+ 12 to + 15 Vdc
+ 24 Vdc
Use digital logic
LCD display unit analog inputs meter pulse transmitter power supply (100 mA dc version)
DC status / analog transmitters
DC Power Supply Voltage Use
Figure 2 - 6
Two field-wiring connectors are located on the front edge of the power supply board. TB1 accepts AC power input (either 115 or 230 Vac) and provides a fused output for an optional internal space heater. TB2 accepts AC Voltage input and provides fused AC Voltage output to the permissive circuits.
Installation ______________________________________________________________ 2 - 11
DanLoad 6000 (v6.00) __________________________________________________________
Jumper Settings (Field Wiring Diagram CE-12692) Standard Supply
Jumper
JO1-1 to JO1-2
JO2-1 to JO2-2
JO1-2 to JO2-2
Function
115 Vac power input
230 Vac power input
AC Power Input Jumpers
Figure 2 - 7
The AC power jumpers are soldered wire jumpers located on the DC power supply board.
AC power input should be specified at order time so that the jumpers are installed correctly at the factory.
For the CE-Mark supply using AC power input, install jumper JP2 for 155 VAC operation, or remove jumper JP2 for 230 VAC operation.
2 - 12 ______________________________________________________________ Installation
_________________________________________________________ DanLoad 6000 (v6.00)
# CPU Board (version 1)
Installed horizontally on top of card cage with component side up.
The main processor board has two CPU's (central processing units). One CPU processes the control panel and communications functions and the other CPU performs flow measurement and process input / output signal handling. Dual port RAM (random access memory) is used by both CPU's to transfer data. Data is maintained in a non-volatile state for ten years by an on-board battery. The CPU board also contains one 3-terminal connector which is dedicated to one or two dry contact closure inputs used for sensing the position of a swingarm switch. Communications is via a plug-in DUART board that mounts on top of CPU version 1. See “DUART”.
CPU Board Jumper Settings
Jumper
E16 to E17
E7 to E8
E2 to E3
Function
4Mbit EPROM with firmware
3.00 & up
4Mbit EPROM with firmware
2.00 & up
Enable display failure /internal temp alarm LED (yellow LED)
CPU Board Jumpers
Figure 2 - 8
CPU Board and Analog Inputs Board Combinations - Jumper Settings
The DanLoad 6000 can be configured without an analog inputs board or with a 2-channel analog inputs or an 8-channel analog inputs board. Jumpers are provided for configuration of analog ground and digital ground. These jumpers should be set as follows.
Jumper Function
E12 to E13 on the CPU Board No Analog Inputs
Board installed
Remove E12 to E13 on CPU board and install JP1 on Analog
Inputs Board
Analog Inputs Board is installed
CPU & Analog Inputs Board Combination Jumpers
Figure 2 - 9
Installation ______________________________________________________________ 2 - 13
DanLoad 6000 (v6.00) __________________________________________________________
# CPU Board (version 2)
Installed horizontally on top of card cage with component side up.
On-board communications ports and the RS232 - RS485 option is jumper selectable.
The address for the communication port is software selectable.
Dual Display connector (P2):
The primary display wires to the top position and the secondary display wires to the bottom position.
On-board Analog inputs include one 4-20 mA and one 100 ohm RTD input. The on-board swing-arm switches have been removed; standard discrete inputs can be used instead.
Communications - One RS485 and 1 RS232 OR two RS485 ports (jumper selectable).
Channel 1 is always RS485. Channel 2 is RS232 or RS485 as shown.
PC
984
985
986
987
Jumper RS232
JP1 1&2 closed
JP2 1&2 closed
JP3
JP4
RS485
2&3 closed
2&3 closed
1&2 closed 2&3 closed
1&2 closed 2&3 closed
CPU Board Jumpers - Comm Ch 2
Figure 2 - 10
Analog Inputs - Calibration Values
Calibration values are required for the analog inputs. These values are printed on a label located on top of U40. The label has the program codes and four values for each type of input. These values must be entered into the program codes when using the analog inputs, in particular, after the unit has been cold started.
4-20 mA
LL (low low)
LH (low high)
PC
988
989
RTD
LL (low low)
LH (low high)
HL (high low) 990 HL (high low)
HH (high high) 991 HH (high high)
CPU Analog Inputs Program Codes
Figure 2 - 11
2 - 14 ______________________________________________________________ Installation
_________________________________________________________ DanLoad 6000 (v6.00)
# DUART (used with CPU Version 1)
(Dual Universal Asynchronous Receiver Transmitter) Communications Board
Optional DUART module can be installed, with the component side down, on top of the main processor board.
One dual serial communications port module (DUART module) with 1 RS-485 and 1 RS-
232 OR 2 RS-485 ports is optional. The communications module is not required for standalone operation of the DanLoad 6000. However, the DUART is required if the data logging feature is used or if communication to an Automation System is required.
Switch Settings (Field Wiring Diagram CE-12693)
The address of the DanLoad 6000 serial port is set by an eight position DIP switch located on the optional DUART board. Each address must be unique for data access by a terminal automation system.
Address
.
4
.
255
2
3
0
1
Switch SW1 6 1
Decimal weight 6 1
<reserved>
2
2
3
4
4
8
5
16
6
32
7
64
8
128 on on on on on on on on off on on on on on on on on off on on on on on on off off on on on on on on
.
on on off on on on on on
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
off off off off off off off off
DUART Board Address Switch
Figure 2 - 12
Installation ______________________________________________________________ 2 - 15
DanLoad 6000 (v6.00) __________________________________________________________
# 2-Ch Meter Pulse Board (MPB)
Recommended card cage locations are slots J5 and / or J6, component side faces left
(toward the power supply). The recommended location for a single meter pulse board is slot
J5.
The two-channel meter pulse board provides 8 to 15 Vdc or 24 Vdc power for two meter pulse preamplifiers and accepts meter pulse inputs from two meter preamplifiers or dual inputs from one meter. The 2-Ch Meter Pulse Board can be used with 1 single pulse meter,
1 dual pulse meter or 2 single pulse meters. The meter preamps or pulsers can be powered with any one of three options. Options 1 and 2 are implemented by installing a plug-on piggyback power supply module. These modules are adjustable 8-15 VDC power supplies with either 15 ma (Daniel P/N 3-6000-002) or 100 mA (Daniel P/N 3-6000-022) outputs.
Option 3 uses 24 VDC supplied from the power-supply board. The DC power source for each meter preamplifier is jumper selectable. Two optically isolated raw meter pulse outputs
(prover outputs) are provided. These outputs are for meter proving and are duplicates of the raw meter pulse stream. Two DC Voltage control outputs are provided. These control outputs are assignable to various functions. One common use for these outputs is to drive external pulse per unit quantity totalizers.
# Power Down Pulse Counting
Should power failure shut the system down, power to the pulsers and preamps will be sustained long enough to accumulate pulses until the flow control valve closes.
This is available with the 15 mA P/S option only (P/N 3-6000-002).
# Dual Pulse Security for a Single Flow Meter
Dual pulse security is available per the IP252 Level-B standard. This is accomplished by monitoring two meter pulse inputs that are electrically 90 degrees out of phase. Reference program codes 233 and 234 in Section 6.13 of this manual.
Note
The 2-Ch Meter Pulse Board has been replaced by the 4-Ch Meter Pulse Board and is no longer manufactured. The 4-Ch Meter Pulse Board is a direct replacement for the
2-Ch board. Depending on your configuration, wiring changes may be necessary.
Please review the 2-Ch and 4-Ch wiring diagrams carefully.
2 - 16 ______________________________________________________________ Installation
_________________________________________________________ DanLoad 6000 (v6.00)
JP7
JP7
JP7
JP6
JP2
JP4
JP2
JP4
JP2
JP7
JP7
JP4
Jumper Settings (Field Wiring Diagram CE-12694)
P/N 3-6000-022, 100 mA P/S - P/N 3-6000-002, 15 mA P/S
Jumper Connection Function meter 1 preamp power = 24 Vdc JP1
JP5
JP1
JP5
JP1
JP3
JP3
JP5
1 to 2 in
2 to 3 in
1-to-2
1-to-2
3-to-4 out meter 1 preamp power = 8 to 15 Vdc (PS1) meter 1 input optically isolated and floating, requires external 5 to 24 Vdc supply meter 1 input optically isolated JP3
JP3
JP3
JP8
1 to 2
3-to-4
2-to-3 out in meter 1 input direct meter 1 standard input filtering
( 5 kHz. low pass filter) meter 1 additional high frequency filtering
( 50 Hz. low pass filter) meter 2 preamp power = 24 Vdc 1-to-2 in
2-to-3 in
1-to-2
1-to-2
3-to-4 out
1-to-2
3-to-4
2-to-3 out in meter 2 preamp power = 8 to 15 Vdc (PS2) meter 2 input optically isolated and floating, requires external 5 to 24 Vdc supply meter 2 input optically isolated meter 2 input direct meter 2 normal input filtering
(5 kHz. low pass filter) meter 2 additional high frequency filtering
(50 Hz. low pass filter)
2-Channel Meter Pulse Input Board Jumpers
Figure 2 - 13
Installation ______________________________________________________________ 2 - 17
DanLoad 6000 (v6.00) __________________________________________________________
# 4-Ch Meter Pulse Board (MPB)
Recommended locations are slots J5 and / or J6, component side faces left (toward the power supply). The recommended location for a single 4-Ch meter pulse board is slot J5.
See Figure 2-14 for 4-Ch meter pulse board jumper settings.
The 4-Channel meter pulse board provides 5, 15 or 24 volts, which may be jumper selected
(JP17, 18, 19,20) for flow meter pulse preamplifiers. The meter pulse board is able to supply power at 24 volts at 200 mA when used with Daniel’s enhanced line-powered switcher power supply. When using Daniel’s standard power supply, the load capacity is lower. The
4-Ch meter pulse board accepts inputs from up to two physical meters. Each physical meter can have pulse security independently of any others. Pulse security identification is IP 252 level “B” using dual pulse stream, electrically out of phase. Two DC voltage control outputs are provided. These are assignable to various functions. One common use for these outputs is to drive an electrical pulse-per-unit quantity totalizer.
MPB
3-6000-042
3-6000-132
Input Signal
+12 V square wave (nominal)
+4 V square wave (nominal)
2 - 18 ______________________________________________________________ Installation
_________________________________________________________ DanLoad 6000 (v6.00)
# Dual Pulse Security for a Single Flow Meter
Dual pulse security is available per the IP252 Level-B standard. This is accomplished by monitoring two meter pulse inputs that are electrically 90° ±89° out of phase. Reference program codes 233 and 234 in Section 6.13 of this manual.
Installation ______________________________________________________________ 2 - 19
DanLoad 6000 (v6.00) __________________________________________________________
2 - 20 ______________________________________________________________ Installation
_________________________________________________________ DanLoad 6000 (v6.00)
Identification between board 1 and board 2 for P/N 3-6000-042, -132.
4-Channel Meter pulse board
3-6000-042 - For dual pulse (IP252 level B) or single Preamp operation:
First board
Meter 1A, short jumper JP1
Meter 2A, short jumper JP2
Open JP3 and JP4
Second board
Meter 1A, short jumper JP3
Meter 2A, short jumper JP4
Open JP1 and JP2
3-6000-132 - (Euro version) For dual pulse (IP252 level B) operation:
First board
Meter 1A, short 1&2 on jumper JP1
Meter 2A, short 1&2 on jumper JP2
Open JP3 and JP4
Second board
Meter 1A, short 1&2 on jumper JP3
Meter 2A, short 1&2 on jumper JP4
Open JP1 and JP2
3-6000-132 - (Euro version) For one preamplifier per meter (no pulse security):
1 through 4 meters
Please note that 1 board can handle 4 meters.
First Meter:
Second Meter:
Meter 1A, short 2&3 on jumper JP1
Meter 1B, short 2&3 on jumper JP2
Third Meter: Meter 2A, short 2&3 on jumper JP3
Fourth Meter: Meter 2B, short 2&3 on jumper JP4
Installation ______________________________________________________________ 2 - 21
DanLoad 6000 (v6.00) __________________________________________________________
Jumper Settings (Field Wiring Diagram CE-15532 - P/N 3-6000-042, -132)
Meter
1A 1B 2A 2B
JP1 JP2 JP3 JP4
Connection Function in Enable meter input X
JP11
JP15
JP11
JP15
JP11
JP15
JP12
JP16
JP12
JP16
JP12
JP16
JP13
JP6
JP13
JP6
JP13
JP6
JP14
JP5
JP14
JP5
JP14
JP5
JP9 JP10 JP8 JP7
1-to-2
3-to-4 out
1-to-2
3-to-4 in
2-to-3 in out in meter input optically isolated and floating, requires external
5 to 24 Vdc supply meter input optically isolated local ground meter input direct local ground meter standard input filtering
( 5 kHz. low pass filter) meter additional high frequency filtering
( 50 Hz. low pass filter)
4-Channel Meter Pulse Input Board Jumpers
Figure 2 - 14
Notes
Meter Channels 1A and 2A are the primary meter inputs.
Meter Channels 1B and 2B are used as the second input for dual pulse meter inputs.
2 - 22 ______________________________________________________________ Installation
_________________________________________________________ DanLoad 6000 (v6.00)
The voltage levels factory setting is for 15 VDC when using the Linear P/S 3-6000-027, -031.
4-Channel Meter Pulse Board 3-6000-042, -132
Meter Pulse Preamp or Pulser Voltage Output -- Jumper Schedule
Factory Setting: 15 Volts
When using Linear P/S 3-6000-027, -031
Maximum Current 100 mA
Jumper options: For 5 VDC or 12-15 VDC @ 100 mA
Close JP17 1 and 2
Close JP18 2 and 3
For 5 Volts adjustable: Close Jumper JP19 and JP20
Jumper options:
For 15 Volts adjustable: Close Jumper JP19, Open JP20
For 24 VDC @ 100 mA
Close JP17 2 and 3, Open JP18,
JP19 and JP20 don’t care
When using the CE-Mark Line Switcher P/S 3-6000-067, -068
On the Line Switcher P/S: Close JP3 2 and 3 (Soldered)
Maximum Current 400 mA (200 mA per MPB)
4 channel meter pulse board (P/N 3-6000-047, -132)
Factory adjustment: 12.5 VDC
Jumper options: For 5 VDC, 12-15 VDC or 24 VDC @ 200 mA
Close JP17 1 and 2
Close JP18 1 and 2
For 5 Volts Adjustable:
For 15 Volts Adjustable:
For 24 Volts Adjustable:
Close Jumper JP19 and JP20
Close Jumper JP19, Open JP20
Open Jumpers JP19 and JP20
Installation ______________________________________________________________ 2 - 23
DanLoad 6000 (v6.00) __________________________________________________________
# MPMC (Meter Pulse Microcontroller) Board (P/N 3-6000-044)
The MPMC Board is a plug-on piggyback board to the 4-Ch meter pulse board.
The 4-Ch meter pulse board is known as the “smart” meter pulse board when fitted with a
Meter Pulse Microcontroller (MPMC) Board (P/N 3-6000-044). With a smart 4-Ch meter pulse board installed, the DanLoad 6000 can be configured to make use of the following features provided by the MPMC. The plug-on board is shown as part of the main board noted in the previous section.
MPMC Version Features Provided
1.00
2.00
Factored pulse outputs
Factored pulse outputs and turbine meter calibration monitoring
MPMC Version Comparisons
Figure 2 - 15
2 - 24 ______________________________________________________________ Installation
_________________________________________________________ DanLoad 6000 (v6.00)
# AC Discrete Input / Output Board (AC I/O)
Recommended locations are slots J1 and / or J2, component side faces left (toward the power supply). The recommended location for a single AC I/O board is slot J1.
[Note: There are two different versions of the AC I/O board (Ver. 1 & Ver. 2). Terminal connections are the same on each version of the board. However, the on-board jumper configuration is different for each version of the board. Note drawing CE-12695 in
Appendix E and information in Figures 2-14 and 2-15.]
The AC I/O board accepts two discrete (ON/OFF) status inputs and provides eight discrete
(ON/OFF) control outputs. Note Figures 2-14 and 2-15 for jumper settings to set the discrete input voltage level selection options (24 Vdc, 24 Vac, 90-240 Vac or Vdc). Internal series resistors in each input circuit should be jumpered (bypassed) if 24 Vac or 24 Vdc signals are used. Control output circuits are 24 to 230 Vac only. Each output circuit is rated to switch an inductive load of 2 Amps ac maximum, such as a relay or solenoid coil.
Status inputs are processed as indicated:
Version 1 AC I/O Board (Field Wiring Diagram CE-12695)
Inputs are externally powered by 120/240 volts AC/DC or 24 volts AC/DC by installing a jumper. This voltage should be applied through a contact closure only, as a solid-state relay may not drop below the input voltage threshold when deenergized.
The status input is ON when the contact is closed or the voltage is present on the input.
The status input is OFF when the contact is open or the voltage is removed.
Version 2 AC I/O Board (Field Wiring Diagram CE-12695)
All functions are the same as the Version 1 AC I/O Board except that each voltage range has a jumper selection (24 VAC, 24 VDC, 120 VAC and 240 VAC), and the inputs will function with either contact closures or solid-state relays.
Note: Version 2 board will not work with 120/240 VDC.
Note
Ganging Triac Outputs: Due to the leakage current inherent to the triac, ganging of AC triac outputs to one common point is not recommended. If output ganging is required, the use of interposing relays is recommended in order to provide proper isolation.
Installation ______________________________________________________________ 2 - 25
DanLoad 6000 (v6.00) __________________________________________________________
Jumper Settings - Version 1 AC I/O Board (Field Wiring Diagram CE-12695)
(Assembly Drawing CE-12693 - P/N 3-6000-005)
Jumper Connection Function
W1 out in
Input 2 90-to-240 Vac / Vdc
Input 2 24 Vac / Vdc
W2 out in
Input 1 90-to-240 Vac / Vdc
Input 1 24 Vac / Vdc
Version 1 AC I/O Board Jumpers
Figure 2 - 16
Jumper Settings - Version 2 AC I/O Board (Field Wiring Diagram CE-12695)
(Assembly Drawing CE-12722 - P/N 3-6000-045)
Jumper Connection Function
JP1
JP2
JP1
JP2 pins 1 to 2 pins 1 to 2 pins 2 to 3 pins 2 to 3
Input 2 is 24 Vac or 24 Vdc
Input 1 is 24 Vac or 24 Vdc
Input 2 is 120 Vac
Input 1 is 120 Vac
JP1
JP2 out out
Input 2 is 240 Vac
Input 1 is 240 Vac
Version 2 AC I/O Board Jumpers
Figure 2 - 17
2 - 26 ______________________________________________________________ Installation
_________________________________________________________ DanLoad 6000 (v6.00)
# Enhanced I/O Board and Additive Injector I/O Board
Recommended locations are slots J1 and / or J2, component side faces left (toward the power supply). The recommended location for a single Enhanced I/O board is slot J1.
[Note: There are two different versions of the Enhanced I/O board. The Ver. 1 style board is shown in drawing CE-12697 in Appendix E as the “Additive Injector (I/O) Board”. The
“Additive Injector Board” will be recognized as an Enhanced I/O Board when the DanLoad
6000 displays the identity and location of the boards in the card cage. The Ver. 2 style board is shown in drawing CE-19027 in Appendix E as the “Enhanced (I/O) Board”. Terminal connections are the same on each version of the board. However, the on-board jumper configuration is different for each version of the board.]
The Enhanced (or Additive Injector) I/O board accepts six discrete (ON/OFF) status inputs
(24 Vac or 24 Vdc maximum voltage) and provides six discrete (ON/OFF) control outputs.
Note Figures 2-16 and 2-17 for jumper settings to select discrete input voltage levels for the two board styles. Control output circuits are 24 to 230 Vac only. Each output circuit is rated to switch an inductive load of 2 Amps ac maximum, such as a relay or solenoid coil. Inputs are available as high-speed (130 Hz maximum with a minimum pulse width of 3 ms), low speed (10 Hz maximum with a minimum pulse width of 50 ms) or a mixture of both. Be sure to specify the correct part number.
Status inputs are processed as indicated:
# Version 1 (Additive Injector) I/O Board (Field Wiring Diagram CE-12697)
Internally powered status input (Note Reverse Logic):
The status input is ON when the contact is open.
The status input is OFF when the contact is closed.
Externally powered status input:
The status input is ON when the contact is closed and the voltage is present on the input.
The status input is OFF when the contact is open and the voltage is removed.
Notes
Ganging Triac Outputs: Due to the leakage current inherent to the triac, ganging of AC triac outputs to one common point is not recommended. If output ganging is required, the use of interposing relays is recommended in order to provide proper isolation.
Inputs can be configured ON = open or ON = closed.
Installation ______________________________________________________________ 2 - 27
DanLoad 6000 (v6.00) __________________________________________________________
# Version 2 Enhanced I/O Board (Field Wiring Diagram CE-19027)
Internally powered status input:
The status input is ON when the contact is closed.
The status input is OFF when the contact is open.
Externally powered status input or solid-state relays:
There are three voltage ranges which are jumper selectable (24 VAC,
24VDC, 120 VAC or 240 VAC). When using DC voltage, the positive voltage must be on the common input to two-channel inputs.
The status input is ON when the contact is closed.
The status input is OFF when the contact is open.
2 - 28 ______________________________________________________________ Installation
_________________________________________________________ DanLoad 6000 (v6.00)
Jumper Settings - Version 1 Enhanced (Additive Injector) I/O Board
(Field Wiring Diagram CE-12697) - P/N 3-6000-010 (low speed), -060 (high speed), -059
(combination low and high speed)
Input
1&2
3&4
5&6
Jumper
W3
W2
W1
Internal Power
SHORT PINS
1&2, 3&4, 5&6
SHORT PINS
1&2, 3&4, 5&6
SHORT PINS
1&2, 3&4, 5&6
External Power
OPEN
NO JUMPERS
OPEN
NO JUMPERS
OPEN
NO JUMPERS
Version 1 Enhanced (Additive Injector) I/O Board Jumpers
Figure 2 - 18
Note
The maximum voltage for discrete inputs on the Additive Injector Board is 24 Vac or
24 Vdc.
Installation ______________________________________________________________ 2 - 29
DanLoad 6000 (v6.00) __________________________________________________________
2 - 30 ______________________________________________________________ Installation
_________________________________________________________ DanLoad 6000 (v6.00)
Jumper Settings - Version 2 Enhanced I/O Board
(Field Wiring Diagram CE-19027) - P/N 3-6000-036 (low speed), -048 (high speed), -049
(combination low and high speed)
Note
When using a Linear Power Supply P/N 3-6000-027, -031 JP10 needs to have pin 2-3.
When using the Switching Power Supply P/N 3-6000-067, -068 JP10 needs to have pins 1 to 2.
Jumper Schedule
Select Internal Power
JP10 pins 2 to 3
Input
Channel
24 Vdc
Internal Power
1 and 2 JP9 1 to 2, 3 to 4, 5 to 6
JP8 1 to 2
JP7 1 to 2
3 and 4 JP6 1 to 2, 3 to 4, 5 to 6
JP5 1 to 2
JP4 1 to 2
5 and 6 JP3 1 to 2, 3 to 4, 5 to 6
JP2 1 to 2
JP1 1 to 2
20 to 30
Vac or Vdc
JP9 all out
JP8 1 to 2
JP7 1 to 2
JP6 all out
JP5 1 to 2
JP4 1 to 2
JP3 all out
JP2 1 to 2
JP1 1 to 2
External Power
102 to 140
Vac
JP9 all out
JP8 2 to 3
JP7 2 to 3
JP6 all out
JP5 2 to 3
JP4 2 to 3
JP3 all out
JP2 2 to 3
JP1 2 to 3
204 to 260
Vac
JP9 all out
JP8 all out
JP7 all out
JP6 all out
JP5 all out
JP4 all out
JP3 all out
JP2 all out
JP1 all out
Version 2 Enhanced I/O Board Jumpers
Figure 2 - 19
Installation ______________________________________________________________ 2 - 31
DanLoad 6000 (v6.00) __________________________________________________________
# DC Discrete Input / Output board (DC I/O) (Field Wiring Diagram CE-12696)
Recommended locations are slots J3 and / or J4, component side faces left (toward the power supply). The recommended location for a single DC I/O board is slot J3.
The DC I/O board accepts six 24 Vdc or 24 Vac discrete (ON/OFF) status inputs and provides four discrete (ON/OFF) control outputs. The nominal input level is 24 Vdc or 24
Vac, either dry contact closures or externally powered, depending on internal jumper configuration. See Figure 2-18. Control output circuits are 24 Vdc only. Each output circuit is rated to switch a non-inductive load of 250 mA dc maximum. Inputs are available as high speed (130 Hz maximum with a minimum pulse width of 3 ms), low speed (10 Hz maximum with a minimum pulse width of 50 ms) or a combination of both. Be sure to specify the correct part number.
Status inputs are processed as indicated:
Internally powered status input:
The status input is ON when the contact is closed.
The status input is OFF when the contact is open.
Externally powered status input:
The status input is ON when the contact is closed and voltage is present on the input.
The status input is OFF when the contact is open and the voltage is removed.
Note
Inputs can be configured ON = open or ON = closed.
2 - 32 ______________________________________________________________ Installation
_________________________________________________________ DanLoad 6000 (v6.00)
Jumper Settings - DC I/O Board (Field Wiring Diagram CE-12696) - P/N 3-6000-006
(low speed), -058 (high speed), -057 (combination of low and high speed)
Jumper
W1 2-to-3 in
W1 1-to-2
W1 3-to-4 in
W2 2-to-3 in
Connection Function
Input 6 floating, 24 Vac or 24 Vdc external input
Input 6 internal 24 Vdc power furnished
Input 5 floating, 24 Vac or 24 Vdc external input
Input 5 internal 24 Vdc power furnished W2 1-to-2
W2 3-to-4 in
W3 2-to-3 in
W3 1-to-2
W3 3-to-4 in
Input 4 floating, 24 Vac or 24 Vdc external input
Input 4 internal 24 Vdc power furnished
W4 2-to-3
W4 1-to-2
W4 3-to-4 in in
W5 2-to-3 in
W5 1-to-2
W5 3-to-4 in
Input 3 floating, 24 Vac or 24 Vdc external input
Input 3 internal 24 Vdc power furnished
Input 2 floating, 24 Vac or 24 Vdc external input
Input 2 internal 24 Vdc power furnished
W6 2-to-3 in
W6 1-to-2
W6 3-to-4 in
Input 1 floating, 24 Vac or 24 Vdc external input
Input 1 internal 24 Vdc power furnished
DC I/O Board Jumpers
Figure 2 - 20
Installation ______________________________________________________________ 2 - 33
DanLoad 6000 (v6.00) __________________________________________________________
#
#
2-Channel Analog Input Board (Field Wiring Diagram BE-12707) - P/N 3-6000-061 o C)
Recommended location is slot J7, component side faces left (toward the power supply).
The 2-channel analog input board accepts one 4-wire RTD (resistive temperature device) input and one 4 to 20 mA dc current loop input. The RTD input must be a platinum RTD,
100 Ohm base resistance at 32 degrees Fahrenheit (0 degrees Celsius). The RTD alpha is and Vref is provided for the RTD. The 4 to 20 mA dc current loop contains an internal 225
Ohm precision resistor. The maximum transmitter loop load is 975 Ohms. Analog transmitter power of 24 Vdc is provided. The RTD inputs are available in a standard range specify the correct part number.
Refer to Figure 2-9 for jumper settings.
8-Channel Analog Input Board (Field Wiring Diagram CE-12698) - P/N 3-6000-064 o C)
Recommended location is slot J7, component side faces left (toward the power supply).
The 8-channel analog input board accepts four 4-wire RTD (resistive temperature device) inputs and four 4 to 20 mA dc current loop inputs. RTD inputs must be platinum RTD's,
100 Ohm base resistance at 32 degrees Fahrenheit (0 degrees Celsius). The RTD alpha is and Vref is provided for the RTD's. Each 4 to 20 mA dc current loop contains an internal
225 Ohm precision resistor. The maximum transmitter loop load in 975 Ohms. Analog transmitter power of 24 Vdc is provided. The RTD inputs are available in a standard range specify the correct part number.
Refer to Figure 2-9 for jumper settings.
2 - 34 ______________________________________________________________ Installation
_________________________________________________________ DanLoad 6000 (v6.00)
2.3
Mechanical Installation
In planning the physical installation of the DanLoad 6000, consider ease of use of the instrument with the operator in a safe and comfortable position. Consideration must also be given to performance of maintenance tasks without disrupting ongoing product delivery operations in close proximity. It may be helpful to draw rough diagrams of the normal actions of the operator during the different possible batch delivery related tasks. Be especially mindful of the location of the operator in relation to the location of one or two tanker vehicles and their related loading arm / bottom loading hose connections. Some location / position restrictions may be present when a
DanLoad 6000 is used as a retrofit or upgrade in an existing installation. However, mechanical installation planning should still be performed. It may be possible to correct an inconvenient controller mounting location that exists in a current loading rack installation when a DanLoad 6000 is retrofit at the installation.
The major steps performed during installation are listed below.
#
#
#
#
#
#
#
#
#
#
#
#
Plan the installation
Fabricate device supports and lay electrical conduit
Mount the DanLoad 6000 and other load rack devices
Run and connect all wiring
Verify and tag each wire
Seal conduit within 18-inches (450 mm) of each device
Secure cases and covers of all devices
Apply electric power
Setup (configure) DanLoad 6000 and any other devices as required
Disable product block valves and additive block valves to prevent any product or
additive flow - then verify system monitor and control functions with dry piping
Enable one product block valve at a time and one additive injection system at a time
- then verify the piping integrity and system operation in increments for each product and each additive handling system
Perform meter proofs to determine DanLoad 6000 meter calibration
Consider the points listed below during installation planning for a DanLoad 6000.
# Maintenance access:
The operator panel is hinged at the bottom side and opens down for ease of maintenance access. All conduit routing should be to the rear, sides, or down. No object should be located under the DanLoad 6000 and in front of the conduit connections for a distance of approximately 15-inches (380 mm) below the instrument.
Installation ______________________________________________________________ 2 - 35
DanLoad 6000 (v6.00) __________________________________________________________
#
#
#
#
Mounting height:
Recommended mounting height is approximately 45 to 50 inches (1.14 to 1.27 meters) above grade to the bottom of the DanLoad 6000 case. Mounting height determines the ease of viewing the display panel and ease of use of the keypad.
Mounting position:
North / south / east / west orientation of the operator control panel is somewhat predetermined by the loading facility design. Consider the location of the user / operator in relation to one or two tanker vehicles present and connected at the loading island.
Mounting fixtures:
Mounting fixtures must be fabricated for the DanLoad 6000. Four M10-1.5 metric thread bolts for mounting are provided with each DanLoad 6000. The instrument can be bottom mounted or rear mounted. Bottom mounting is preferable due to the weight of the device.
The mounting attachment should be a 1/8-inch (3 mm) (minimum) thick mild steel member with four 7/16-inch (11.5 mm) diameter holes that match the bolting pattern being used.
The steel member may be sheet, angle, channel, or other shape.
The forward pair of mounting screw holes in bottom mount fixtures must be centered no more than 3/4-inch (19 mm) from the edge. The case has a 2-degree taper to the rear. The standard case may need a shim as much as 0.170-inch (4.3 mm) thick at the rear pair of screws to level the instrument. Leveling the case will allow for best conduit alignment.
Fixtures for rear mounting may need additional bracing to ensure rigidity.
Special installation considerations:
The DanLoad 6000 is designed for installation in an outdoor environment. The instrument is weather proof and explosion proof per applicable standards. Some of the following installation suggestions concerning environmental protection describe accepted engineering practices and should not be considered to be limitations on the utility of the instrument.
# If the loading rack / island area is covered, the DanLoad 6000 should be located so that the user / operator is protected or partially protected from direct rainfall.
2 - 36 ______________________________________________________________ Installation
_________________________________________________________ DanLoad 6000 (v6.00)
#
#
#
Tropical climates: It is advisable to place sunshades above the DanLoad 6000 and other electronic instruments, such as process transmitters. Sunshades should be located to prevent direct sunlight on the instruments during the hottest part of the day
(10:00 to 15:00). Sunshades can be constructed of metal, fiberglass, or other suitable materials. They should be rear sloping to direct rain to the rear of the instrument, away from the user / operator. Avoid sharp edges or corners on sunshades to prevent injuries.
Desert areas / blowing sand: In areas where blowing sand in common, it is advisable to install a cover to protect the operator control panel during idle time.
Continuous blowing sand over an extended time period can affect the readability of the key legends and the display panel due to the sandblasting effect. A cover can be fabricated from raw materials or may consist of modified NEMA 4 weatherproof enclosure with a sealed rear cutout for placement over the operator panel. Use care in the design of any hinged cover so that wind gusts do not move the cover and cause injuries. Any cover design must allow for maintenance access to the DanLoad 6000.
The operator panel is hinged to open in the down direction for maintenance access.
High humidity: In areas of continuous high humidity, it is advisable to place a 3inch x 3-inch desiccant pack inside the DanLoad 6000 case. Desiccant packs should be placed so that expansion due to moisture absorption does not interfere with any of the equipment or wiring inside the case. Two sources of desiccant packs are:
# Waterguard Desiccants
P.O. Box 1079
16023 I-10 East, Suite 30
Channelview, Texas 77530
# A+ Corporation
Prairieville, Louisiana 70769
Installation ______________________________________________________________ 2 - 37
DanLoad 6000 (v6.00) __________________________________________________________
2.4
Electrical Installation
Warning
Shut off all sources of AC and DC power to the loading island site before installing the
DanLoad 6000.
2.4.1
General Considerations
Use two or three cable entries provided on the bottom of the enclosure for wiring access to the
DanLoad 6000.
# A threaded 1-inch female NPT (or M25 x 1.5 mm metric) connection on the left side of the unit (for AC power and control / status signals).
# A spare threaded 1-inch female NPT (or M25 x 1.5 mm metric) connection on the right side of the unit (may be used for meter pulse wiring if it is desired to segregate meter pulse wiring from all other signals).
# A threaded 2-inch female NPT (or M50 x 1.5 mm) connection for DC cabling and low voltage level signals in the center.
Note
All cable entries must be sealed within 18-inches (450 mm) of the enclosure with suitable sealing / potting compound.
Guidelines for field wiring installation:
#
#
External AC and DC wiring must be routed in separate conduits.
Record cable / wire routing and interconnection information so that as-built documentation for the system can be generated later.
# Provide remote circuit breakers and optional disconnect switches for all AC and DC power input circuits.
# Follow power and signal field wiring grounding standards.
2 - 38 ______________________________________________________________ Installation
_________________________________________________________ DanLoad 6000 (v6.00)
#
#
#
#
#
Use only stranded copper wire, equal to or larger gauges as indicated on the basic wiring diagrams located at the rear of this section, do not cut or weaken wire strands during insulation removal.
All wire ends should be clearly marked with slip-on wire tags or similar devices, the wire tags should preferably be color coded to indicate the voltage level and marked with the specific signal name.
Power and signal wires should be cut with an additional length of approximately 2-inches for service loops to allow terminal board / connector removal.
All wiring should be positioned within the unit to avoid unnecessary crimping and overcrowding, and to insure proper clearance for the instrument door and hinges.
After completion, thoroughly check the wiring to insure that input AC power and all field input / output signals are correctly connected at the DanLoad 6000 terminations and at the terminations located on the corresponding field device.
2.4.2
Selection / Installation of Electrical Wire and Cable
All wiring must conform to the National Electrical Code, local state or other jurisdiction, and company standards and practices. Recommendations for 115 / 230 Vac power wiring:
# Use multi-strand copper conductor wire and cable for connecting the DanLoad 6000 to the power source and the field devices.
# All wire and cable must be in new condition, and must adhere to the manufacturer's quality standards with the size, type of insulation, voltage rating.
#
#
#
#
#
Recommended wire types and sizes for AC power input to the DanLoad 6000:
# Power feed should be 115 or 230 Vac, 47 to 63 Hertz, single phase, three wire. A
15 Amp circuit breaker and optionally a power disconnect switch must be located in a safe area.
Wire size AWG 14 for power feed for distances up to 250 feet.
Wire size AWG 12 for power feed for distances of 250 to 500 feet.
Wire size AWG 10 for power feed for distances of 500 to 1000 feet.
Contact Daniel Industries, Inc., Customer Service - Electronics Division, for power feed distances greater than 1000 feet.
Installation ______________________________________________________________ 2 - 39
DanLoad 6000 (v6.00) __________________________________________________________
#
#
#
#
#
#
#
#
# Single-conductor wiring must be THWN type, which is moisture and heat-resistant thermoplastic with nylon jacket, approved for dry-and-wet locations, and has a maximum operating temperature of 75 degrees Celsius (167 degrees Fahrenheit).
The wire or cable jacket must contain the Underwriters Laboratories, Inc. mark for
Gasoline and Oil Resistant, II.
Shielded wires and cables for meter pulse signals must have shield-drain wires. The shielddrain wires must not be more than two AWG sizes smaller than the conductors for the cable.
The shield-drain wire must be connected to ground at only one end of the run.
RS-485 serial data signals should be connected via two twisted pairs with overall shield,
AWG 28 to AWG 22. Ideally, the capacitance should not be greater than 16 pF per foot
(Belden 9842 for example). The use of a signal common (ground) conductor connected to each device is a recommended option. Capacitance greater than 16 pF per foot may be used at reduced baud rates and/or with shorter data communication cable runs. See typical communications connection drawings in Appendix E.
RS-232 single ended serial data signals should be AWG 28 to AWG 18 for cable lengths to
15 meters (50 feet). Consult factory for cable lengths greater than 15 meters.
All cables must have either Teflon or PVC exterior jacket.
Insulated wire and cable must be installed in accordance with the manufacturer's recommendation. Maximum wire tension, maximum insulation pressure and minimum bending radius must not be exceeded.
Use suitable lubrication during wire pulls in conduit to prevent wire stress.
All cables and individual wires must have cable or wire markers at each termination. Markers must contain the specific wire or cable codes designated for that particular circuit. The wire and cable markers must be legible and permanent.
Check all wiring connected to the DanLoad 6000 for continuity, proper size, and proper classification. Verify the source or destination of each circuit before connection to the
DanLoad 6000 and related devices.
2 - 40 ______________________________________________________________ Installation
_________________________________________________________ DanLoad 6000 (v6.00)
2.4.2.1
Input / Output Field Signal Wiring
Recommendations for process signal wiring:
#
#
#
Metal conduit must be used for all process signal wiring.
Use separate conduits for AC Voltage and DC Voltage circuits.
All process signal wiring must be a single, continuous length between field devices, and the
DanLoad 6000, unless the length and / or conduit runs require that multiple pulls be made.
In these instances, the individual conductors must be interconnected with suitable terminal blocks.
2.4.2.2
Electrical Grounds
Recommendations for electrical grounds:
# A clamp type ground lug (color green) is located on the inside bottom front of the case.
Chassis ground conductors (color code green) inside the DanLoad 6000 enclosure should be stranded, insulated, copper wire. These device chassis ground conductors should all be connected to the clamp type ground lug.
# A clamp type ground lug is located on the outside of the case at the rear of the lower right
(facing the operator panel) casting rib. This ground point should be connected to a copper ground rod as described below.
# A single-point ground (the outside case ground lug) must be connected to a copper-clad, ten-foot long, 3/4-inch diameter steel rod, which is buried, full-length, vertically, into the soil as close to the equipment as is practical. (Grounding rod furnished by others.)
# Resistance between the copper-clad steel ground rod and the earth ground must not exceed
25 Ohms. If necessary, additional ground rods may be driven into the ground, while a spacing of not less than 6 feet is used to separate each of the ground rods. Additionally, the ground rods must be interconnected with a continuous stranded wire, sized as indicated below.
Installation ______________________________________________________________ 2 - 41
DanLoad 6000 (v6.00) __________________________________________________________
#
#
When several DanLoad 6000 units are located in close proximity, each single point equipment ground must be inter-connected to the single point grounds of the other DanLoad units. These inter-enclosure equipment grounding connections must be made in a daisychain fashion with only one point of the grounding daisy-chain being connected to the actual ground rod.
#
#
#
The equipment-grounding conductors used between DanLoad 6000 units and the copper-clad steel ground rod, or for inter-enclosure equipment ground connections must be sized according to the following specifications:
# Stranded, insulated, copper wire size AWG 8 for distances of less than 15 feet.
Stranded, insulated, copper wire size AWG 6 for distances of 15 to 30 feet.
Stranded, insulated, copper wire size AWG 4 for distances of 30 to 100 feet.
Consult Daniel Industries, Inc., Customer Service Department - Electronics
Division for distances greater than 100 feet.
# All inter-enclosure equipment-grounding conductors must be protected by metallic conduit.
# Shield-drain wires must be connected to ground at only one end of the shielded conductor run.
# External equipment, such as data printers or terminal automation systems, which are connected to the DanLoad 6000, must be powered via isolation transformers to minimize the ground loops caused by the internally shared safety and chassis grounds.
2 - 42 ______________________________________________________________ Installation
_________________________________________________________ DanLoad 6000 (v6.00)
2.4.3
Selection / Installation of Wire Conduit
#
#
Recommendations for conduit installation:
# All conduit and the associated assembly and installation materials used for the installation of the DanLoad 6000 must be in new condition and shall adhere to the manufacturer's quality standards.
# All conduit runs must have an explosion proof sealing (potting) fitting located within 18inches (455 mm) distance from the conduit entrance to the DanLoad 6000.
# The conduit installation must be vapor tight, with threaded hub fittings, sealed conduit joints and gaskets on covers, or other approved vapor-tight conduit fittings.
# Conduit cutoffs must be square. Cutoffs must be made by a cold cutting tool, hacksaw, or by some other approved means that does not deform the conduit ends or leave sharp edges.
# All conduit fitting threads, including factory-cut threads, must be coated with a metalbearing conducting grease, such as Crouse-Hinds STL or equivalent, prior to assembly.
# Temporarily cap the ends of all conduit runs immediately after installation to prevent accumulation of water, dirt, or other contaminants. Conduits must be swabbed out prior to installing the conductors.
Where applicable, explosion proof seals must be installed in the conduit.
Install drain fittings at the lowest point in the conduit run, install seals at the point of entry to the DanLoad 6000 to prevent vapor passage and accumulation of moisture.
# Use liquid tight conduit fittings, such as Myers Scru-tite, or similar, for conduit which is exposed to moisture.
Installation ______________________________________________________________ 2 - 43
DanLoad 6000 (v6.00) __________________________________________________________
2.5
Installing the Secondary Keypad / Display
2.5.1
Hardware Setup / Configuration
Refer to Figure 2-21 Secondary Keypad / Display Connections.
The primary display/keypad is connected to P2 on the CPU board. The secondary display/keypad is connected to P3 on the CPU board.
The jumper (W1) on the secondary keypad board is installed to recognize the key codes from the secondary keypad. The jumper (W1) on the primary keypad board should not be installed.
The weights and measures key (top left of the keyboard) will only function on the primary keypad.
Interface Board
3-6000-034
3-6000-147
3-6000-149
Function
Remote display
Remote start/stop
Remote start/stop and remote display
2.5.2
Software Setup / Configuration
The DanLoad 6000 auto-configures any connected display/keypad modules at power-up/reset of the
CPU board. The yellow (top) and red (bottom) LED's (located to the right of the display) should
"blink" on/off (once) just before text appears on the display. The displays/keypad modules should not be powered on/off independently of the CPU board; they should be powered-up prior to or at the same time as the CPU board.
The primary and secondary keypad/display modules have independently controlled automatic backlighting and contrast adjustment. The primary LCD type (program code 355) and secondary
LCD type (program code 358) should be configured appropriately for each.
The primary and secondary displays present the same information simultaneously. However, only one keypad (primary or secondary) is active at a time. The active keypad is controlled by the swingarm switches (SW2 and SW1) on the CPU board and the configured side detect method (program code 312). A version of the remote display interface also incorporates a remote Start/Stop feature
(assm. 3-6000-149). A second version of the board has only the Start/Stop feature (assm. 3-6000-
147). The field wiring for both boards is shown in Appendix E.
2 - 44 ______________________________________________________________ Installation
_________________________________________________________ DanLoad 6000 (v6.00)
2.5.3
Wiring Details
The cable that connects the 2 interface cards requires 16 conductors, minimum wire size 24 AWG.
The maximum length of the cable should be 2000 feet (610 meters).
2.5.4
Power Requirements
The standard enclosure furnishes a line Power Supply, which can be 120 or 240 VAC, 47 to 63 HZ.
The display/keypad modules power requirement is 7 VDC minimum at 0.5 amperes.
Installation ______________________________________________________________ 2 - 45
DanLoad 6000 (v6.00) __________________________________________________________
Secondary Keypad / Display Connections
Figure 2-21
2 - 46 ______________________________________________________________ Installation
_________________________________________________________ DanLoad 6000 (v6.00)
Note
Appendix A contains several tables with data on the physical and functional configuration of the DanLoad 6000. These tables can be photocopied and unique configuration data can be manually entered to provide a record of specific DanLoad 6000 installations.
This section contains information on the initial setup and configuration of the DanLoad 6000 Preset.
Any combination of up to four flow meters, up to four components, and up to six additives can be defined and controlled. A minimum of one flow meter and one component must be defined. The user performs the initial setup of the DanLoad 6000 via the operator control panel by following an automatic sequence of displayed-prompts and key-press-responses.
The initial setup routine is a general procedure that combines the basic configuration of the instrument with a tutorial function that familiarizes the user with the methods of changing values of program codes. The initial setup procedure does not cover all the different types of program codes.
For instance, the basic setup does not cover product blending, additive injection, or transaction storage definitions.
Section 3.6 contains details on the setup and program codes associated with Product Blending.
Section 3.7 contains details on the setup and program codes associated with Temperature and
Pressure Compensation.
Section 3.8 contains information about Mass Loading Using a Volumetric Flow Meter.
Section 3.9 contains details on the setup and program codes associated with Additive Injection.
Section 3.10 contains details on Transaction Storage Definition which is applicable if user defined transaction tickets are printed or the DanLoad 6000 communicates with a terminal automation system.
The DanLoad 6000 only requires AC power to execute the setup procedure. Therefore, it is possible to preconfigure the instrument in a shop or office before on-site installation. The DanLoad 6000 retains the setup configuration in non-volatile memory when power is disconnected from the unit.
The DanLoad 6000 should have the correct type and number of process signal input / output boards installed before initial setup procedure is begun.
The initial setup procedure is performed in any of the following instances.
#
#
Before or during installation of a new DanLoad 6000 that has not been setup previously.
If a new main processor board, that has not been setup, is installed (Note: Spare main processor boards can be setup for your application in advance. The setup parameters are retained in non-volatile battery-backed RAM (random access memory).
Note: A configured battery backed RAM module can be moved from one main processor board to another main processor board without loss of configuration or totalizer data.)
Note: When changing the CPU board, make sure the replacement board has the same firmware version as the original CPU board. Follow the instructions that come with spare or replacement boards and be sure to handle the CPU Board carefully so that the components do not touch the back of the board.
# If the integrated RAM / battery module on the main processor board is replaced.
Setup _________________________________________________________________ 3 - 1
DanLoad 6000 (v6.00) __________________________________________________________
After the initial setup procedure has been completed, the DanLoad 6000 can be easily reconfigured to add or change operational features such as product blending, additive injection, new delivery control recipes, data logging, and communication with a terminal automation system.
#
#
#
3.1
Overview of DanLoad 6000 Capabilities
The DanLoad 6000:
# Accepts various types and combinations of process input signals, such as flow from pulse output type flow meters, temperatures (RTD), pressures and / or density (4 to 20 mA dc analog), and discrete contact closures indicating various status and permissive conditions.
# Performs mathematical and logical calculations based on configuration program codes
(setup program codes), user / operator input from the keypad, and the current values and states of the process inputs.
# Generates discrete relay / solenoid control output signals based on the results of the mathematical and logical calculations performed.
(Optionally) Transmits selected data logs to a logging printer.
(Optionally) Transmits user defined transaction tickets to a logging printer.
(Optionally) Performs bi-directional communication, functioning as a slave processor for a terminal automation system, distributed processing system, or other host computer. The
DanLoad 6000 Communications Specification, part number 3-9000-674, contains information for programmers and engineers involved in implementing the DanLoad 6000 as a node in a communications network.
The DanLoad 6000 can be set up to perform many different tasks based on the requirements of various load rack applications. Setup is accomplished by physical configuration (installing circuit boards) and then executing the setup routine. The setup routine or logical configuration is accomplished by user interaction with the operator control panel which consists of a multi-line / graphical LCD display panel and a numeric / function keypad.
Information on installation planning, design, and physical configuration of the DanLoad 6000 is covered in Section 2 - Installation. Therefore, it is assumed at this time that the instrument contains the process input / output signal boards which provide the physical signal handling capacity for the intended load rack application. The physical configuration, locations and types of process input / output boards, can be sensed by the DanLoad 6000 and displayed for verification at the start of the setup routine.
3 - 2 _________________________________________________________________ Setup
_________________________________________________________ DanLoad 6000 (v6.00)
Program Codes
Program codes are all configurable parameters of the DanLoad 6000. Each Program Code consists of the following four parts. A three-digit identification number, a name, a selection or value (note:
some values are selected from a predefined pick-list, other values are free form entry), and one to
four program code attributes. The selection or value of a program code affects the general or specific operation of the DanLoad 6000. Each three-digit identification number / name combination identifies the specific selection or value. Identical names are repeated when the associated function is required at several places in a series of similar functions. Therefore, the name is the general identifier of the program code and the three-digit identification number is the specific identifier of the program code.
Example: 085 Low flow restart volume 50
Item Description
085 The three-digit program code is in the range of 001 to 991.
Not all numbers in the series are used. The program code number is a unique identifier of an associated value or selection.
Low flow restart volume
50
<attribute> (not shown)
The name of the program code can be unique or can be repeated for similar program codes in a series of program codes. In this example: program code 085 / 091 / 097 / 103
Low flow restart volume where each three-digit identification number corresponds to one component: 1, 2, 3, or 4.
The value of the program code. In this example, the value can be any number from 0 to 99999.
Program codes may have one or more of the following four attributes set active: Read only, Weights and measures,
Data logging, Value changed. See Section 6.1 for additional information on program code attributes.
Program codes are divided into twenty-five functional groups. Each functional group is divided into one or more display pages which can be shown on the display panel. Program codes are accessible for monitoring or changing when the DanLoad 6000 is operating in the Program Mode. A diagram of the Program Mode menu tree is shown in Figure 3 - 1. All program codes are accessible via the
Setup selection of the Program Mode Menu. Functional groups of program codes are listed in
Figure 3 - 2. The value part of a program code can be changed by keypad entries.
Setup _________________________________________________________________ 3 - 3
DanLoad 6000 (v6.00) __________________________________________________________
Operating Modes
The method of user interaction with the DanLoad 6000 is defined by the functional state of the instrument. Communications and interaction with a terminal automation system is defined by the state of the Operating Mode.
Functional mode (set by the user via the Display/Keypad):
# Loading Mode Normal operation with the instrument controlling batch product deliveries to a tanker vehicle.
# Program Mode Permits initial setup and modification of the operation of the instrument. Access to this mode is passcode restricted and can only be entered while the DanLoad 6000 is not controlling a batch delivery operation and a delivery transaction is not open.
Operating mode (set by state of program code 025 Operating mode and by the state of program code 343 auto/manual changeover INPUT):
# Auto Remote control operation, by communicating with a terminal automation system and local validation of configured safety circuits.
# Manual Communicates status to a Terminal Automation System, but without remote control functions. Performs local validation of configured safety circuits.
3 - 4 _________________________________________________________________ Setup
________________________________________________________________________________________ DanLoad 6000 (v6.00)
Program Mode Menu
Alarm reset 6 Alarm reset display
Reprint transaction 6 Reprint transaction display
Setup - Setup menu ______________________________________________________
*
Program code attributes 6 Program code attributes display *
*
Set date and time 6 Set date and time display *
*
Set contrast/backlighting 6 Set contrast/backlighting display *
*
Diagnostics - Diagnostics menu _______________________________ *
Reprint cutoff - Reprint end-of-day processing data
* *
* *
* *
CALMON status - Calibration monitoring Diagnostics Menu Setup Menu
Firmware versions Security parameters
Additive calibration - Additive meter calibration screen RAM tests Unit parameters
Keypad Valve parameters
EXIT (ALT+CLEAR) Display Meter parameters
Inputs/Outputs Component parameters
DUART Delivery parameters
ARCNET Digital valve parameters
Crash analysis Pulse per unit outputs
Show memory Additive delivery parameters
Print configuration Factors
Exit (ALT+CLEAR) Alarms
I/O parameters
Additive I/O parameters
Component I/O parameters
Temperature/pressure/density
Recipes
Data communications
Dynamic data display
Data logging
Blending
Additive pumps/block valves
LPG/pressure
Transaction storage
Transaction ticket
Analog inputs
Exit (ALT+CLEAR)
M enu Tree - Figure 3 - 1
3-5 ___________________________________________________________________________________________________ Setup
________________________________________________________________________________________ DanLoad 6000 (v6.00)
Parameters Program Code Used For
Security parameters
Unit parameters
Valve parameters
Meter parameters
Component parameters
Delivery parameters
Digital valve parameters
Pulse per unit outputs
Additive delivery parameters
Factors
Alarms
I/O parameters
Additive I/O parameters
Component I/O parameters
Temperature / pressure / density
Recipes
Data communications
Dynamic data display
Data logging
Blending
Additive pumps/block valves
LPG/Pressure
Transaction data storage
Transaction ticket
400 to 425
426 to 479
480 to 661
662 to 672
679 to 695
696 to 710
711 to 799
800 to 817
818 to 833
834 to 902
920 to 982
001 to 024
025 to 047
048, 049
050 to 061
065 to 077
078 to 111
112 to 127
128 to 134
135 to 168
169 to 219
220 to 279
280 to 379
380 to 399 operation security global parameters flow control valves flow meters liquid components batch deliveries digital flow control valves quantity pulses to external equipment additive injection flow meter factors and flow rates actions and limits input / output signal assignments additive injection signal assignments component block valve signal assignments standard quantity calculation product / batch deliveries logging / terminal automation system operator data view (programmable) reports to printer product blending control additive pump and block valve control select pressure calculation and control methods allocate memory for transaction data storage user defined transaction ticket format
Analog inputs 983 to 991 v2 CPU board calibration for 4-20 mA RTD
Program Code Groups - Figure 3 - 2
3-6 ___________________________________________________________________________________________________ Setup
_________________________________________________________ DanLoad 6000 (v6.00)
3.2
Operator Interface
User / operator interaction with a DanLoad 6000 is described below.
# The user issues a command via a single key press / release action or by simultaneously pressing / releasing two keys. While operating in the Loading Mode, all operator entries are single-key press actions. While operating in the Program Mode, some user entries require simultaneous two-key actuations.
# The DanLoad 6000 responds by either executing the command immediately or by prompting the user, via the display panel, for additional data entry.
# If the command is executed immediately, the displayed information will change in some manner to indicate response to the command.
# If the command cannot be completed without additional information from the user, one of various types of data input prompt displays will be shown. Now the user has the option to enter the data in response to the displayed prompt or to return the DanLoad 6000 to the previous state without modifying any internal or external state or configuration.
3.2.1
Data Display Operation
While operating in the Program Mode, data from the DanLoad 6000 is presented to the user on an
8-line by 40-column LCD display panel. Miscellaneous messages and data are displayed in the format shown in the General Display Format, Figure 3 - 3.
General Display Format
Figure 3 - 3
Setup _________________________________________________________________ 3 - 7
DanLoad 6000 (v6.00) __________________________________________________________
One common format of the general display is the Program Code View display, Figure 3 - 4. The
Program code View display is used throughout the initial setup procedure and in the future for monitoring and / or changing program code values / selections.
Program Code View
Figure 3 - 4
The field types displayed in the Program code View, Figure 3 - 4, are described below.
# Header line An alpha-numeric field that is used to describe the contents of the display. Usually a program codes group or sub-group title, such as:
Meter 1 parameters
# ccc A three-digit field containing the Program Code
identification number that specifics a unique program code.
The range of the program code series is 001 to 991 (several program code numbers in the series are not assigned). All program codes / parameters are described in the tables in
Appendix A and Section 6 - Program Code Definitions.
# name An alpha-numeric field that contains the name that describes the function of the program code. Names are up to 34characters long. Identical names are used for functions that are repeated several times in a series of similar program codes for different physical or logical items. A typical name is:
Meter ID
3 - 8 _________________________________________________________________ Setup
_________________________________________________________ DanLoad 6000 (v6.00)
# vvvvvvvv A variable length numeric, alpha-numeric, or selection field that contains the value or selection of the corresponding parameter (Program Code). The contents of this field can be changed by the user (unless the program code attribute is
Read-only). The value / selection is changed via key entries.
The key entry sequences are dependent on the type of field and are described in the following section. The three types of fields that can be displayed in this area are:
#
#
#
numeric The field can contain a variable number of digits (0 thru 9), a decimal separator (defined by program code 040 Decimal separator), and a minus sign (-).
alpha-numeric The field consists of a variable number of alpha-numeric characters (also called a string).
selection The field consists of one of an internally defined option selected from a list of possible options for this field entry.
# Message line An alpha-numeric field used to display a message to the user.
Several prompt messages can be user defined in the applicable sections of the following setup description.
Setup _________________________________________________________________ 3 - 9
DanLoad 6000 (v6.00) __________________________________________________________
3.2.2
Keypad Operation
The keypad, located on the front panel, provides the method for the local operator to enter commands and data into the DanLoad 6000. Example of keypad layouts for different languages are shown below.
Keypad (English Version)
3 - 10 _________________________________________________________________ Setup
_________________________________________________________ DanLoad 6000 (v6.00)
Keypad (Spanish Version)
Keypad (French Version)
Setup _________________________________________________________________ 3 - 11
DanLoad 6000 (v6.00) __________________________________________________________
Key Primary Function Alternate Function
0 thru 9
ALT
0
1
3
6 numeric digits used in combination with other keys to modify the function of the other keys, see descriptions in the
ALTERNATE FUNCTION column
0 digit
1 digit
3 digit
6 digit view I/O configuration summary toggle minus sign '-' increase display contrast (darken) decrease display contrast
(lighten)
START start batch delivery
STOP/PRINT stop batch delivery/print batch/transaction report
ENTER
CLEAR
SELECT
8
7
9
6
W&M accept value or execute option remove selected value scroll options list scroll up scroll down
PROGRAM
EXIT
BACKSPACE scroll left scroll right the Weights and Measures security switch
(round, spring loaded, sealable switch located in the upper left area of the keypad; this switch is sealable in the depressed (CLOSED) position)
Key Functions
Figure 3 - 5
3 - 12 _________________________________________________________________ Setup
_________________________________________________________ DanLoad 6000 (v6.00)
Several keys perform dual functions, dependent on the operating mode of the DanLoad 6000. The
Loading Mode is active if the Loading Display, the Additive Selection Display, or the Recipe
Selection Display is currently showing on the display panel. The Program Mode is active if the
Program Mode Menu or any related sub-menu is currently showing on the display panel. Specific functions of the keys in the Loading Mode and the Program Mode are described below.
Key Function
Loading Mode only:
START Initiate a batch delivery after entry of the preset quantity.
STOP/PRINT Suspend a batch delivery operation in progress or end transaction in progress.
Print an optional transaction report that may include batch data.
Loading Mode and Program Mode:
W&M (spring loaded captive switch located in the upper left area of the keypad)
The Weights and Measures security switch provides global restriction for modification of all program codes that have the Weights and Measures attribute set ON. This restriction prevents users / operators from modifying the values or selections of these program codes. See Section 6.1 Program
Code Attributes for a complete description of program code attributes and the
Weights and Measures security switch.
# CLOSED Depressed and captive with the slot in the vertical position.
Can be wire sealed in this position. Critical weights and measures variables cannot be modified.
# OPEN Extended with the slot in the horizontal position. Critical weights and measures variable can be modified (the switch must be
OPEN prior to accessing the Program Mode to enable modification capability).
Setup _________________________________________________________________ 3 - 13
DanLoad 6000 (v6.00) __________________________________________________________
Key Function
ALT This key is used in conjunction with several other keys to change the primary function performed by the other key. The primary function of a dual function key is indicated on the top of the key face (white letters / black background).
The alternate function of a dual function key is indicated on the bottom of the key face (black letters / white background). Numeric keys 0, 1, 3, and 6 also have alternate functions as indicated below. The ALT key should be pressed and maintained in the depressed position while simultaneously pressing and releasing an alternate function key to execute an alternate function.
0 thru 9
(Loading Mode)
(Program Mode)
ALT+0
ALT+1
Numeric keys used for numeric data entry.
Numeric keys used for numeric data entry and selection of alpha character group for data entry.
Active in Program Mode only, activates display of the physical configuration of the DanLoad 6000. The first page displayed contains the location of the process signal input / output boards detected during the power-up sequence.
Successive pages, accessed by the 98 keys, show the currently configured state of physical input / output to logical input / output assignments in the following groups: RTD inputs, 4-20 mA inputs, Discrete inputs, Discrete outputs
Active in Program Mode only. Toggles the minus sign on or off for a numeric entry. Can be used before, during, or after entry of a numeric value.
ALT+3
ALT+6
ENTER
(Loading Mode)
Active in Loading Mode and Program Mode. Increases the display contrast
(darkens the display).
Active in Loading Mode and Program Mode. Decreases the display contrast
(lightens the display).
(Program Mode)
Accept or bypass data item entry or preset quantity entry and continue.
Accept the value or selection highlighted by the box cursor.
3 - 14 _________________________________________________________________ Setup
_________________________________________________________ DanLoad 6000 (v6.00)
Key Function
PROGRAM (ALT+ENTER)
(Loading Mode) Change to Program Mode.
(Program Mode) Ignore any edit made to the current field selected by the box cursor and restore the original value / selection.
CLEAR
(Loading Mode) Clear the current data item entry or preset quantity entry.
Remove the Dynamic Data Display window from the loading. display
Clear the current numeric or alphanumeric entry.
(Program Mode)
EXIT (ALT+CLEAR)
(Loading Mode)
(Program Mode)
Bypass the data item entry sequence. If data item entry is defined
Step to the next higher menu level. Change to Loading Mode when the Program Mode Menu is displayed.
SELECT
(Loading Mode)
(Program Mode)
Display dynamic data window on the loading display.
Scroll through selection options. Step to next character position when editing an alpha-numeric string entry.
BACKSPACE (ALT+SELECT)
(Loading Mode) No function.
(Program Mode) Step to previous character position when editing an alpha-numeric string entry. Scroll backward through selection options.
98 (Loading Mode) Change Dynamic Data Display page.
Step to next or previous program code (parameter) display line.
(Program Mode)
67 (ALT+9 or ALT+8)
(Loading Mode)
(Program Mode)
No function.
Step to next or previous character entry when editing an alphanumeric string entry.
Setup _________________________________________________________________ 3 - 15
DanLoad 6000 (v6.00) __________________________________________________________
3.3
Initial Setup Procedure Overview
The initial setup procedure guides the user through a sequence of displayed-prompts and key- pressresponses. The user accomplishes the following three tasks while executing the initial setup procedure.
# Accept or modify several default program code values / selections that inform the DanLoad
6000 about the physical characteristics of the batch loading system. Section 3.5 contains information on process input / output channel assignment.
# Accept or modify several default program code values / selections that inform the DanLoad
6000 about the type of flow calculations and logical operations to be performed.
# Guide the user through interactive verification and / or program code value changes. This tutorial function familiarizes the user with the display format and the operator interface, using the keypad.
Read all of this section and review Section 6 - Program Code Definitions prior to performing the initial setup procedure. In most cases, desired responses to the prompts encountered during the initial setup procedure can be determined during execution of the setup procedure. However, if the correct response cannot be determined during the setup procedure, it is permissible to accept any or all of the default values / selections for the program codes. Any default value or selection that is accepted or modified can be changed easily at any time in the future.
The initial setup procedure automatically enters default values / selections for some program codes that are not covered by the procedure. In some cases, these default values / selections require modification for the intended application. Review the additional information contained in Sections
3.6 to 3.12 after the initial setup procedure is completed. This additional information should be reviewed to assure that the DanLoad 6000 is properly configured for your installation.
3.3.1
Data Entry
Several key press responses are required during execution of the initial setup procedure. The responses are a press / release of ENTER or 9 to continue, numeric data entries with the 0 thru 9 numeric keys, option selection scrolling with the SELECT key, or alpha-numeric data entry. The value or option displayed is accepted and entered by pressing the ENTER key or either the 9 or 8 arrow key. Methods for data entry are described below.
3 - 16 _________________________________________________________________ Setup
_________________________________________________________ DanLoad 6000 (v6.00)
#
#
#
Numeric data entry
Place the box cursor over the selected program code with the 9 or 8 arrow keys. Enter the desired number with the numeric keys 0 through 9. Numeric entries are toggled between negative and positive values by entering the numeric value in the field and then pressing and holding the Alt key while pressing the 1 digit key. If an entry error is made, press the
CLEAR key to clear the field and start again, or toggle the +/- sign to the opposite state.
Option data entry
Selection options are contained in short lists permanently stored in the DanLoad 6000. Place the box cursor over the selected program code with the 9 or 8 arrow keys. If necessary, use the SELECT key or the BACKSPACE KEY (ALT+SELECT) to scroll the list forward or backward until the desired option is displayed.
Alpha-numeric data entry
If alpha-numeric data entry is permitted in a field, the message line will display the following prompt: 0=Space, 1=A, 2=a, 3=0, 4=#, 5="
This prompt indicates to the user that an alpha-numeric string of characters can be entered.
The numbers 1 through 5 point to a specific location in a continuous string of characters. For example, the number 1 points to the letter A, a string of upper case letters continue to Z, the next character is a, a string of lower case letters continue to z, the next character is 0, a string of numbers continues to 9. In other words, each group of characters is in one continuous string of all possible characters. The apparent groups of characters do not wrap around to the start of that group.
Setup _________________________________________________________________ 3 - 17
DanLoad 6000 (v6.00) __________________________________________________________
2 r s t u p q n o x y v w z j k l m
I h f g c d e a b
3
2
3
4
0
1
7
8
5
6
9
1
R
S
T
U
P
Q
N
O
X
Y
V
W
Z
J
K
L
M
I
H
F
G
C
D
E
A
B
4
# number/pound
$ dollars
% percent
!
?
question mark exclamation point
& ampersand
+ plus
minus
* asterisk
,
.
/ slash
= equal dot comma
5
(
;
:
'
" double quote apostrophe colon semicolon left parenthesis
) right parenthesis
< less than
[
> greater than left bracket
] right bracket
{ left brace
\
} right brace backslash
_ underline
^ circumflex
~ tilde
á a acute
Í I acute
ó o acute
ú u acute
ñ n tilde (eñe)
ä a diaeresis (umlaut)
ë e diaeresis (umlaut)
ï I diaeresis (umlaut)
ö o diaeresis (umlaut)
ü u diaeresis (umlaut) space
Alpha-Numeric Characters
Figure 3 - 6
3 - 18 _________________________________________________________________ Setup
_________________________________________________________ DanLoad 6000 (v6.00)
#
Figure 3 - 6 contains a list of all available alpha-numeric characters organized into five groups. The characters in group 5 will vary slightly depending on the language selection
(program code 028). Alpha-numeric characters are entered in the following manner when the prompt is displayed.
C The flashing square cursor is positioned in the leftward field position. The cursor indicates the current character entry position within the alpha-numeric field.
C The cursor is moved one character position right each time the SELECT key is pressed. The cursor is moved one character position left each time the
BACKSPACE (ALT+SELECT) key is pressed.
C To enter an alpha-numeric character in the current character position, press the number key 0, 1, 2, 3, 4, or 5 which indicates the group of characters which contains the desired entry. Any number group selector can be pressed after the initial selection, if an error is made. (Note: An easy method to access the Z character is press 2 to display lower case a then press the 7 (ALT+8) key.)
C The first character of the selected group will now be displayed in the active character position.
C To select another character from the specified group of characters, press the RIGHT
ARROW (6 ) which is the (ALT+9) to move to the next character in the selection string. Or, press the (7) which is the (ALT+ 8) to move to the previous character in the selection string. The character selections will jog in sequence automatically if both the ALT key and either one of the arrow keys are simultaneously maintained depressed. When the desired character is displayed in the active character position, release the keys.
C Use the SELECT or the BACKSPACE (ALT+SELECT) key to step the cursor to the next or any desired position in the alpha-numeric field. Repeat the entry sequence described above until the field content is as desired.
Special alpha-numeric data entry
Program codes 129 / 132 Control meters in the Pulse per unit outputs group and 139 / 144
/ 149 / 154 / 159 / 164 Control meters in the Additive parameters group select one of the fixed options G, N, or X in the following manner. Place the box cursor over the selected program code with the 9 or 8 arrow keys. Maintain the ALT key depressed and select the desired option with the 9 or 8 arrow keys.
Setup _________________________________________________________________ 3 - 19
DanLoad 6000 (v6.00) __________________________________________________________
3.4
Initial Setup Procedure
The Weights and Measures switch located in the upper left area of the keypad should be rotated until the captive pin passes through the slot and releases the switch to the extended (OPEN) position.
The electrical jumper configuration for individual circuit boards installed at this time is described in Section 2 - Installation. The electrical jumper configuration should be verified and AC power should be connected and applied to the instrument.
The sequence of the initial setup procedure is presented below with examples of the displays presented to the user, an explanation of the contents of the display, and the user response to each display.
The display example above shows the firmware (application software) version of the DanLoad 6000 and the date and time that AC power input was last removed from the instrument.
3 - 20 _________________________________________________________________ Setup
_________________________________________________________ DanLoad 6000 (v6.00)
The display example above shows the results of automatic diagnostic tests that check the operation of the RAM (random access memory). The normal message is Please wait while the test is in progress and the normal result message is Passed. A Failed message indicates that a hardware problem exists in the DanLoad 6000.
The display example above shows the location of all process input / output signal boards installed and the serial communications address of the DanLoad 6000. A message DUART = ###, where ### is 000 to 255, indicates the communications address for the dual universal asynchronous receiver
/ transmitter module that handles RS 232 / RS 485 serial communications.
On the V1 CPU, the DUART is a daughter Board with an address switch. For firmware versions 5.3
and higher the address switch is no longer used to configure the unit address. Program code 662 is used to identify the address of the unit.
On the V2 CPU, the DUART is built-in and is addressed using Program code 662.
The tables located in Appendix A should be photo-copied at this time and the copies used for entry of the physical input / output signal assignments for the DanLoad 6000. The individual channel assignments can be viewed and recorded at this time. While viewing the slot assignment display above, press any key to continue. The following display will be shown.
Setup _________________________________________________________________ 3 - 21
DanLoad 6000 (v6.00) __________________________________________________________
The display example above shows one of several similar displays which indicate the automatic input
/ output signal numbering performed by the DanLoad 6000. The 9 and 8 arrows keys are used to page through this display group. Display types included in this group are:
I/O Signal Type
Meter inputs (shown above)
RTD inputs
Maximum Number
4 *
4 * (5 for v2 CPU)
4-20 mA inputs
Discrete inputs (can be more than one display page)
8 * (9 for v2 CPU)
24 *
Discrete outputs (can be more than one display page)
*
28 *
If circuit board configuration causes additional I/O points of any type to be present, the additional I/O points cannot be assigned logically. (The
I/O points are not accessible.)
Section 2.4.1 contains additional information on automatic assignment of input / output channels.
The fields located in this display group are described below.
#
#
Header line
01
Defines the input / output signal type.
Sequential number for this input. The sequence starts at 01 and continues through the highest input or output channel of that type.
The DanLoad 6000 assigns these numbers automatically by sensing the type of board in each slot (J1 to J7). Boards are scanned from left to right. Therefore, similar type channels in leftward located boards will have lower numbers than similar type channels in rightward located boards. A minimum of one meter pulse board must be present. If an analog board is not present, the RTD inputs and 4-
20 mA inputs groups will display the message No points of this type.
3 - 22 _________________________________________________________________ Setup
_________________________________________________________ DanLoad 6000 (v6.00)
#
#
#
#
Chan #
Meter Pulse
J5
Sequential number of the physical input / output channel on the corresponding board. The sequence starts at 0. The maximum value for this field is 7, which corresponds to the eighth output on an AC
I/O board (channels 0 to 7). All other boards have fewer channels than the AC I/O board.
This field indicates the board type in the indicated slot. Displays in this field can be: 2-channel or 4-channel Meter, 2-channel or 8-
channel Analog, AC I/O, DC I/O, or Enhanced I/O.
This field indicates the physical location of the board. Displays in this field can be: J1 through J7.
ALT+SELECT to reconfigure
Configuration during the initial setup procedure is automatic and no response to this prompt is required. If an input / output signal board is added in slots J1 to J7 in the future, the DanLoad 6000 senses the presence of the new board and always displays the current configuration in the Slot # <board type> display. However, the input / output channels are not renumbered until the manual command (ALT+SELECT) to reconfigure is issued.
(Note: If the input / output signal board arrangement of a configured
DanLoad 6000 is changed and the ALT+SELECT command is issued, input / output points may be renumbered. The physical I/O to internal logical signal may be changed when the channels are
renumbered to correspond to the new configuration.)
Notes
The two swing arm switch inputs on the Main Processor Board and the two / four meter pulse inputs and two high resolution meter pulse outputs on the Meter Pulse Board are dedicated functions and are not shown in the Configuration Summary Display.
The v2 CPU (introduced in 1997) has a built-in DUART, but does not have dedicated swingarm inputs. AC or DC discrete inputs on I/O boards are used instead.
Version 5.50 software can be used with v1 CPU boards per the following:
1.
The communications address must be configured via program code 662 since
2.
3.
the DUART board’s address switch is ignored.
Either the dedicated swing-arm discrete or inputs are used for side detection depending on program codes 312, 37 and 377. See note at the beginning of
5.12 in the software specification.
4-20 mA input 01 and RTD input 01 on the CPU board are inaccessible.
Setup _________________________________________________________________ 3 - 23
DanLoad 6000 (v6.00) __________________________________________________________
3.5
Process Input / Output Signal Handling
All input / output signal board slots (J1 to J7) are electrically identical. However, for electrical isolation of AC and DC signals, only AC I/O or Enhanced I/O boards should be installed in slots
J1, J2 or J3. It is strongly suggested that board placement follow the recommended layout indicated in the descriptions of each board in Section 2. The recommended board layout provides electrical isolation of AC Voltage control and status signals (AC I/O and / or Enhanced I/O boards) by the vertical metal partition that can be located between slots J2 and J3 or J3 and J4. In addition, if an analog input signal board is installed, this board is electrically and physically isolated in the rightward slot J7. A DanLoad 6000 basic configuration contains the following boards.
I/O Board main processor
2 RS-485
or
1 RS-485 and 1 RS-232 one meter pulse
(2-ch or 4-ch)
Input
2 DC (dedicated function: swing arm)
Capacity
Output
N/A
2 pulse
- OR -
4 pulse
2 pulse (dedicated function: high resolution meter pulse for 2-ch meter pulse board only)
2 DC control
8 AC control
6 AC control one AC I/O or one Enhanced I/O
2 AC status
6 DC/AC status
Basic Configuration
Figure 3 - 7
For a v2 CPU installation, the “base” DanLoad 6000 has one 2- or 4-Channel Meter Pulse board and one AC I/O board. The v2 CPU board (1997) has one 4-20 mA input and one RTD input built-in.
Up to two 2- or 4-Channel Analog Inputs boards can be added for measuring temperatures, pressures and densities. Note that the DanLoad 6000 cannot correct densities at measured temperatures to densities at standard temperatures. Up to two meter pulse boards (of the same kind or mixed) can be used.
3 - 24 _________________________________________________________________ Setup
_________________________________________________________ DanLoad 6000 (v6.00)
Basic configuration considerations:
# Serial communications require an RS-485 / RS-232 DUART module. For v1 CPU boards, a DUART module is required for data logging to a printer or data logging device. The
DUART is integral to the v2 CPU board.
# The meter pulse input board can be either 2-channel or 4-channel types. One or two boards can be installed. If two boards are installed, they can be any combination of 2-channel and
4-channel boards. However, there can be a total of only four flow meters. If two 4-channel boards are installed, four meters with two pulse signals from each meter can be implemented for IP-252 level 'B' pulse security. For pulse security verification, pulse input Channel A is used for flow measurement and pulse input Channel B is used for verification of Channel
A integrity).
# The swing arm input on v1 CPU boards is normally from either a single switch or dual switch swing arm. This input is used for swing arm side detect and keypad side enable and to indicate the active load rack side to a terminal automation system.
3.5.1
Physical Input and Output Signal Assignment
The DanLoad 6000 automatically assigns physical input and output channel numbers during initial setup or when manually commanded to do so. The channel assignment is performed as follows. The instrument scans the input / output signal boards located in slots J1 (leftward) through J7
(rightward) in that order. Each board is identified and the physical channels on the board, indicated in Appendix A, are assigned a sequential channel number corresponding to the same type channel.
These physical I/O channel assignments can be viewed by pressing the ALT+0 key while operating in the Program Mode. While viewing the channel assignments, the prompt message ALT+SELECT
to reconfigure is displayed on the message line. Issuing this command causes the DanLoad 6000 to re-number the physical input / output channels if the board complement has been altered in any manner since the last configuration. There are five different types of input / output signals that can be handled by the DanLoad 6000. These channel types are listed below.
I/O Channel Type Description
Meter inputs Dedicated meter pulse input numbers 01 and 02 if one meter pulse board is installed. Dedicated meter pulse input numbers 01, 02, 03, 04 if two meter pulse boards are installed. (Four channel meter pulse boards implement channels 1A / 1B and 2A / 2B OR 3A / 3B and 4A / 4B depending on board jumper configuration.)
Setup _________________________________________________________________ 3 - 25
DanLoad 6000 (v6.00) __________________________________________________________
I/O Channel Type Description
Input Type
# of RTD inputs
# of 4-20 mA inputs
Analog Input Signal Channel Assignment
1 each 2-
Ch
1
1
2 each 2-
Ch
2
Analog Board Type
1 each
8-Ch
4
2 each
8-Ch
8
2 4 8
1 each 2-Ch /
1 each 8-Ch
5
5
Discrete inputs
Discrete outputs
Assigned discrete input numbers from 01 to the maximum number of discrete status inputs present, in the order that the inputs are encountered by the configuration scan.
Assigned discrete output numbers from 01 to the maximum number of discrete control outputs present, in the order that the inputs are encountered by the configuration scan.
The physical channel assignments are indicated under each channel type header in the following format.
cc Chan n <board type> in Jn where: cc =
Chan n
<board type>=
Jn
=
=
Logical (software assigned) input / output number (for this type of point) assigned to this point. This number is assigned automatically. Discrete Vdc and Vac status inputs are numbered sequentially in the same series. Each channel number is dependent on the I/O board location and the physical board channel. Vdc and Vac control outputs are numbered sequentially in the same series, dependent on the I/O board location and the physical board channel.
Sequential channel number 0 to n that identifies the physical channel on the
I/O board. The maximum range for this number is 0 to 7. (Note: Maximum of 8 output channels on an AC I/O board.)
Board name: 2-Ch. Meter, 4-Ch. Meter, AC I/O, DC I/O, Enhanced I/O,
2-Ch. Analog, 8-Ch. Analog
Slot number, J1 through J7, where the board is located.
3 - 26 _________________________________________________________________ Setup
_________________________________________________________ DanLoad 6000 (v6.00)
The logical input / output number assignments are solely dependent on I/O board locations. This assignment informs the DanLoad 6000 of the physical input / output signal configuration and assigns non-duplicated logical channel numbers (leftward column) for identifying each point. The physical channel assignments cannot be changed. The assignments are determined by the process I/O board complement and type of boards.
Fail Safe Operation
The operating state of a discrete output is OPEN or deenergized when the controlled device is in a
OFF, CLOSED, NORMAL, or SAFE state. Discrete outputs that control flow control valves, block valves, or pumps are energized or CLOSED to OPEN the valve or RUN the pump motor so that an open wire, open coil, or power failure to the DanLoad 6000 will cause the affected valve(s) to move to their CLOSED positions and pump motors to stop running. This method of handling control outputs assures that operation of the loading system is inherently fail-safe.
Safety circuits (permissive status inputs) are normally closed switch or relay contacts that indicate a normal or safe condition from the corresponding device. Common permissive devices are vehicle ground connection detectors, tank overspill detectors, and fire warning systems. The DanLoad
6000 has the capability of detecting up to eight general purpose safety circuit inputs, six recipe selection inputs, and four block valve status inputs. Several normally closed contacts for different safety circuits can be field wired in series. This implementation reduces the number of physical discrete inputs required, but also generalizes the common safety input. The DanLoad 6000, or terminal automation system, cannot determine the specific device that has generated the safety circuit open alarm when several permissive signals are wired in series.
3.5.2
Inverted Discrete Inputs
Inverted discrete inputs. In order to provide greater flexibility with field signals, most discrete input
functions (e.g. safety circuit inputs, see the list below) can be configured to be "open" when power is applied, "closed" otherwise, by simply adding 50 to the actual discrete input number, i.e.
.
.
51
52
.
.
2
0
1
Discrete input Meaning number
.
Point not configured
First discrete input, closed when power applied
.
Second discrete input, closed when power applied
.
.
First discrete input, closed when no power applied
Second discrete input, closed when no power applied
Setup _________________________________________________________________ 3 - 27
DanLoad 6000 (v6.00) __________________________________________________________
Discrete inputs numbers 51 and above are called inverted discrete inputs. The DanLoad 6000 validates inverted discrete inputs based on the actual number of discrete inputs, e.g. if there are 10 discrete inputs (two AC I/O boards and a DC I/O board), discrete inputs 0 thru 10 and 51 through
60 can be configured.
The configuration summary display ("ALT"+"0" in program mode) and the I/O diagnostic use only
real discrete inputs, not inverted state discrete inputs.
In Setup, inverted discrete inputs can be configured for the following:
- Safety circuit inputs
- Recipe selection inputs
- Component block valve inputs
- Auto/manual change-over
- Primary alarm reset switch
- Flow control valve stem switch inputs
- Flow control valve close inputs
- Meter flow inputs
- Additive selection inputs
- Swing 1 and swing 2 inputs
- End input
It is not be meaningful to configure inverted discrete inputs for the following:
- Additive feedback/meter inputs
Logical Signal Processing
The DanLoad 6000 implements logical signal handling techniques at the process signal interface level by allowing any process input or output signal to be connected to any physical input or output channel of the same type, such as RTD, status input, or control output. This is accomplished by assigning each physical input and output channel to an internal logical channel (function) during the setup procedure via the program codes. This design provides flexibility for the user by allowing one common physical configuration of the DanLoad 6000 to be adaptable to most applications. In addition, the spare parts stocking requirements are greatly reduced so that only a minimal number of different types of electronic signal input / output boards are required.
The actual links (assignments) between physical input and output channels 76 logical inputs and outputs 76 internal logical processing of these channels
3 - 28 _________________________________________________________________ Setup
_________________________________________________________ DanLoad 6000 (v6.00)
#
#
#
#
#
# are performed automatically during the initial setup of the DanLoad 6000. These assignments can be manually changed later if required. The current physical channel to logical channel assignments can be viewed at any time. All physical input / output channel to logical channel assignments are defined in the following program code groups. Appendix A contains worksheets that identify each point.
Meter parameters, program codes 050 to 061
I/O parameters, program codes 280 to 360
Recipe I/O parameters, program codes 361 to 379
Component I/O parameters, program codes 400 to 425
Additive I/O parameters, program codes 380 to 399
Additive pumps / block valves, program codes 800 to 833
The channel assignments defined by these program codes are viewable while operating in Program
Mode. The rightward column of the program code display line contains a one or two digit number.
This number is the currently assigned logical channel number in the series of channel numbers corresponding to the type of channel.
Discrete status inputs and outputs are assigned to default logical channels during setup. During initial setup, carefully verify that all input and output point assignments match the actual wiring of your installation. See Appendix A for default channel assignments.
Press the EXIT (ALT+CLEAR) key to exit the input / output signal configuration display area and continue with the initial setup.
The display example above shows messages that indicate the initial setup procedure has never been executed on this DanLoad 6000. Enter the factory default passcode, 6000, with the numeric keys and then press the ENTER key.
The Set Date and Time display is shown next. This display provides the method the set the current date and time for the DanLoad 6000 internal calendar / clock. The date and time are maintained by an on-board battery on the main processor board and do not require external power.
Setup _________________________________________________________________ 3 - 29
DanLoad 6000 (v6.00) __________________________________________________________
Set Date and Time Display
Figure 3 - 8
The current date and time are displayed in the formats indicated in the Set Date and Time display.
The date format is always in the form (mm/dd/yy) during the initial setup. After the initial setup is complete, the date format can be change via program code 038 Date format, if desired. The date and time default during initial setup and before modification is: 01/01/93 00:00:ss [January 1,
1993, several seconds (ss) after midnight (00:00:00)]. The flashing underline cursor is displayed right of the Enter new date (mm/dd/yy): prompt line for entry of a different date than the current date. Use numeric keys 0 to 9 to enter all or part of a new date. If it is desired to leave the value for any component of the current date unchanged, press the ENTER key. The ENTER key must be pressed once after each component of the date is entered or to accept the current value in that component. After the date has been entered or accepted, the flashing underline cursor moves to the right of the Enter new time (hh:mm:ss) prompt. The time value is entered or accepted in a similar manner as the date entry. The EXIT (ALT+CLEAR) key may be used at any time to step to the next entry line.
The Set Date and Time display can be accessed at any time after the initial setup procedure is completed by selecting Set Date and Time from the Program Menu.
The display example above shows the gross and standard values of the flow meter accumulators.
The values may be zeros as indicated or some other values.
3 - 30 _________________________________________________________________ Setup
_________________________________________________________ DanLoad 6000 (v6.00)
The display example above shows the default selection No, which indicates that the application is single component loading. The default selection sets the number of flow meters, number of flow control valves, number of components to 1, and unit type to sequential with automatic control of the block valve.
If the application requires blending of two to four components, press the SELECT key to scroll the pick list to the Yes option. Press the ENTER or the 9 arrow key to select the next program code.
The Type of blender defaults to Seq.(auto). If another type of blending control is desired, press the
SELECT key to scroll the options list (options are described in Section 6 - 026 Unit type. Press the 9 arrow key to select the next program code.
If Type of blender is Seq.(auto) or Seq.(manual), the next prompt displayed is:
065 Number of components which defaults to 2
If Type of blender is In-line or Off-rack, the next prompt displayed is:
050 Number of meters which defaults to 2
Accept or change the default value as required.
Setup _________________________________________________________________ 3 - 31
DanLoad 6000 (v6.00) __________________________________________________________
Note
For the remaining description of the initial setup procedure, it is assumed that:
Is this unit a blender? selection remains the default option No
The following description covers one flow meter, one flow control valve, and one component. The procedure for defining multiple devices and components is similar except for the requirement to define additional program codes for the additional devices and components.
3 - 32 _________________________________________________________________ Setup
_________________________________________________________ DanLoad 6000 (v6.00)
The display example above shows program codes related to flow meter number 1. The No selection for blending has set the number of meters to 1, program code 050 indicated below is not displayed in the initial setup procedure:
050 Number of meters 1
051 Meter ID M1
Default string M1. The alpha-numeric data entry prompt is displayed on the bottom line to allow the user to change this string to any five characters.
052 Valve to be controlled 1
Default value is valve number 1. Assigns a flow control valve to control flow through this meter.
A flow control valve must be assigned to each meter to control the batch loading. More than one meter be assigned to the same flow control valve.
Note
If the DanLoad 6000 is configured as a Seq.(auto) or Seq.(manual) multi-component blender, components are defined at this time. If the DanLoad 6000 is configured as an In-line or Off-
rack blender, flow meters 2 through 4, as required, are defined at this time.
Setup _________________________________________________________________ 3 - 33
DanLoad 6000 (v6.00) __________________________________________________________
The display example above shows program codes related to component number 1. The No selection for blending has set the number of components to 1, program code 065 indicated below is not displayed in the initial setup procedure:
065 Number of components 1
066 Component ID Component #1
Default string Component #1. The alpha-numeric data entry prompt is displayed on the message line to allow the user to change this string to any sixteen characters.
067 Meter 1
Default value 1. This number indicates that flow meter 1 is assigned to measure this component.
Only one flow meter, meter 1, is defined at this time so 1 is the only valid assignment. However, this assignment can be from 1 to 4 depending on the number of flow meters defined in the installation. (This program code defines the relation between components (products) and flow meters.)
068 Mass adjustment 0.000000
Default selection 0.000000. This program code sets the “mass computation adjustment” factor (1), such that: Mass = Std volume x (Density - Buoyancy x 1). While the std volume is typically similar in magnitude to the gross volume, i.e. a similar number of units, the mass may be substantially different from both.
Note
If the DanLoad 6000 is configured as a Seq.(auto) or Seq.(manual) multi-component blender, additional components are defined at this time.
3 - 34 _________________________________________________________________ Setup
_________________________________________________________ DanLoad 6000 (v6.00)
The display example above shows global program codes related to the delivery method used to deliver all defined components. The default delivery program codes should be verified or changed as required to match the requirements of the installation.
078 Maximum preset qty 3000
Default value 3000. The entry sets the upper quantity limit, for any batch delivery, that can be entered by the user / operator during a loading operation setup. The value is typically set to the quantity of the largest compartment to be loaded in any authorized tanker vehicle. Operating procedures may require loading of a quantity in excess of this number by loading more than one batch to one compartment.
079 Minimum preset qty 50
Default value 50. The entry defines the lower quantity limit, for any batch delivery, that can be entered by the user / operator during a loading operation setup. This quantity is referred to as the
flushing quantity at some installations. Refer to Section 6.8 for details on the special value zero (0) operation.
080 Preset/delivery type Gross
Default selection Gross. This selection indicates that the gross quantity calculation is used for delivery control. The flow control valve always controls ramp up to high flow rate based on gross delivered quantity. The flow control valve controls ramp down to the low flow rate and terminates delivery based on the quantity type selection in this field.
Setup _________________________________________________________________ 3 - 35
DanLoad 6000 (v6.00) __________________________________________________________
081 Delivery display type Gross
Default selection Gross. This selection indicates that the Loaded, Remaining, and Transaction values are displayed in gross quantity.
082 Stop key action Low flow
Default selection Low flow. This selection indicates the action to take after the STOP key is pressed during a batch delivery. The flow rate is reduced until the low flow rate is achieved and then the load is terminated by commanding the flow control valve to close.
083 Fall back qty 1000
Default value 1000. This value is the quantity that flows at a fall back flow rate before the DanLoad
6000 attempts to ramp up to the next higher flow rate.
3 - 36 _________________________________________________________________ Setup
_________________________________________________________ DanLoad 6000 (v6.00)
The display example above shows program codes related to the delivery method used to deliver the component number 1 only. These default delivery program codes should be verified or changed as required depending on the design of the installation.
084 Low flow start qty 50
Default value 50. This value indicates the quantity units that must be loaded at the low flow rate before issuing the high flow command to the flow control valve. (Sequential unit type only.)
085 Low flow restart qty 20
Default value 20. This value indicates the quantity units that must be loaded at the low flow rate before issuing the high flow command to the flow control valve. If the quantity specified by program code 084 Low flow start quantity has been delivered, this quantity is used after restart of a batch delivery that has been temporarily suspended for any reason. (Sequential unit type only.)
086 Low flow stop qty 50
Default value 50. This value indicates the quantity units that must be loaded at the low flow rate before issuing the close command to the flow control valve at the end of a batch delivery operation.
Setup _________________________________________________________________ 3 - 37
DanLoad 6000 (v6.00) __________________________________________________________
087 Line pack delay (s) 2
Default value 2. This value indicates that the pump run relay output is energized two seconds before the command is issued to open the flow control valve to low flow rate setting.
088 Pump stop delay (s) 30
Default value 30. This value indicates that the command to close the flow control valve is issued and 30 seconds later the pump run relay output is de-energized.
089 Block valve delay (s) 0
Default value 0. This value indicates that the control output to open the component block valve is issued and 0 seconds later (immediately) the command to open the flow control valve to low flow rate is issued. The block valve control output is opened (block valve closed) at the termination of the batch delivery.
Note
If the DanLoad 6000 is configured as a multi-component blender, additional components are defined at this time.
3 - 38 _________________________________________________________________ Setup
_________________________________________________________ DanLoad 6000 (v6.00)
The display example above shows global program codes related to the method used to adjust flow control valves, additive pump control, and blending.
108 Ramp clicks 30
Default value 30. This value is the number of times that the DanLoad 6000 attempts to increase the flow rate to a higher flow rate without success, before ceasing attempts and maintaining the fall back flow rate. Click refers to the jog output to the valve control solenoids.
109 Maintenance clicks 30
Default value 30. This value is the number of times that the DanLoad 6000 attempts to maintain the current normal flow rate without success, before ceasing attempts and falling back to the next lower flow rate. Click refers to the jog output to the valve control solenoids.
110 Additive pump stop (s) 10
Default value 10. This value is the number of seconds between the end of the load operation and deenergizing the additive pump control circuits.
111 Primary component 1
Default value 1. This value sets the number of the component to use for calculation of blend ratios and for clean line flushing. (Only applicable when program code 722 Blend error method set to
Grspctsmpl or Stdpctsmpl .)
Setup _________________________________________________________________ 3 - 39
DanLoad 6000 (v6.00) __________________________________________________________
The display example above shows global program codes related to the method used to handle meter factors for all components / flow meters.
169 Number of factors/component 2
Default value 2. This value indicates that two meter factors for each component at two different flow rates (low flow start/stop and high flow) will be defined. Up to four flow rates for each component can be defined.
170 Meter factor method Fixed
Default selection Fixed. This selection indicates that the exact meter factors are used and no mathematical interpolation of the meter factor values between associated flow rate points will be performed.
3 - 40 _________________________________________________________________ Setup
_________________________________________________________ DanLoad 6000 (v6.00)
The display example above shows program codes related to component number 1 only. The
DanLoad 6000 maintains the fixed relationship between each defined component and each flow meter so that high flow measurement accuracy can be maintained when multiple components are delivered through one flow meter.
Note
The values of program code 171 / 182 / 193 / 204 Nominal K-factor have great affect on control of the quantity of product delivered and flow measurement accuracy. These program code values must be set properly before any loading operation is performed.
171 Nominal K-factor 23.0
Default value 23.0. This value indicates the K-factor (system factor) for the flow meter. [NOTE:
The initial K-factor should be the pulses per quantity unit obtained from the flow meter identification plate or from the manufacturer. This number should be mathematically rounded to one decimal place (nn.n), if necessary].
172 Master meter factor 1.0000
Default value 1.0000. This value is the base meter factor value used for comparison with all system meter factor entries. Program code [175 / 177 / 179 / 181] [186 / 188 / 190 / 192] [197 / 199 / 201
/ 203] [208 / 210 / 212 / 214] Comp p meter factor f meter factors are compared to the program code
172 / 183 / 194 / 205 Master meter factor for the component and are considered invalid if they deviate more than +/- the percentage value of program code 215 Master MF %. In this example, assuming that program code 215 Master MF % is the default value of 2.00, acceptable meter factors must be within the range of 0.9800 to 1.0200 (NOTE: The master meter factor is calculated by the
171 Nominal K-factor divided by the actual K-factor and mathematically rounded to four decimal places.)
173 Stop rate 120
Default value is 120. This program code defines the flow rate at which a component is delivered during the component’s configured low flow stop quantity at the end of an in-line batch. The overall flow rate of the blend at the end of a batch is the sum of the stop rates of any flowing components.
Setup _________________________________________________________________ 3 - 41
DanLoad 6000 (v6.00) __________________________________________________________
The display example above shows program codes related to component 1 and meter factor 1 (low flow rate) only.
174 Comp 1 flow rate 1 200
Default value 200. This value is the calibration flow rate for meter factor 1 and is also the low flow start and stop flow rate for sequential unit type. The flow rate is in quantity units per minute (such as gallons per minute). The engineering units are dependent on the value of program code 171
Nominal K-factor which determines the quantity unit accumulation units and flow rate units for the flow meter.
Example: If quantity units are gallons, engineering units for this program code are gallons per minute.
175 Comp 1 meter factor 1 1.0000
Default value 1.0000. This value is the meter factor for flow rate 1 program code 174 Comp 1 flow
rate 1. (NOTE: The meter factor is calculated by the program code 171 Nominal K-factor divided by the actual K-factor and mathematically rounded to four decimal places.)
3 - 42 _________________________________________________________________ Setup
_________________________________________________________ DanLoad 6000 (v6.00)
The display example above shows program codes related to component 1 and meter factor 2 (which is the high flow rate for sequential unit type with the number of factors set to 2).
176 Comp 1 flow rate 2 500
Default value 500. This value is the flow rate for meter factor 2 in quantity units per minute (such as gallons per minute). The engineering units are dependent on the value of program code 171
Nominal K-factor which determines the quantity unit accumulation units and flow rate units for the flow meter. Example: If quantity units are gallons, engineering units for this program code are gallons per minute.
177 Comp 1 meter factor 2 1.0000
Default value 1.0000. This value is the meter factor for flow rare 2. (NOTE: The initial meter factor should be 1.0000 until an actual meter factor can be determined from a meter proof. The initial meter factor is calculated by program code 171 Nominal K-factor divided by the actual Kfactor and mathematically rounded to four decimal places.)
Note
A third and fourth flow rate for component 1 can be defined at this time if desired. If the component's meter will be proved at more than two flow rates, additional flow rates / meter factors can be defined at this time.
Setup _________________________________________________________________ 3 - 43
DanLoad 6000 (v6.00) __________________________________________________________
The display example above shows global program codes that set the limits for validation of manually entered meter factors.
215 Master MF % 2.00
Default value 2.00. This value is the set point for verification of individual component meter factors with respect to the Master meter factor for the component. Program codes for master meter factors and components are indicated in the table below.
Components 6
Master Meter Factors 6
Comp x meter factor 1
Comp x meter factor 2
Comp x meter factor 3
Comp x meter factor 4
1 2 3 4
172 183 194 205
175 186 197 208
177 188 199 210
179 190 201 212
181 192 203 214
3 - 44 _________________________________________________________________ Setup
_________________________________________________________ DanLoad 6000 (v6.00)
216 Adjacent MF % 0.25
Default value 0.25. This value is the set point for verification of individual component meter factors with respect to adjacent meter factors for the component. Program codes for master meter factors and adjacent meter factors are indicated in the table below. Entering 0.00 disables the validation.
Master Meter Factors 6
Adjacent Meter Factors 9
Comp x meter factor 1
9
8
Comp x meter factor 2
9
8
Comp x meter factor 3
9
8
Comp x meter factor 4
Components
1 2 3 4
172 183 194 205
175 186 197 208
177 188 199 210
179 190 201 212
181 192 203 214
217 Passcode per transaction
Not implemented.
No
218 Product units mnemonic Gal
Input a product units name (up to six characters) for display on the loading screen and printing on data logs. This allows the description to be in any language or local abbreviation.
219 Use restart qty No
Select either “No” or “Yes”. If “No” is selected, start up each component by loading its low flow start quantity at its low flow rate. If “Yes” is selected, start up the first component by loading its low flow start quantity at its low flow rate. Start up further components by loading their low flow restart quantities at their low flow rates.
Setup _________________________________________________________________ 3 - 45
DanLoad 6000 (v6.00) __________________________________________________________
The display example above shows a global program code that sets the storage time for secondary alarm conditions.
220 Secondary alarm reset (s) 300
Default value 300. This value indicates that active alarms designated as Secondary alarms will be automatically cleared (reset) after 300 seconds has elapsed.
The time limit allows time for the operator to correct a condition that causes a secondary alarm to occur during loading. The secondary alarm condition terminated the batch delivery. However, if the cause of the secondary alarm is cleared within the time specified by program code 220
Secondary alarm reset (s), the product delivery can be restarted. If the cause of the alarm is not cleared within the time specified by program code 220 Secondary alarm reset (s), the batch delivery is ended and a new batch must be defined before delivery can resume.
3 - 46 _________________________________________________________________ Setup
_________________________________________________________ DanLoad 6000 (v6.00)
The response to each alarm is controlled by the setting of the Alarm Action corresponding to that alarm. The four possible alarm actions are described below. The alarm actions for several alarms are limited to less than four selections. The Alarm action for several alarms is pre-determined and cannot be changed.
Alarm Action
Primary
Secondary
Info
Off
Description
If a delivery is in progress, the flow control valve is shut and the delivery is suspended. Delivery cannot resume until the alarm is cleared.
RED (lower) LED on operator panel is steady ON
Either or both alarm discrete outputs, program codes 287
Alarm output 1 and 379 Alarm output 2 is maintained closed (if defined and enabled by the corresponding mask).
Alarm data is stored in Alarm Storage Memory.
If a delivery is in progress, the flow control valve is shut and the delivery is suspended. Delivery cannot resume until the alarm is cleared or the Secondary alarm reset time has elapsed.
RED (lower) LED on operator panel is pulsed ON / OFF
Either or both alarm discrete outputs, program codes 287
Alarm output 1 and 379 Alarm output 2 is pulsed (if defined and enabled by the corresponding mask).
Reset
Keypad in Program Mode.
Alarm reset discrete input, program code 344 Primary alarm reset (if defined).
Terminal automation system.
Correct cause of alarm
Automatically reset after time value in program code 220 Secondary alarm
reset (s) has elapsed.
Alarm data is stored in Alarm Storage Memory.
The alarm can be reset by correcting the cause, e.g.
reconnecting a safety circuit, in which case the batch can be restarted if the remaining quantity is not less than the minimum preset quantity. The alarm is reset automatically at the end of a configurable time period (program code
220) , in which case the batch can be restarted (“Press
START when ready of STOP to cancel”) if the remaining quantity is not less than the minimum preset quantity.
An event message is displayed on the message line of the display panel for ten seconds or special processing is performed. (Example of special processing is issuing a temperature failure alarm.)
Alarm data is stored in Alarm Storage Memory.
Disable monitoring of this alarm.
<not applicable>
<not applicable>
Alarm Action Summary
Figure 3 - 9
Setup _________________________________________________________________ 3 - 47
DanLoad 6000 (v6.00) __________________________________________________________
The display example above shows program codes which define the global method of processing low and high flow rate conditions for any defined flow meter.
221 Low flow alarm action Primary
Default selection Primary. This selection indicates that if the Low flow alarm becomes active, the current delivery operation will be suspended.
222 Minimum flow rate 100
Default value 100. This value is the minimum flow rate (quantity units per time unit) allowed for the time period indicated by program code 223 Low flow time (s).
223 Low flow time (s) 10
Default value 10. This value is the elapsed time allowed for the flow rate to be continuously below the minimum flow rate specified by program code 222 Minimum flow rate before the alarm is triggered.
224 High flow alarm action Primary
Default selection Primary. This selection indicates that if the High flow alarm becomes active, the current delivery operation will be suspended.
3 - 48 _________________________________________________________________ Setup
_________________________________________________________ DanLoad 6000 (v6.00)
225 Maximum flow rate 660
Default value 660. This value is the maximum flow rate (quantity units per time unit) allowed for the time period indicated by program code 226 High flow time (s). This flow rate setting should be set above and close to the normally expected high flow rate. This setting allows rapid detection of a loss of control of the flow control valve condition.
226 High flow time (s) 10
Default value 10. This value is the elapsed time allowed for the flow rate to be continuously below the minimum flow rate specified by program code 225 Maximum flow rate before the alarm is triggered.
Setup _________________________________________________________________ 3 - 49
DanLoad 6000 (v6.00) __________________________________________________________
The display example above shows program codes which define the method of processing several flow related error conditions.
227 Overrun limit qty 2.0
Default value 2.0. This value is the quantity units allowed to be delivered which exceed the preset quantity. The alarm can only occur after the DanLoad 6000 has attempted to stop the delivery in the normal manner. The alarm priority selection is permanently set to Primary. If the Overrun limit
quantity alarm becomes active, the delivery operation in progress will be suspended. (NOTE: It may be necessary to temporarily set this value to a significantly larger value while the first several batches are delivered at a new installation. This is required so that the DanLoad 6000 can calculate the final trip or closing quantity delivered. The DanLoad 6000 does not calculate the final trip quantity if the delivery is terminated by an alarm action.)
Warning
Use several small quantity batch deliveries to load a vessel after initial setup. This procedure permits verification of proper flow control valve operation and prevents overfilling the vessel.
228 Underflow alarm action Off
Default selection Off. This selection indicates the action taken if the delivered quantity is less than the value of program code 229 Underflow limit quantity. The Off selection disables the underflow alarm.
3 - 50 _________________________________________________________________ Setup
_________________________________________________________ DanLoad 6000 (v6.00)
229 Underflow limit qty 5.0
Default value 5.0. This value is the number of quantity units allowed for the delivered quantity to be less than the preset quantity at the end of a batch delivery operation.
230 No flow t-o alarm action Primary
Default selection Primary. This selection indicates that if the No flow alarm becomes active, the current delivery operation will be suspended.
231 No flow t-o (s) 5.0
Default value 5.0. This value is elapsed time allowed for not receiving any pulses from the flow meter when the system is in a component flowing configuration.
Example: The pump is running, the block valve is OPEN, and the flow control valve is OPEN and no pulses are detected.
232 Unauthorized flow qty 10.0
Default value 10.0. The quantity of unauthorized flow at which an unauthorized flow alarm occurs.
The DanLoad 6000 measures pulses continuously, not just when a batch is in progress. Zero disables the unauthorized flow alarm. If the unauthorized flow quantity is set to "something point 1", e.g. 0.1,
1.1 or 2.1, then a meter's unauthorized flow counter (the internal one that causes the alarm to be raised, not the running totalizer seen in the dynamic data display or by the automation system) is cleared whenever the meter is authorized for a batch; this prevents the "unauthorized flow alarm will eventually happen" problem. The default value is 10.0.
Setup _________________________________________________________________ 3 - 51
DanLoad 6000 (v6.00) __________________________________________________________
The display example above shows program codes related to the method of processing pulse security error conditions. These program codes are only applicable in installations that used IP-252 pulse security methods and only during batch deliveries. Reference program codes 233 and 234 in Section
6.13 of this manual and item below.
Note
Pulse security implementation is hardware and software dependent. The value of program code 233 Error limit (pulses) must be set to 0, to prevent triggering this alarm if the physical flow meter installation does not provide the required dual pulse train to the DanLoad 6000.
233 Error limit (pulses) 0
Default value 0. This value is the allowable accumulated error count due to comparison differences between dual pulse train inputs from one flow meter. The priority selection is internally set to
Primary. If an Error limit alarm becomes active, the current batch delivery operation will be stopped.
234 Reset count (pulses) 10000
Default value 10000. This value is used reset the accumulated pulse comparison error count from dual pulse train comparison to be reset to zero after 10000 errors have been accumulated during the current delivery operation.
Example: If program code 233 Error limit (pulses) is set to 10 and program code 234 Reset
count (pulses) is set to 1000, the DanLoad 6000 allows no more than 10 pulses errors for each accumulated 1000 input pulses.
3 - 52 _________________________________________________________________ Setup
_________________________________________________________ DanLoad 6000 (v6.00)
235 Data logging alarm action Info
This selection is used to specify the action taken when a data logging alarm (overwriting an alarm message in the alarm message storage memory) occurs.
236 Time-out ch. A (s) 10
This value specifies the allowable time between receiving messages from the terminal automation system before issuing a Comms failure channel A alarm. Zero disables the alarm.
237 Time-out ch. B (s) 10
This value specifies the allowable time between receiving messages from the terminal automation system before issuing a Comms failure channel B alarm. Zero disables the alarm.
Setup _________________________________________________________________ 3 - 53
DanLoad 6000 (v6.00) __________________________________________________________
Alarm parameters (cont'd)
238 Temp fail alarm action Primary
239 Minimum temperature -40.0
240 Maximum temperature 110.0
241 Density fail alarm action Primary
242 Minimum density/gravity 0.0000
243 Maximum density/gravity 0.0000
The display example above shows program codes related to the method of RTD temperature input signal and density input signal error conditions.
238 Temp fail alarm action Primary
Default selection Primary. This selection indicates that the current delivery operation will be suspended if the process temperature input is less than the value of program code 239 Minimum
temperature or greater than the value of program code 240 Maximum temperature. A Primary alarm must be manually reset or specifically reset from a terminal automation system. The Primary setting detects temperature input failures. The backup temperature specified by program code 434 / 437 /
440 / 443 Comp x backup temp is not used in the Primary mode.
239 Minimum temperature -40.0
Default value -40.0. This value is lower limit allowed for a process temperature input before a Temp
fail alarm is issued. (Note: -40 degrees Celsius is the lowest temperature that can be measured by a standard RTD input.)
240 Maximum temperature 110.0
Default value 110.0. This value is upper limit allowed for a process temperature input before a Temp
fail alarm is issued. (Note: +110 degrees Celsius is the highest temperature that can be measured by a standard RTD input.)
3 - 54 _________________________________________________________________ Setup
_________________________________________________________ DanLoad 6000 (v6.00)
241 Density fail alarm action Primary
Default selection Primary. This selection indicates that the current delivery operation will be suspended if the process density/gravity input is less than the value of program code 242 Minimum
density/gravity or greater than the value of program code 243 Maximum density/gravity. A Primary alarm must be manually reset or specifically reset from a terminal automation system. The Primary setting detects density/gravity input failures. The backup density/gravity specified by program code
457 / 459 / 461 / 463 Comp x backup density/gravity is not used in the Primary mode.
242 Minimum density/gravity 0.0000
This value is lower limit allowed for a process density input before a Density fail alarm is triggered.
243 Maximum density/gravity 0.0000
This value is upper limit allowed for a process density input before a Density fail alarm is triggered.
Setup _________________________________________________________________ 3 - 55
DanLoad 6000 (v6.00) __________________________________________________________
The display example above shows program codes related to the method of processing the indicated error conditions.
244 Minimum pressure 0.0
This value is the low pressure set point used for validation of pressure input signals.
245 Maximum pressure 0.0
This value is the high pressure set point used for validation of pressure input signals.
246 Additive error limit 3
This value sets the error count limit for triggering an Additive error limit alarm. (See Section 3.9 for additional information.)
247 Additive feedback count 0
The expected number of feedback pulses per additive ratio cycle for the “Mech” additive injection method, e.g. 1 for Titan PAC-3 “confirmation pulse”, 2 for Hyrolec injector. The number of seconds within which the additive feedback input must go on and off again after the additive ratio output has been energized for the “Handshake” additive injection method, e.g. 5 (per Mapco).
248 Block valve time (s) 10
This value sets the time allowed for a component block valve to close after the block valve control output has been deenergized at the end of a loading operation or when a loading operation is temporarily stopped.
3 - 56 _________________________________________________________________ Setup
_________________________________________________________ DanLoad 6000 (v6.00)
The display example above shows program codes related to the method of processing the indicated error conditions.
249 Circuit 1 alarm action Secondary
This selection specifies the action to be taken if safety circuit 1 is open during a batch.
250 #1 Ground detector open
This alphanumeric entry is the configurable message that is displayed when safety circuit 1 is open during a batch.
251 Circuit 2 alarm action Primary
This selection specifies the action to be taken if safety circuit 2 is open during a batch.
252 #2 Overspill detector open
This alphanumeric entry is the configurable message that is displayed when safety circuit 2 is open during a batch.
Setup _________________________________________________________________ 3 - 57
DanLoad 6000 (v6.00) __________________________________________________________
The display example above shows program codes related to the method of processing the indicated error conditions. Note that safety circuits 3 and 4 alarms have alternate uses as the “end” and “recipe selection” alarms respectively.
253 Circuit 3 alarm action Secondary
This selection specifies the action to be taken if safety circuit 3 is open during a batch.
254 #3 Permissive power failure
This alphanumeric entry is the configurable message that is displayed when safety circuit 3 is open during a batch.
255 Circuit 4 alarm action Secondary
This selection specifies the action to be taken if safety circuit 4 is open during a batch.
256 #4 Additive injection failure
This alphanumeric entry is the configurable message that is displayed when safety circuit 4 is open during a batch.
3 - 58 _________________________________________________________________ Setup
_________________________________________________________ DanLoad 6000 (v6.00)
The display example above shows program codes related to the method of processing the indicated error conditions.
257 Circuit 5 alarm action Secondary
This selection specifies the action to be taken if safety circuit 5 is open during a batch.
258 #1 Arm down side 1
This alphanumeric entry is the configurable message that is displayed when safety circuit 5 is open during a batch.
259 Circuit 6 alarm action Secondary
This selection specifies the action to be taken if safety circuit 6 is open during a batch.
260 #2 Arm down side 2
This alphanumeric entry is the configurable message that is displayed when safety circuit 6 is open during a batch.
Setup _________________________________________________________________ 3 - 59
DanLoad 6000 (v6.00) __________________________________________________________
The display example above shows program codes related to the method of processing the indicated error conditions.
261 Circuit 7 alarm action Secondary
This selection specifies the action to be taken if safety circuit 7 is open during a batch.
262 #7 Walkway down side 1
This alphanumeric entry is the configurable message that is displayed when safety circuit 7 is open during a batch.
263 Circuit 8 alarm action Secondary
This selection specifies the action to be taken if safety circuit 8 is open during a batch.
264 #8 Walkway down side 2
This alphanumeric entry is the configurable message that is displayed when safety circuit 8 is open during a batch.
3 - 60 _________________________________________________________________ Setup
_________________________________________________________ DanLoad 6000 (v6.00)
The display example above shows program codes related to the method of processing the indicated error conditions.
265 Circuit 5 type 1
This selection limits checking for an open safety circuit 5.
266 Circuit 6 type 2
This selection limits checking for an open safety circuit 6.
267 Circuit 7 type 1
This selection limits checking for an open safety circuit 7.
268 Circuit 8 type 2
This selection limits checking for an open safety circuit 8.
269 Alarm o/p 1 mask 8388607
A one in the bit corresponding to the alarm type means that alarms of that type should control the alarm output according to the alarm action. The default value is 8388607 for all 23 alarm types.
270 Alarm o/p 2 mask 0
A one in the bit corresponding to the alarm type means that alarms of that type should control the alarm output according to the alarm action. The default value is 0, i.e. no alarm types.
Setup _________________________________________________________________ 3 - 61
DanLoad 6000 (v6.00) __________________________________________________________
The following table indicates the scope of the values of program codes 265 to 268.
1
2
Type
0
Program Code 265 to 268 Circuit x type
Description
Check Safety circuit x while a batch is in progress
Check Safety circuit x while a batch is in progress ONLY at side 1 *
Check Safety circuit x while a batch is in progress ONLY at side 2 *
* Determined by the state of the swing arm switch inputs to the CPU board and the configured side-detect method (program code 312).
3 - 62 _________________________________________________________________ Setup
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The display example above shows program codes related to the method of processing the indicated error conditions.
271 Unauth additive flow vol 0.0000
This selection sets the volume of unauthorized additive flow at which an additive X failure alarm is raised for the “Meter” and “Control” injection methods.
272 Prod/add -% 0
This selection sets the percentage of the ideal quantity of additive at any point in a batch below which an additive failure alarm is raised.
273 Prod/add +% 0
This selection sets the percentage of the ideal quantity of additive at any point in a batch above which an additive failure alarm is raised.
Setup _________________________________________________________________ 3 - 63
DanLoad 6000 (v6.00) __________________________________________________________
The display example above shows program codes related to the method of processing the indicated error conditions.
276 Ramp down alarm action Primary
A ramp down alarm is raised when the alarm is active and the DanLoad 6000 is unable to reduce the flow rate to a lower, desired flow rate within the time specified. This selection determines if the ramp down alarm action is enabled (Primary) or disabled (Off).
277 Ramp down time (s) 4
This selection sets the time in seconds allowed for ramp down before the ramp down alarm is raised.
278 Additive per 1000 error limit 1
This selection sets the number of ratio quantities worth of additive by which the actual quantity of additive can differ from the ideal quantity of additive at any point in a batch before an additive failure alarm is raised.
279 End time (s)
This selection sets the end time in seconds.
180
3 - 64 _________________________________________________________________ Setup
_________________________________________________________ DanLoad 6000 (v6.00)
The display examples above show program codes related to the method defining recipes that control the delivery of components in blending operations. Validation of recipe component percentages is performed when a recipe is selected and when a preset quantity is entered. Component percentages are validated as follows.
Setup _________________________________________________________________ 3 - 65
DanLoad 6000 (v6.00) __________________________________________________________
# Sequential blending
The sum of the percentages referenced by program code 486 Sequence to load program code must equal 100.
Example: Sequential Blending
(065 Number of components = 3)
Program Code
481 Name
482 Comp 1 %
483 Comp 2 %
484 Comp 3 %
485 Comp 4 % or ratio qty
486 Sequence or low proportion
Valid
70
20
10
0
312
Invalid
70
30
0
0
320
# In-line blending
The sum of the percentages of components specified by program code 065 Number of
components must equal 100.
Example: In-line Blending
(065 Number of components = 3)
Program Code
481 Name
482 Comp 1 %
483 Comp 2 %
484 Comp 3 %
485 Comp 4 % or ratio qty
486 Sequence or low proportion
Valid
70
20
10
0
Invalid
70
20
0
10
Note: For an in-line blender, the “sequence or low proportion” should normally be filled with zero’s unless one or more low proportion components are required.
3 - 66 _________________________________________________________________ Setup
_________________________________________________________ DanLoad 6000 (v6.00)
480 Number of recipes 1
Default value 1. This value causes one set of recipe definition program codes to be available for configuration. This value can be printed on Transaction Reports.
481 Recipe name Recipe #1
Default string Recipe #1. The alpha-numeric data entry prompt is displayed on the message line to allow the user to change this string to any sixteen characters. The name of the currently selected recipe is shown in the upper left area of the display while operating in the Loading Mode. This value can be printed on Transaction Reports.
482 Comp 1 % 100.00
Default value 100. This value sets the recipe to define a single component (component #1) for delivery. This value was set automatically because of the initial selection of No blending (one flow meter, one flow control valve, and one component)
483 Comp 2 % 0.00
Default value 0. This value indicates that this component is not loaded by this recipe.
484 Comp 3 % 0.00
Default value 0. This value indicates that this component is not loaded by this recipe.
485 Comp 4 % or ratio qty 0.00
Default value 0. This value indicates that this component is not loaded by this recipe.
Setup _________________________________________________________________ 3 - 67
DanLoad 6000 (v6.00) __________________________________________________________
486 Sequence or low proportion 1
Default value 1. This value indicates that only component 1 is delivered when this recipe is selected.
If more than one component is defined, the other components can be specified in the sequence to load by indicating the component number at the desired sequence place in this program code.
For sequential blending:
Indicates the sequence to load the preconfigured components.
Example: Program code 486 Sequence to load set to 142 indicates that during sequential loading, component 1 is loaded first, component 4 is loaded second, component 2 is loaded third, then the complete batch is terminated.
For in-line blending:
Sequence positions xxxx correspond to components 1, 2, 3, and 4 respectively. For each preconfigured component, a zero in program code 486 Sequence to load indicates that the component is a high-proportion component. A one in program code 486 Sequence to load indicates that the component is a low-proportion component that is loaded during the high flow time of the batch.
Example: Program code 486 Sequence to load set to 010 indicates that this is a 3-component blender and during in-line blending, components 1 and 3 are high-proportion components and component 2 is a low-proportion component, i.e. delivered during the high flow part of the batch.
3 - 68 _________________________________________________________________ Setup
_________________________________________________________ DanLoad 6000 (v6.00)
The display example above shows that the initial setup procedure is finished. Press the EXIT
(ALT+CLEAR) key to continue. The DanLoad 6000 is now in the Loading Mode. Additional program codes, such as those controlling additive injection, that were not covered in the initial setup procedure should be reviewed and modified if required at this time.
Assuming that only one recipe was defined, the loading display indicated below is displayed.
Loaded 0
+)))),
* *
* *
* *
* *
.))))-
The Loading Display example above is the normal display that is presented to the user / operator during presetting batch quantities and batch deliveries. The user / operator is able to define the delivery quantity and monitor the delivery operation via this display and the keypad. Batch delivery operations are described in Section 4 - Operation.
Setup _________________________________________________________________ 3 - 69
DanLoad 6000 (v6.00) __________________________________________________________
3.6
Product Delivery and Blending
From two to four products can be blended into a composite stream and delivered. The Delivery -
Blending table located in Appendix A contains an overview of all physical input and output signals and internal control program codes that are related to product delivery / blending equipment and procedures.
The basic configuration of the type of blending to be performed is controlled by the entry in program code 026 Unit type. The configurable blender types are described below.
3.6.1
Sequential Blending
Sequential blending is the loading of one product at one time through one flow meter and one flow control valve. The blend ratio is correct only after all components of the blend have been loaded.
A DanLoad 6000 that controls loading of one product is configured as a sequential blender, although no component blending action is performed. Block valve control for each component can be controlled either automatically or manually as described below.
# Seq.(auto)
The DanLoad 6000 controls the opening and closing of the component block valves automatically.
# Seq.(manual)
The DanLoad 6000 prompts the operator to open and close the component block valves at the start and end of each batch loading.
Prompt:
Prompt:
Open block valve - press ENTER after a batch delivery has been configured and the START key is pressed
Close block valve - pres ENTER after delivery of the batch and after the flow control valve has been closed
The response to either prompt is to press the ENTER key to execute the open or close block valve operation.
3 - 70 _________________________________________________________________ Setup
_________________________________________________________ DanLoad 6000 (v6.00)
#
#
The loading method for sequential blending is described below.
# Preset the batch quantity (the total quantity of the components to be loaded) and press the
START key.
# Open the flow control valve to increase the flow rate of the first component to the low flow rate value and maintain the low flow rate for the specified low flow start quantity (program code 84 for component 1 and other components as required).
# Open the flow control valve to increase the flow rate of the component to the high (normal) flow rate value and maintain the flow rate during the component delivery.
# Close the flow control valve to decrease the flow rate of the component to the low flow rate value and deliver the specified quantity at the low flow shutdown rate.
After the low flow rate quantity has been delivered, shut the flow control valve.
If only one component was specified in the recipe, the batch delivery is complete at this time, if another component was specified in the recipe, this component is loaded in the same manner as specified by the steps listed above. The total batch quantity preset in step
1 remains the same. The sequence of component loading is repeated for each component specified by the recipe and in the sequence to load specified by the recipe. The sequence to load is program code 486 for recipe number 1.
3.6.2
In-Line Blending
In-line blending is the simultaneous blending and loading of two to four products. Each product has a dedicated flow meter and flow control valve. In-line blending can be either non-proportional or proportional as described below.
# In-line non-proportional
In-line non-proportional blending is accomplished by delivering the low-proportion quantity component(s) of the blend at their assigned high (normal) flow rate(s) during the first part of the delivery of the high-proportion component at its high (normal) flow rate. The blending control is set by program code 486 / ... / 660 Sequence to load for the active recipe. This method of delivery is implemented so that the flow meter for each component is operating near its maximum rated flow rate to assure maximum measurement accuracy for each component in the blend. After the low-proportion quantity component(s) have been delivered, the high-proportion quantity component continues delivery until the blend ratio is attained. The total blend ratio can be in error until the total preset quantity is delivered.
Setup _________________________________________________________________ 3 - 71
DanLoad 6000 (v6.00) __________________________________________________________
#
#
In-line proportional
(Note: In-line proportional blending can only be implemented in cases where proportion of each component in the blend is great enough to permit the component flow meter to operate above the minimum specified flow rate of the meter during the entire batch loading cycle.)
In-line proportional blending is accomplished by controlling the ratio between all components at all times during the delivery by controlling the individual flow rate of each component. The ratio of the delivered blend is correct at all times during the delivery.
Therefore, the delivery can be stopped at any time and the delivered blend will be within tolerance.
•
•
•
“Side” Stream Blending
"Side" stream blending is similar to in-line blending except one product component is delivered upstream to another product component. "Side" Stream blending is typically used to inject ethanol into gasoline. Ethanol is injected into the gasoline stream and the blend is measured by the custody transfer meter. The basic control/operation of side Stream Blending is described below:
Program code 023 – “Side” Stream Blending, allows to enable side stream blending.
Setting program code 024 - Sequential proportional, to “Yes” allows proportional blending of side stream component (ethanol) with primary component (gasoline).
( Note: This program code is applicable only when DanLoad 6000 is configured for sequential blending.)
Set up the Side Stream Meter Program codes 053/056/059/062. These program codes specify the meter number used as a Side Stream Meter. For example, assume that meter 1 is the primary premium blend stream meter used for loading Premium and measures the blend of Premium and Ethanol. Meter 2 is the primary regular blend stream meter used for loading Regular and measures the blend of Regular and
Ethanol. Meter 3 is the side stream meter for measuring the Ethanol component volume.
Program code 053, 056, 059, and 062 correspond respectively to preset meters 1, 2,
3, and 4 set in PC 051, 054, 057, and 060 . In the above example meter 1 (PC 051) measures the combined blend volume of both the Premium component and the
Ethanol component, and meter 2 (PC 054) measures the combined blend volume of both the Regular component and the Ethanol component, Meter 3 (PC 057) measures only the Ethanol volume.
As an example, the user sets program code 053 = 3, 056 = 3, and 059=0. This configuration indicates that the Ethanol measured by Meter 3 is passing through the
Premium meter 1 (053) and through the Regular meter 2 (056). Meter 3 (059) is not being used to measure a final delivered flow, however the volume being measured by meter 3 flows though meter 1 or meter 2.
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_________________________________________________________ DanLoad 6000 (v6.00)
•
•
•
•
Set up the Midgrade Primary blend Stream meter (if applicable) Program Code
063.This program code defines the meter number where the side stream (Ethanol stream) passes through in case of more than two product blending.
(Note: This program code is applicable only when DanLoad 6000 is configured for inline blending.
For example, meter 1 is for Premium, meter 2 is for Regular and meter 3 is for
Ethanol. Set program code value to 1 if the Premium meter (meter 1) is used to pass the Ethanol for Midgrade product (Blending of Premium, Regular and Ethanol).
The Block valve operation of “Side” stream sequential blending is not changed.
The block valve operation of “Side” stream in-line blending is changed as follows:
Assign an output (Program Code 400/402/404/406) to open a block valve to allow the side stream component (e.g. Ethanol) to blend with the wild stream component
(e.g. Gasoline). For two component blending (One component must be the side stream component) the block valve output will be "Closed" when the corresponding wild stream component is used.
(Note: Do not assign any output for the side stream component.)
Assign an input (Program code: 401/403/405/407) to monitor the status switch for the block valve defined in program code 400/402/404/406.
Setup _________________________________________________________________ 3 - 73
DanLoad 6000 (v6.00) __________________________________________________________
# Delivery Parameters
Define the pump / block valve / flow control valve timing relationship. The program codes indicated below set the timing for each component.
open start open close stop
BV PUMP FCV FCV BV PUMP
| | | | | |
| | | | | |
| | | | |
| |--------LPD-------| |---–PSD---|
|-----------BVD-------------| where:
BV -
FCV -
LPD -
BVD -
PSD block valve flow control valve
Define batch loading control program codes.
087 / 093 / 099 / 105 Line pack delay (s)
089 / 095 / 101 / 107 Block valve delay (s)
088 / 094 / 100 / 106 Pump stop delay (s)
Startup:
The line pack delay and block valve delay are relative to the opening of the flow control valve at the start of a loading operation. The diagram indicates the line pack delay time is shorter than block
valve delay time. Both of these delays are independent and only related to the opening of the flow control valve. Therefore, the delays may be set to open the block valve and start the pump simultaneously or to start the pump before opening the block valve. If 0 seconds delay is entered for the line pack delay and the block valve delay, the pump starts, the block valve opens, and the flow control valve opens simultaneously. The logic does not allow configuration for starting the pump or opening the block valve after the flow control valve is commanded OPEN.
Shutdown:
The flow control valve is shut to stop the flow. The block valve is automatically closed when no flow is detected. For a normally terminated delivery, the pump stop delay is from the time that no flow is detected until the pump output is de-energized.
Program code 248 Block valve time (s) in the Alarms group sets the time period to allow after sending a block valve CLOSE command (discrete output OPEN) before activating an Unable to
close block valve # alarm, if the block valve fails to respond to the CLOSE command. A zero indicates “redirect to recipe selection inputs” for recipes 1 through 6 and “not used” for recipes 7 and above.
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# Digital Valve Parameters Define operation of flow control valves.
This group of program codes define the characteristics for operation of digital flow control valves
(throttling valves) only. Fixed set point stem switch valves do not use these program codes.
However, two-stage valves with one or two stem switches do use the Solenoid 1 and Solenoid 2 control outputs to control the valve actuator. The control logic for digital flow control valves is shown in Figure 3 - 10. And the control and status logic for two-stage valves is shown in Figure
3 - 11 and Figure 3 - 12.
Digital Flow Control Valve Operation
Valve State
Closed Opening Static Open Closing
Device
Solenoid 1 (upstream) control output
Upstream pilot valve (cavity fill)
Off On
Open Closed
Solenoid 2 (downstream) control output
Off On
Downstream pilot valve (cavity drain) Closed Open
On
Closed
Off
Closed
Off
Open
Off
Closed
Digital Flow Control Valve
Figure 3 - 10
The incremental open / close state of a digital flow control valve, such as a Daniel model 1815 or
Dan-Flo valve, is controlled by two variable duration pulsed control outputs (Solenoid 1 and
Solenoid 2). A digital flow control valve has a sealed variable capacity chamber downstream of the movable plug. The upstream surface area and cavity surface area of the plug plus pressure exerted by a closing spring, closes the plug against the seat and stops all flow through the valve when the upstream process liquid is allowed to enter the cavity (through normally open Solenoid 1). This is the normal state of the valve with neither solenoid powered.
Setup _________________________________________________________________ 3 - 75
DanLoad 6000 (v6.00) __________________________________________________________
The valve is opened to the low flow set point by closing the upstream (cavity fill) pilot and opening the downstream (cavity drain) pilot. The DanLoad 6000 senses the flow rate from the meter pulse input and stops the valve from opening when the desired flow rate is attained. The valve open / close action is stopped at any position by closing the downstream (cavity drain) pilot and closing the upstream (cavity fill) pilot. Flow rate through the flow meter is adjusted dynamically. The valve is closed by closing the downstream (cavity drain) pilot and opening the upstream (cavity fill) pilot.
Warning
The Daniel model 1815 flow control valve has an needle valve located in the upstream pilot circuit that can be used to restrict the flow in this circuit and slow the valve opening speed. A corresponding needle valve located in the downstream pilot circuit can be used to restrict flow in that circuit and slow the valve closing speed. These two needle valves are normally set fully open so that the DanLoad 6000 has maximum possible control of the valve. These needle valves should only be adjusted by persons familiar with the operation of these valves. Use caution when delivering a product after one or both of these needle valves have been adjusted.
Mis-adjustment of the needle valves can cause tank overfill and spillage or under delivery.
Two-Stage Flow Control Valve (without Stem-Switches) Operation
Device
Solenoid
1 control output
Solenoid
2 control output
Off
Closed
Off
Opening to
Low Flow
Start &
Low Flow
Start
On
Off
Opening to
Full
Open & Full
Open
On
On
Valve State
Closing to
Low Flow
Stop &
Low Flow
Stop
On
Off
Two-Stage Flow Control Valve (without Stem-Switches)
Figure 3 - 11
Closed
Off
Off
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_________________________________________________________ DanLoad 6000 (v6.00)
The Solenoid 1 and Solenoid 2 control outputs are used to control the open / close position of a flow control valve without stem switches. A flow control valve without stem switches does not control the flow rate based on rate of flow feedback from the flow meter. The flow rate at low flow start high flow (normal flow) and low flow stop is controlled by an external flow rate regulator. Control output Solenoid 1 is closed to open the valve. The valve opens to the low flow start position and the low flow start quantity is delivered at that rate. After the low flow start quantity has been delivered, control output Solenoid 2 is closed to open the flow control valve to the high (normal flow rate) position. When the remaining quantity equals the low flow stop quantity, control output
Solenoid 2 is opened to position the valve at the low flow stop flow rate. After the low flow stop rate is delivered, control output Solenoid 1 is opened and the flow control valve is fully shut. All flow through the valve ceases.
Two-Stage Flow Control Valve (with Stem-Switches) Operation
Output
Solenoid 1 control output
Solenoid 2 control output
Off
Off
Closed/
Closing
Valve State
Opening Static
Open
(“locked”)
On On
On Off
Two-Stage Flow Control Valve (with Stem-Switches)
Figure 3 - 11b
The normally closed stem switch (stem switch 1) is monitored during initial opening so that the valve can be locked at low flow start. The normally open stem switch (stem switch 2) is monitored while ramping down from high flow so that the valve can be locked at low flow stop.
Setup _________________________________________________________________ 3 - 77
DanLoad 6000 (v6.00) __________________________________________________________
3.7
PL
Temperature compensation and pressure compensation of the liquid quantity to the quantity at standard conditions can be used together or independently. One of several standards can be selected for temperature compensation. One of several standards can be selected for pressure compensation.
Each standard is applicable to a specific density range of hydrocarbon liquids. Each standard is applicable to a specific temperature or pressure range. Temperature compensation is commonly used when loading refined hydrocarbon liquids and crude oil, though in some cases it may be performed by a terminal automation system. Both temperature and pressure compensation are normally used when loading liquefied petroleum gas (LPG). Tables 3 - 1, 3- 2, and 3 - 3 contain information on the applicability of the various standards.
Note
Daniel Industries, Inc. and Daniel Measurement and Control Products (“Daniel”) shall not be held responsible or liable in any way for loss or damage, including, but not limited to, consequential damage, resulting from the use of volume correction tables or related mathematical relationships or for violation of any federal, state, or municipal laws, regulations, or practices of the United States or of any foreign country.
The DanLoad 6000 can also calculate mass from the quantity at standard condtions. See Section 3.8,
Mass Loading Using a Volumetric Flow Meter.
3 - 78 _________________________________________________________________ Setup
_________________________________________________________ DanLoad 6000 (v6.00)
PL
Off
Linear
API 6A
API 6B
API 6C
API 24A
API 24B
API 54A
API 54B
API 54C
IMP/PEMEX
Yes
Yes
Yes
Yes
Table 24 (Old) Yes
Table 54 (Old) Yes
Petrobras Yes
TP-16
China
Yes
Yes
API 6D
API 54D
4311 1
CAN 54B
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Off
Yes
Yes
Yes
Notes:
Const
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
No 2
No 2
No 2
Yes
Yes
No 2
No 2
No 2
No 2
No 2
No 2
No 2
No 2
No 2
No 2
Yes
C Options
PL
API
11.2.1
API
11.2.2
Yes
Yes
Yes
Yes
Yes
No 1
No 1
No 1
No 1
No 1
No 1,2
No 1,2
No 1,2
No 1,2
Yes
No 2
Yes 3
Yes
Yes
No 1
No 1,2
Yes
No 1,2
PL together.
1 = The density ranges do not overlap.
2 = The density units are not the same for C and C .
TL PL
3 = The C option enables special processing for the C option.
Yes
Yes
Yes
No 2
No 2
Yes
Yes 3
No 2
Yes
No 2
Yes
No 2
Yes
API
11.2.1M
Yes
Yes
No 2
No 2
No 2
No 2
No 2
API
11.2.2M
Yes
Yes
No 1,2
No 1,2
No 1,2
No 1,2
No 1,2
No 1
No 1
No 1
No 1,2
No 2
Yes
No 1,2
No 2
Yes
No 1,2
No 1
No 2
No 1
Setup _________________________________________________________________ 3 - 79
DanLoad 6000 (v6.00) __________________________________________________________
Option kg/m3
C
T L
Table 24
Table 54
API 6A
API 24A
API 54A
API 6B
API 24B
API 54B
IMP/PEMEX
Linear
(User ")
C
P L
API 11.2.2
API 11.2.2M
API 11.2.1
API 11.2.1M
User F-factor
CAN 54B
Density Range Overlaps (Approximate) for CTL and CPL Options (Table 3 - 2)
Density Range
350 400 450 500 550 600 650 700 750 800 850 900 950 1000 1050 1100
TTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTT
0.500 to 1.100 kg/l (. 500 to 1100 kg/m3)
TTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTT
0 to 100 degrees API (6110 to 1.0760 (610 to 1075 kg/m3)
TTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTT
0.6110 to 1.0760 (610 to 1075 kg/m3)
TTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTT
610 to 1075 kg/m3
TTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTT
0 to 85 degrees API (653 to 1075 kg/m3)
TTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTT
0.6535 to 1.0760 (653 to 1075 kg/m3)
TTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTT
653 to 1075 kg/m3
TTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTT
0.6495 to 1.0730 (. 649 to 1072 kg/m3)
TTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTT
Unlimited density
TTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTT
Notes:
1
2
TTT ...
Relative density 0.350 to 0.637 (density 349.7 to 636.4)
PPPPPPPPPPPPPPPPPPPPPPPPPPPPPP
350 to 636 kg/m3
PPPPPPPPPPPPPPPPPPPPPPPPPPPPPP
0 to 90 degrees API (638 to 1074 kg/m3)
PPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPP
638 to 1074 kg/m3
PPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPP
Unlimited density
PPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPP
653 TO 1075 kg/m3 T
TTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTT
3 - 80 _________________________________________________________________ Setup
_________________________________________________________ DanLoad 6000 (v6.00)
3
4
5
Program code 445 F-factor X 1000000000 is the component’s compressibility factor * 10 9 in quantity units per pressure unit. This entry is only used if program code 444 Pressure
option is set to Const, since the other CPL options calculate the F-factor based on the temperature and density.
Values of density and gravity are scaled dependent on the setting of program code 046. Set this carefully since it is also used for mass computation. The density/gravity scale follows.
046 Density/gravity scale Format
1
2 xxxx.x
xxx.xx
3
4 (default) xx.xxx
x.xxxx
Setup _________________________________________________________________ 3 - 81
DanLoad 6000 (v6.00) __________________________________________________________
API 6A
API 6B
Temp Range Density Input / Reference Temperature
API gravity
API gravity
Density Range
0 to 40 degrees API
40 to 50 degrees API
50 to 100 degrees API
0 to 40 degrees API
40 to 50 degrees API
50 to 85 degrees API
N/A API 6C None [inputs are "T and t (" at base temperature and batch temperature)]
API 24A
API 24B
API 54A
API 54B
API 54C N/A
Density kg/m3
Density kg/m3
None
0.8250 to 1.0760
0.7795 to 0.8250
0.6110 to 0.7795
0.8250 to 1.0760
0.7795 to 0.8250
0.6535 to 0.7795
610 to 778 kg/m3
778 to 824 kg/m3
824 to 1075 kg/m3
653 to 778 kg/m3
778 to 824 kg/m3
824 to 1075 kg/m3
IMP/PEMEX
Table 24 (Old)
Table 54 (Old)
Petrobras
TP-16
CAN 54B
Note:
Density kg/l
Density kg/m3
0.6495 to 1.0730
0.500 to 1.100 (full range).
0.500 to 1.100 kg/l (full range).
Any temperature and relative density.
0.8250 to 1.0760
0.7795 to 0.8250
0.6110 to 0.7795
653 to 778 kg/m3
778 to 824 kg/m3
824 to 1075 kg/m3
Density / gravity inputs are not validated by the DanLoad 6000. The table shows the valid density / gravity ranges for the temperature compensation selections.
3 - 82 _________________________________________________________________ Setup
_________________________________________________________ DanLoad 6000 (v6.00)
3.7.1
Temperature Correction to a Non-Standard Reference Temperature
Temperature correction to a non-standard reference temperature (using existing C tables) has been
TL implemented, in particular temperature correction to 86.0°F using API 6B per ESSO Thailand (and others in South East Asia) is possible.
C
TL
option
Off
Linear
API 6A
API 6B
API 6C
API 24A
API 24B
API 54A
API 54B
API 54C
IMP
Old 24
Old 54
P'Bras
TP-16
China
6D
54D
4311 1
NH3
CAN 54B
Standard ref.
temp.
N/A
N/A
60.0°F
60.0°F
N/A
60.0°F
60.0°F
15.0°C
15.0°C
N/A
20.0°C
60.0°F
15.0°C
20.0°C
60.0°C
20.0°C
60.0°F
15.0°C
60.0°F
60.0°F
15.0°C
Correction to nonstandard ref. temp.
No
No
Yes
Yes
No
Yes
Yes
Yes
Yes
No
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes and allows temperature correction to a non-standard reference temperature. A "No" in the right-hand
Setup _________________________________________________________________ 3 - 83
DanLoad 6000 (v6.00) __________________________________________________________ to one that has a standard reference temperature then the reference temperature (program code 430), which is used for all components, is automatically modified to the standard reference temperature
TL not have a standard reference temperature then the reference temperature is not modified. Thus, if reference temperature is required, it is necessary to configure each component's C option prior to
TL configuring the reference temperature (program code 430). (Note: The temperature units (program
When a C factor is computed for a C option that has a standard reference temperature, the
TL TL
DanLoad 6000 tests whether the configured reference temperature is equal to the standard reference
TL
TL
It should be noted that the reference temperature (program code 430) can be modified indirectly, i.e.
TL and measures protected by default.
3 - 84 _________________________________________________________________ Setup
_________________________________________________________ DanLoad 6000 (v6.00)
Note the following examples using test data:
Ref. temp.
60.0°F
60.0°F
86.0°F
API 6B, PC 427 = F
Observed temp.
Density or gravity
80.9°F
86.0°F
80.9°F
35.10
35.10
35.10
Ref. temp.
20.0°C
20.0°C
17.5°C
IMP, PC 427 = C
Observed temp.
Density or gravity
6.0°C
17.5°C
6.0°C
0.7210
0.7210
0.7210
0.9903
0.9879
1.0024
Ref. temp.
60.0°F
60.0°F
66.5°F
API 24A, PC 427 = F
Observed temp.
Density or gravity
56.5°F
66.5°F
56.5°F
0.8760
0.8760
0.8760
1.00160
0.99710
1.00451
Ref. temp.
15.0°C
15.0°C
20.0°C
API 54A, PC 427 = C
Observed temp.
Density or gravity
22.5°C
20.0°C
22.5°C
740.0
740.0
740.0
C factor
TL
0.9916
0.9944
0.9972
1.01743
1.00311
1.01428
Setup _________________________________________________________________ 3 - 85
DanLoad 6000 (v6.00) __________________________________________________________
3.8
Mass Loading Using a Mass Flow Meter
When the mass of product is required (for display, data logging or delivery control) there are two options; 1) use a mass meter, e.g. a Coriolis effect flow meter, which reports "pulses per unit mass" to the DanLoad 6000, or 2) use a volumetric flow meter, e.g. a turbine meter, which reports "pulses per unit gross volume" to the DanLoad 6000 and have the DanLoad 6000 compute the mass from the gross volume. Both options are possible with the DanLoad 6000. This section describes the first option.
The mass flow meter should be interfaced to the DanLoad 6000 via a transmitter (available from the mass flow meter's vendor) that converts the raw Coriolis frequency to a scaled pulse stream. The scaling is usually widely adjustable. The particular type of transmitter used determines the electrical signal interface; the DanLoad 6000's meter pulse board must be strapped appropriately. Refer to
Section 2.2.2 Input/Output Board Description and jumper settings or contact Daniel Customer
Service for proper strapping configuration. The transmitter reports pulses per unit mass to the
DanLoad 6000, i.e. you can think of the mass meter as having a K-factor defined as the number of pulses per unit of mass flow, e.g. 10 pulses per kilogram. (Some mass flow transmitters can report pulses per unit of volume, in which case it can be treated, by the DanLoad 6000, as a volumetric flow meter which is not discussed here.)
The K-factor (number of pulses per unit of mass flow, program code 171, 182, etc. per component) should be configured on the DanLoad 6000. If the meter's calibration adjustment is via the mass flow transmitter, all the meter factors on the DanLoad 6000 should typically be set to 1.0000. If the meter's calibration adjustment is via the DanLoad 6000, the meter factors on the DanLoad 6000 should be adjusted based on the observed error during proving runs until the required accuracy is achieved. (It is important to understand that the accuracy achieved depends on the mass flow meter's
repeatability.)
The configured K-factor and meter factor at each flow rate are applied to the input pulse stream in the same way as for gross volume:
Mass = (
E i=1
#factors (# pulses at rate i * meter factor for rate i)) / K-factor
Thus, the various gross and standard quantities displayed, printed and reported to an automation system are, in fact, mass. All batch, meter and component quantities on the DanLoad 6000, including flow rates, should be interpreted as being in units of mass as determined by the K-factor.
Configure the gross and standard product units mnemonics appropriately (program codes 217 and
218 respectively). When an operator enters a preset quantity and presses "START" the DanLoad
6000 delivers the requested number of mass units of product. The DanLoad 6000 cannot convert
from mass to volume. No temperature options (program code 432, etc. per component) or pressure pl cannot be meaningfully applied to mass. However, it is possible for
3 - 86 _________________________________________________________________ Setup
_________________________________________________________ DanLoad 6000 (v6.00) the DanLoad 6000 to sample (and calculate mass throughput weighted average values for) temperature (RTD), pressure (4-20 mA) and density (4-20 mA) inputs throughout a batch for display, printing and reporting to an automation system, by configuring the appropriate inputs (per meter), the sample quantity (program code 431) and the density option (program code 456, etc. per component). The DanLoad 6000 does not correct the input density to standard conditions. Density correction to standard conditions must be done externally, e.g. by a densitometer or the mass flow transmitter which can send the "live" value to the DanLoad 6000 via a 4-20 mA output.
3.9
Mass Loading Using a Volumetric Flow Meter
When the mass of product is required (for display, data logging or delivery control) there are two options; 1) use a mass meter, e.g. a Coriolis effect flow meter, which reports "pulses per unit mass" to the DanLoad 6000, or 2) use a volumetric flow meter, e.g. a turbine meter or PD meter, which reports "pulses per unit gross volume" to the DanLoad 6000 and have the DanLoad 6000 compute the mass from the gross volume. Both options are possible with the DanLoad 6000. This section describes the second option.
In order to have the DanLoad 6000 compute product mass, the DanLoad 6000 should first be configured to compute the standard volume (net volume) in the usual way, i.e. specify temperature units, temperature correction option per component, pressure correction option per component, temperature input (RTD) per meter or backup temperature per component, density input (4-20 mA) per meter or backup density per component, etc. See Section 3.7, Temperature and Pressure
Compensation. The temperature and pressure correction options are likely to dictate the density units used by the DanLoad 6000. If a "live" density input is used, the input density should be corrected to standard conditions external to the DanLoad 6000.
Mass computation is enabled by entering a mass computation adjustment factor per component, which causes the standard volume to be recomputed as mass, i.e. for "standard quantity" read "mass".
Thus, batch mass, meter mass totalizers, component mass totalizers, etc. can be displayed in the dynamic data display, printed on data logs and requested by an automation system. The meter standard quantities to 2 decimal places (data codes 147, etc.) are not recomputed as mass, and still show the standard volume even when mass computation is enabled. This allows meters to be proved volumetrically, if required. If meters are proved by mass, i.e. by comparison with a weighscale, the following should be considered:
- The weighscale's resolution/accuracy will contribute to overall inaccuracy.
- The meter factor adjustment (program code 175, 177, etc. for component 1)
is still applied to the gross volume measured by the DanLoad 6000.
- Flow rates on the DanLoad 6000 are in gross volume units per minute.
Setup _________________________________________________________________ 3 - 87
DanLoad 6000 (v6.00) __________________________________________________________
The mass computation adjustment factor provides the flexibility to compute mass in almost any units
(pounds, kilograms, etc.) from volume and density in almost any units. However, it should be noted that the DanLoad 6000 displays mass only in (rounded to nearest) whole units, e.g. ±0.5 tons if the mass computation adjustment factor computes tons. See program code 68 for more information and examples. An adjustment for buoyancy in air can be included in the mass computation. See program code 426 for more information.
It is also possible to preset by mass, e.g. to preset and load a batch of 10,000 kilograms, by enabling mass computation (as described above) and then setting the preset/delivery type to "Std" (standard quantity). See program code 80 in Section 6 for more information.
Care should be exercised when enabling mass computation and, more importantly, when presetting by mass since the number of mass units can be very different from the number of volume units.
Small batches should be loading in order to verify the configuration and calculations.
3.10
Additive Injection
From one to six additives, or no additives, can be injected into the loaded product stream. Program code numbers are indicated in the text in the following manner. One three-digit number indicates that the parameter applies globally to all additive injection. Six three-digit numbers separated by slashes (/) indicate that a separate parameter applies to each of the six additives injected. The six three-digit program code numbers are in additive numerical order (additive 1 through 6).
The primary features of the additive injection control system are listed below.
# Allows direct control of additive injection (for up to 6 physical additives) via an "additive panel" (additive meter and on/off valve), thus making so-called "smart" additive injector systems obsolete. This also makes the DanLoad 6000 a more attractive economical solution for load rack automation when additive injection is required.
# Allows different injection methods (additive injector types) for each logical additive so that old and new additive injection equipment can be mixed on a single loading arm, e.g. mix additive panels on the same loading arm.
# Provides multiple injection rates (concentrations) per additive via the "Multi Rate" additive selection method.
# Provides recipe gross and standard running totalizers and additive running totalizers to facilitate product and additive inventory management.
3 - 88 _________________________________________________________________ Setup
_________________________________________________________ DanLoad 6000 (v6.00)
# Provides (functional) backward compatibility with previous DanLoad 6000 versions, though actual program codes may be different.
#
#
Provides reporting (data logging) capabilities to facilitate product and additive inventory management and configuration.
Provides an additive meter calibration screen with a step-by-step procedure for computing an additive meter’s K-factor.
Typically, "smart" additive injector systems control the flow of additive into product via an on/off valve and an additive meter. The "smart" additive injector must be interfaced to an electronic preset
(batch controller), PLC or other automation system via hard-wired signals (flow permissive, pulse per gallon, feedback and alarm) or communications (RS-232 or RS-485).
The DanLoad 6000 electronic preset controls and meters additive flow directly, and thus combines the functionality of an advanced electronic preset and multiple "smart" additive injector systems.
This has the following advantages:
# Overall electronic preset/additive injector system cost is reduced. The saving on "smart" additive injectors may even cover the cost of the electronic preset!
# System installation is simplified due to reduced interfacing requirements. All that is needed is an output to each additive control valve and an input from each additive meter.
# System operation is simplified. The DanLoad 6000 directly controls the flow of product and additives. Configuration, calibration, alarm processing, diagnostics, etc. all take place at the
DanLoad 6000. Some possible causes of alarms (due to interfacing) are eliminated.
# Additive clean line start processing is improved. Unlike existing "smart" additive injector systems, the DanLoad 6000 knows the preset volume, which allows injection cycles to be spread over most of the batch and prevents "spurious" over-injection alarms on small batches.
Setup _________________________________________________________________ 3 - 89
DanLoad 6000 (v6.00) __________________________________________________________
The DanLoad 6000 can control up to six physical additives. One additive ratio output (typically a discrete output on an AC I/O or enhanced I/O board) and one additive meter input (typically a "low speed" or "high speed" discrete input (depending on the pulse width) on a DC I/O board or enhanced
I/O board) is required per additive. The additive meter and on/off valve are usually mounted on an
"additive panel" which provides additional piping for additive meter calibration. The DanLoad
6000's additive ratio output is wired to the on/off valve. The additive meter is wired to the DanLoad
6000's additive meter (additive feedback) input. The end user must ensure the additive meter output does not exceed the DanLoad high speed input frequency and minimum pulse width specification.
Additive volume is measured via a K-factor per additive which is used for both authorized and unauthorized additive flow. "Selected" additives become "authorized" when a batch is started, remain authorized while the batch is stopped become "unauthorized" when the batch ends, which allows an authorized additive to be injected manually when a batch stops due to under-injection.
The "Multi Rate" additive selection method allows multiple additive ratios (concentrations of additive) to be configured per additive by configuring an additive ratio per recipe, and can be used with any injection method or combination of injection methods. However, since the program code for a recipe's component 4 percentage is used to configure the recipe's "override" additive ratio volume, the DanLoad 6000 is limited to a maximum of three components in this configuration.
Recipe and additive running totalizers allow product and additive thruput for a particular customer to be monitored. (The workability of this scheme depends somewhat on there being no more than one additive per recipe.) The recipe gross and standard running totalizers (data codes 151 through
218) and the additive running totalizers (data codes 96 through 101) can be displayed in the dynamic data display, printed on the data logging printer (via the totalizers data log) or requested via automation system communications (command code 22h).
The configuration summary data log (a report showing all program code values) can be printed from the diagnostics menu in the manual operating mode. The format is similar to the pages in Setup.
For each setup group, the unit address, current date and time and the setup group name is printed.
(Within the DanLoad 6000, each setup group is generated as a separate data log so that it is possible to form feed after each setup group is printed.) For each page in each setup group, the page heading is printed. For each program code in each page in each setup group, the program code, program code description and program code value are printed (forty columns wide, just like in Setup).
The DanLoad 6000 application program can verify that the volume of additive measured is within configured limits throughout a batch, and raise an alarm, Additive X failure, where X is the additive number 1 to 6, and stop the batch loading if the volume of additive measured is not within configured limits. This provides a low-cost alternative to smart injector systems.
3 - 90 _________________________________________________________________ Setup
_________________________________________________________ DanLoad 6000 (v6.00)
Additive is typically injected in bursts or doses, so that the actual product to additive ratio varies widely during a batch, particularly near the start of a batch. This is illustrated in the table on the for every 40 gallons of product delivered.
The DanLoad 6000 is aware of the varying product to additive ratio during loading and does not trigger erroneous additive injection alarms unless actual ratio errors exist. Additionally, the following two clean line volume parameters affect the rate of additive injection.
# Program code 138 Clean line qty sets the quantity of product to deliver at the end of the batch loading without additive injection. For sequential blending, the value set by program code 138 Clean line qty applies to each component in the blend. This function prevents additive contamination in subsequent product deliveries.
# Program code 714 Clean line qty sets the quantity of pure primary component, set by program code 111 Primary component, to deliver at the end of the delivery. This function prevents product contamination in subsequent product deliveries. If, for a particular batch, the preset quantity is less than or equal to the clean line quantity, the batch is delivered as if there were no clean line quantity configured.
Additive in Product
Product
(gallons)
80
119
120
159
160
39
40
79 cm 3
0
100
100
200
200
300
300
400 gallons
0
0.0264
0.0264
0.0528
0.0528
0.0793
0.0793
0.1057
Product/additive ratio
4
1515
2992
1515
2254
1513
2083
1514
Setup _________________________________________________________________ 3 - 91
DanLoad 6000 (v6.00) __________________________________________________________
3.10.1
Additive Injection Configuration
"044 Additive units". This identifies the units and format in which additive volumes are displayed and printed, i.e. the external additive units, and provides a mnemonic for additive units on data logs.
The internal additive units depend on the additive injection method (program codes 141, 146, etc.) per additive and, for the "Meter" and "Control" injection methods, the product units (program code
29). Select one of the following:
# "cc". Additive volumes are displayed and printed in cubic centimeters formatted as
9999999.99.
# "in3". Additive volumes are displayed and printed in cubic inches formatted as
9999999.99.
# "Gal". Additive volumes are displayed and printed in gallons formatted as
99999.9999.
# "L". Additive volumes are displayed and printed in liters formatted as 99999.9999.
The default value is "cc".
"136 Selection method". The method by which additives are selected in the manual operating mode.
(In the automatic operating mode the additive selection method is determined by the automation system. Refer to the Authorize Transaction (06h) command in the DanLoad 6000 Communications
Spec.) Select one of the following:
# "External". All configured ("Number of additives") additive ratio outputs are cycled.
An additive can be selected by an external contact, e.g. an automation system relay or a key-switch.
# "Prompt". The operator is prompted to select additives at the start of each transaction. (Additive selection screen.)
# "Inputs". Configured ("Number of additives") additive ratio outputs are cycled only if their corresponding additive selection inputs are closed during a batch. (Similar to external, except the DanLoad 6000 knows which additives are being injected.)
# "Recipe". The additives specified by the last two characters of the recipe name, entered as the 2-digit decimal equivalent of an additive "bit map" (see below), are selected automatically. Multiple additives can be selected per recipe.
3 - 92 _________________________________________________________________ Setup
_________________________________________________________ DanLoad 6000 (v6.00)
# "Multi Rate". The additives specified by the last two characters of the recipe name, entered as the 2-digit decimal equivalent of an additive "bit map" (see below), are selected automatically, and the recipe's component 4 percentage (truncated from hundredths to whole units) is interpreted as the additive ratio volume. (This limits the DanLoad 6000 to a maximum of three components.) Multiple additives can be selected per recipe.
The default value is "External". The decimal equivalent of the additive "bit map" for the "Recipe" and "Multi Rate" selection methods is computed by adding together the appropriate values from the right-hand column of the following table:
Additive #
3
4
1
2
5
6
Value
4
8
1
2
16
32
For example, in order to select additives 3 and 5 to be injected into the midgrade recipe enter
"Midgrade______20" for the recipe name. (4 + 16 = 20, the underscore character represents a space.)
The additive "ratio volume" (per additive) is now in whole units of product. However, if the "Multi
Rate" additive selection method is used, the recipe's component 4 percentage (truncated from hundredths to whole units) is used for the additive ratio volume. (The ratio volume in the additive delivery parameters setup group must still be configured if verification using the volume of additive per 1000 of product is to be performed.)
"140 Ratio volume" (1 to 9999). The volume (possibly a combination of gross and/or standard quantities through multiple component meters) in product units (program code 29) which controls one additive injection cycle. The default value is 40.
Setup _________________________________________________________________ 3 - 93
DanLoad 6000 (v6.00) __________________________________________________________
"141 Injection method". The first two injection methods ("Mech" and "Handshake") totalize additive methods ("Meter" and "Control") totalize additive using an additive meter K-factor, and their internal additive units, i.e. for interpreting the K-factor, are the configured product units (program code 29).
For all four injection methods, the DanLoad 6000 converts additive volumes from internal units to external units (program code 44) for display and printing. Since the injection method is configured per additive (program codes 141, 146, etc.), one additive can be injected via a simple mechanical injector ("Mech") while another can be injected and measured via an additive panel ("Control").
Select one of the following:
# "Mech". Additive injection via a mechanical injector (fixed dose per ratio cycle) with feedback. The DanLoad 6000 controls the ratio output (if configured) and totalizes additive using the quantity per pulse on input (if a feedback input is configured) or on output (if not). Additive verification is based on the configured required number of feedback pulses per ratio cycle (program code 247), the configured additive error limit (program code 246) and the volume of additive per
1000 of product (if configured).
# "Handshake". Additive injection via a handshake cycle (mercaptan). The DanLoad
6000 controls the ratio output (if configured) based on the ratio cycle and the feedback input, and totalizes additive using the volume per pulse on input. Additive verification is based on a hard-coded one feedback pulse per ratio cycle, the configured additive error limit (program code 246), the configured additive feedback count (program code 247, interpreted as a number of seconds) and the volume of additive per 1000 of product (if configured).
# "Meter". Additive injection via a mechanical injector (fixed dose per ratio cycle) with additive meter. The DanLoad 6000 controls the ratio output (if configured) and totalizes additive using the additive K-factor on input (if a feedback input is configured). Additive verification is based on the volume of additive per 1000 of product (if configured).
# "Control". Additive control via an on/off valve (variable dose per ratio cycle) with additive meter. The DanLoad 6000 controls (by manipulating the on/off valve) the volume of additive per ratio cycle (unlike the other injection methods) and totalizes additive using the additive K-factor on input (if a feedback input is configured).
Additive verification is based on the volume of additive per 1000 of product (if configured). The volume of additive per 1000 of product must be configured for the
"Control" injection method.
The default value is "Mech".
Note: The "global" totalizing method (program code 137), e.g. "Out", "Out/Sgl", etc., which combined the totalizing method and the feedback method in previous software versions is no longer used.
3 - 94 _________________________________________________________________ Setup
_________________________________________________________ DanLoad 6000 (v6.00)
The ratio cycle "inject %" (program code 137, 0 to 100, default 50) allows the percentage of the adjusted-for-additive-clean-line-start ratio cycle at which injection begins, i.e. the ratio output is switched on, to be configured. For the "Mech", "Handshake" and "Meter" injection methods, injection ends, i.e. the ratio output is switched off, after 50% of the adjusted-for-clean-line-start ratio volume has been delivered. For the "Control" injection method, injection ends, i.e. the ratio output is switched off, when the appropriate volume of additive for the ratio cycle has been metered. Note:
Setting the inject percent (program code 137) to 50 and the injection method (program code 141, etc.) to "Handshake" implements the "inject after ratio volume" control required for mercaptan injection (per Mapco).
"142 Volume/pulse or K-factor" (0.00 to 9999.99). This is used for totalizing additive (both authorized and unauthorized additive flow). This is in "internal additive units". For the "Mech" and injection methods it is the additive meter's K-factor, i.e. pulses per product unit (product units per program code 29). Internal additive units can be converted to external additive units via the configured additive units (program code 44). The default value is 0.00.
"143 Additive per 1000" (0.0000 to 99999.9999). The required volume of additive in external additive units (program code 44) per 1000 units of product. (If the external additive units are "cc", the additive per 1000 is truncated to two decimal places internally, e.g. 50.3456 is truncated to
50.34.) When a non-zero value is configured, the DanLoad 6000 verifies that the volume of additive is within limits (program codes 272, 273 and 278) during a batch and calculates the actual percentage of the required additive per 1000 continuously throughout a batch (data code 239 for additive 1, etc.).
Thus, "additive volume verification" can be enabled (somewhat) independently of the additive injection method (program codes 141, 146, etc.). An additive failure alarm is raised if the measured volume of additive is not within limits during a batch. The default value is 0.0000, i.e. verification disabled.
"246 Additive error limit" (1 to 99). For the "Mech" and "Handshake" injection methods this is the maximum number of pulses by which the actual feedback pulse count can differ from the ideal feedback pulse count before an additive failure alarm is raised. The ideal feedback pulse count is based on the additive feedback count (program code 247) or is 1 (internal default, independent of configuration) for the "Handshake" injection method. The default value is 3.
"247 Additive feedback count" (0 to 9999). The expected number of feedback pulses per additive ratio cycle for the "Mech" additive injection method, e.g. 1 for Titan PAC-3 "confirmation pulse",
2 for Hyrolec injector. The number of seconds within which the additive feedback input must go on and off again after the additive ratio output has been energized for the "Handshake" additive injection method, e.g. 5. The default value is 0.
"271 Unauth additive flow vol (0.0000 to 99999.9999)". The volume (units determined by additive
K-factor) of unauthorized additive flow at which an additive X failure alarm is raised for the "Meter" and "Control" injection methods (program codes 141, 146, etc.). Unauthorized additive flow is detected as a feedback error for the "Mech" and "Handshake" injection methods. Zero disables the alarm. The default value is 0.0000, i.e. disabled.
Setup _________________________________________________________________ 3 - 95
DanLoad 6000 (v6.00) __________________________________________________________
“278 Additive per 1000 error limit" (1 to 99). For the "Meter" and "Control" injection methods this is the number of ratio volumes worth of additive by which the actual volume of additive can differ from the ideal volume of additive at any point in a batch before an additive failure alarm is raised.
The default value is 1.
The last two characters of a recipe's name (program code 481, 487, etc.) specify the additives to be selected for the "Recipe" and "Multi Rate" additive selection method; the last two character's of the recipe's name are not displayed in the recipe selection screen when either one of these additive selection methods is selected. Two digits must be entered in order to select any additives.
"710 Cutoff hour" (0 to 23). The hour (24-hour clock/military time) at which a cutoff (end of day) processing is run by the DanLoad 6000. Cutoff processing is "postponed" until any batch in progress is ended. Cutoff processing includes storing and printing meter, component, recipe and additive totalizers. The default value is 0, i.e. cutoff at midnight.
Once a second, the DanLoad 6000 compares the current hour with configured cutoff hour, the current day with the last cutoff day and the current hour with the last cutoff hour as follows: if (CurrentHour IS EQUAL TO ConfiguredCutoffHour)
BEGIN
if ( (CurrentDay IS NOT EQUAL TO LastCutoffDay)
OR (CurrentHour IS GREATER THAN LastCutoffHour))
BEGIN
RunCutoff()
END
END
This allows multiple cutoffs per day to be run per day by increasing the configured cutoff hour
(program code 710).
3 - 96 _________________________________________________________________ Setup
_________________________________________________________ DanLoad 6000 (v6.00)
Processing
The processing performed for an additive configured for the "Control" (additive panel) injection method is described below.
#
#
#
Prior to starting a batch, the DanLoad 6000...
# Computes the volume of additive per 1000 of product based on the configured "additive per
1000" (for the "External", "Prompt", "Inputs" and "Recipe" selection methods) or the configured "ratio volume", "additive per 1000" and "Comp 4 % or ratio volume" (for the
"Multi Rate" selection method).
Computes the ideal volume of additive per additive ratio cycle.
Compute the adjusted (for clean line start, etc.) additive ratio volume.
Initializes various "per batch" and "per ratio cycle" variables.
#
#
When, during delivery of the batch, the additive control volume, i.e. the volume of product through the configured additive control meters, reaches "inject %" of the adjusted additive ratio volume, the
DanLoad 6000...
# Computes the number of pulses required to close the additive valve on the previous ratio cycle. (Only one additive valve closure number of pulses is used.)
# Computes the number of pulses required during the current ratio cycle to maintain the ideal additive batch volume.
Initializes various "per ratio cycle" variables.
Energizes the additive ratio output, allowing additive to flow, and counts pulses from the additive meter.
When the number of pulses from the additive meter equals the number of pulses required during the current ratio cycle minus the number of pulses required to close the additive valve on the previous ratio cycle, the DanLoad 6000 deenergizes the additive ratio output and continues to count pulse from the additive meter.
Additive volume computation and "additive per 1000 verification" (as for all injection methods) is synchronized with the "per meter" volume computations.
Setup _________________________________________________________________ 3 - 97
DanLoad 6000 (v6.00) __________________________________________________________
Calculations
The processing indicated on the following page is performed continuously during a batch for each selected additive with non-zero "additive per 1000 units".
Compute ideal dose of additive per additive ratio quantity.
Ideal add dose = 143 / ... / 168 Additive per 1000 * 140 / ... / 165 Ratio quantity
--------------------------------------------------------------------------------
1000
Compute the ideal volume of additive for loaded product.
Ideal vol add = Ideal add dose * Actual inj cycles complete
IF Measured vol add < Ideal vol add - (246 Additive error limit * Ideal add dose)
OR Measured vol add > Ideal vol add + (246 Additive error limit * Ideal add dose)
THEN Compute the ideal volume of additive for the current product quantity.
Ideal vol add = Prod vol * Ideal add dose
-------------------------------------
140 / ... / 165 Ratio quantity
Check + and - percentages.
IF Measured vol add < Ideal vol add - (Ideal vol add * 272 Prod/add -%)
-------------------------------------------
100
OR Measured vol add > Ideal vol add + (Ideal vol add * 273 Prod/add +%)
--------------------------------------------
100
THEN Generate an Additive X failure primary alarm.
Stop the batch loading.
ENDIF
ENDIF
3 - 98 _________________________________________________________________ Setup
_________________________________________________________ DanLoad 6000 (v6.00)
3.10.2
Additive Injection Configuration (Typical Examples)
Example 1 (Additive injection configuration)
Configuration
Program
Code
026
065
050
482
139
140
138
111
Description
Unit type
Number of components
Number of meters
Comp 1 %
Control meters
Ratio qty
Clean line qty
Primary component
Value
Sequential
1
1
100
G
40.0
0
0
Preset
Quantity
400
Test Results
Additive Ratio computed by
DanLoad 6000
40.00
Additive injections
10
Setup _________________________________________________________________ 3 - 99
DanLoad 6000 (v6.00) __________________________________________________________
Example 2 (Additive injection configuration)
Program
Code
026
065
050
482
139
140
138
111
Configuration
Description
Unit type
Number of components
Number of meters
Comp 1 %
Control meters
Ratio qty
Clean line qty
Primary component
Value
Sequential
1
1
100
G
40.0
20
0
Preset
Quantity
400
Test Results
Additive Ratio computed by
DanLoad 6000
(400 - 20) ÷ (400 ÷ 40) = 38.00
Additive injections
10
3 - 100 _________________________________________________________________ Setup
_________________________________________________________ DanLoad 6000 (v6.00)
Example 3 (Additive injection configuration)
Program
Code
026
065
050
524
139
140
138
111
Configuration
Description
Unit type
Number of components
Number of meters
Comp 1 %
Control meters
Ratio qty
Clean line qty
Primary component
Value
Sequential
1
1
100
G
40.0
0
10
Preset
Quantity
400
Test Results
Additive Ratio computed by
DanLoad 6000
(400 - 10) ÷ (400 ÷ 40) = 39.00
Additive injections
10
Setup _________________________________________________________________ 3 - 101
DanLoad 6000 (v6.00) __________________________________________________________
Example 4 (Additive injection configuration)
Program
Code
026
065
050
482
139
140
138
111
Configuration
Description
Unit type
Number of components
Number of meters
Comp 1 %
Control meters
Ratio qty
Clean line qty
Primary component
Value
Sequential
1
1
100
G
40.0
20
10
Preset
Quantity
400
Test Results
Additive Ratio computed by
DanLoad 6000
(400 - 10 - 20) ÷ (400 ÷ 40) = 37.00
Additive injections
10
3 - 102 _________________________________________________________________ Setup
_________________________________________________________ DanLoad 6000 (v6.00)
Example 5 (Additive injection configuration)
Program
Code
026
065
050
482
483
067
070
139
140
138
111
714
Configuration
Description
Unit type
Number of components
Number of meters
Comp 1 %
Comp 2 %
Component 1 meter number
Component 2 meter number
Control meters
Ratio qty
Clean line qty (additive)
Primary component
Clean line qty (component)
Value
In line
2
2
60.00
40.00
1
2
GX
40.0
0
1
0
Preset
Quantity
400
Meter 1
Gross
240
Meter 2
Gross
160
Test Results
Additive Ratio computed by
DanLoad 6000
40.00
Additive injections
6
Setup _________________________________________________________________ 3 - 103
DanLoad 6000 (v6.00) __________________________________________________________
Example 6 (Additive injection configuration)
Program
Code
026
065
050
482
483
067
070
139
140
138
111
714
Configuration
Description
Unit type
Number of components
Number of meters
Comp 1 %
Comp 2 %
Component 1 meter number
Component 2 meter number
Control meters
Ratio qty
Clean line qty (additive)
Primary component
Clean line qty (component)
Value
In line
2
2
60.00
40.00
1
2
GX
40.0
60
1
0
Preset
Quantity
400
Meter
1
Gross
240
Meter
2
Gross
160
Test Results
Additive Ratio computed by
DanLoad 6000
(240 - 60) ÷ (240 ÷ 40) = 30.00
Additive injections
6
3 - 104 _________________________________________________________________ Setup
_________________________________________________________ DanLoad 6000 (v6.00)
Example 7 (Additive injection configuration)
Program
Code
026
065
050
482
483
067
070
139
140
138
111
714
Configuration
Description
Unit type
Number of components
Number of meters
Comp 1 %
Comp 2 %
Component 1 meter number
Component 2 meter number
Control meters
Ratio qty
Clean line qty (additive)
Primary component
Clean line qty (component)
Value
In line
2
2
60.00
40.00
1
2
GX
40.0
0
1
30
Preset
Quantity
400
Meter
1
Gross
240
Meter
2
Gross
160
Test Results
Additive Ratio computed by
DanLoad 6000
(240 - 30) ÷ (240 ÷ 40) = 35.00
Additive injections
6
Setup _________________________________________________________________ 3 - 105
DanLoad 6000 (v6.00) __________________________________________________________
Example 8 (Additive injection configuration)
Program
Code
026
065
050
482
483
067
070
139
140
138
111
714
Configuration
Description
Unit type
Number of components
Number of meters
Comp 1 %
Comp 2 %
Component 1 meter number
Component 2 meter number
Control meters
Ratio qty
Clean line qty (additive)
Primary component
Clean line qty (component)
Value
In line
2
2
60.00
40.00
1
2
GX
40.0
60
1
30
Preset
Quantity
400
Meter
1
Gross
240
Meter
2
Gross
160
Test Results
Additive Ratio computed by
DanLoad 6000
(240 - 60 - 30) ÷ (240 ÷ 40) = 25.00
Additive injections
6
3 - 106 _________________________________________________________________ Setup
_________________________________________________________ DanLoad 6000 (v6.00)
Example 9 (Additive injection configuration)
Program
Code
026
065
050
482
483
067
070
139
140
138
111
714
Configuration
Description
Unit type
Number of components
Number of meters
Comp 1 %
Comp 2 %
Component 1 meter number
Component 2 meter number
Control meters
Ratio qty
Clean line qty (additive)
Primary component
Clean line qty (component)
Value
In line
2
2
60.00
40.00
1
2
GX
40.0
60
2
30
Preset
Quantity
400
Meter
1
Gross
240
Meter
2
Gross
160
Test Results
Additive Ratio computed by
DanLoad 6000
(240 - 60) ÷ (240 ÷ 40) = 30.00
Additive injections
6
Setup _________________________________________________________________ 3 - 107
DanLoad 6000 (v6.00) __________________________________________________________
Example 10 (Additive injection configuration)
Program
Code
026
065
050
482
483
067
070
139
140
138
111
714
Configuration
Description
Unit type
Number of components
Number of meters
Comp 1 %
Comp 2 %
Component 1 meter number
Component 2 meter number
Control meters
Ratio qty
Clean line qty (additive)
Primary component
Clean line qty (component)
Value
In line
2
2
60.00
40.00
1
2
GG
40.0
60
2
30
Preset
Quantity
400
Meter
1
Gross
240
Meter
2
Gross
160
Test Results
Additive Ratio computed by
DanLoad 6000
(400 - 60 - 30) ÷ (400 - 40) = 31.00
Additive injections
10
3 - 108 _________________________________________________________________ Setup
_________________________________________________________ DanLoad 6000 (v6.00)
3.10.3
Additive Meter Calibration
The DanLoad 6000's additive meter calibration screen provides a simple, step-by-step procedure for
Milliliters (ml) are equivalent units. Typically, product line pressure, i.e. downstream of the additive meter, should be simulated using a back pressure valve as required per additive panel manufacturer specifications (typically 35 psi) in order to establish an accurate K-factor for normal loading conditions.
Prior to using the additive meter calibration screen, the following parameters should be configured:
# Product units (program code 029) to allow the DanLoad 6000 to compute the metered
# additive injection method ("Meter" or "Control"); it is important to understand the difference between these two methods and configure correctly.
#
# additive meter K-factor, e.g. the value printed on the additive meter additive per 1000 (for the "Control" injection method)
The additive meter calibration screen is accessed by selecting "Additive calibration" from the program mode menu. (A supervisor-privileged passcode is required.)
1234567890123456789012345678901234567890
Program Mode Menu Pg 1 of 2
Alarm reset
Reprint transaction
Setup
Program code attributes
Set date and time
Set contrast/backlighting
More
9
1234567890123456789012345678901234567890
1234567890123456789012345678901234567890
Program Mode Menu Pg 2 of 2
Diagnostics
Reprint cutoff
CALMON status
Additive calibration
Exit (ALT+CLEAR)
More 8
1234567890123456789012345678901234567890
Setup _________________________________________________________________ 3 - 109
DanLoad 6000 (v6.00) __________________________________________________________
The additive meter calibration screen is displayed:
1234567890123456789012345678901234567890
Additive calibration
Additive _
K-factor / Gal
Vol (meter) cc in 0 cycles
Vol (prover) cc
Press ALT+CLEAR to exit
1234567890123456789012345678901234567890
The DanLoad 6000 prompts for an additive number. The operator should enter a valid additive number, i.e. greater than or equal to 1, less than or equal to the configured number of additives
(program code 135) and with injection method "Meter" or "Control". If an invalid additive number is entered the DanLoad 6000 displays "Invalid entry".
When a valid additive number has been entered, the DanLoad 6000 displays the current additive meter K-factor (from Setup), zeros the metered additive volume ("Vol (meter)"), disables the additive's usual counters (which disables the additive unauthorized flow alarm), energizes the additive's pump and block valve outputs (if configured) and prompts "Press START to inject or
STOP to finish", e.g.
1234567890123456789012345678901234567890
Additive calibration
Additive 1
K-factor 2600.00 / Gal
Vol (meter) 0 cc in 0 cycles
Vol (prover) cc
Press START to inject or STOP to finish
1234567890123456789012345678901234567890
If the operator presses the "START" key, the DanLoad 6000 displays “Please Wait” (blinking once every second) for the configured additive calibration delay (program code 720) which allows the operator to move from the preset to the additive injector, if necessary. During this delay time, the
“STOP” key can be pressed to abort the delay and cancel the additive injection. Once the delay time has elapsed, the DanLoad displays “Injecting - press stop to cancel”, performs the configured number of additive injection cycles (program code 661) as described below, and updates the metered additive volume at the end of each additive injection cycle. The metered additive volume is always computed
3 - 110 _________________________________________________________________ Setup
_________________________________________________________ DanLoad 6000 (v6.00)
The processing of an injection cycle depends on the additive's injection method. If the additive's injection method is "Meter", the DanLoad 6000 performs an additive injection cycle as follows:
#
# energizes the additive's ratio output.
waits for the additive meter pulse frequency to fall to zero, i.e. no pulses in one second, or
5 seconds to pass.
# deenergizes the additive's ratio output and waits for the additive meter pulse frequency to fall to zero (some fixed volume injectors inject on both strokes) or 5 seconds to pass.
#
#
#
#
If the additives's injection method is "Control", the DanLoad 6000 performs an additive injection cycle as follows:
# computes the required number of pulses for one injection cycle based on the additive's ratio volume, K-factor and additive per 1000.
energizes the additive's ratio output.
waits until the required number of pulses for one injection cycle have been counted.
deenergizes the additive's ratio output.
waits for the additive meter pulse frequency to fall to zero.
Setup _________________________________________________________________ 3 - 111
DanLoad 6000 (v6.00) __________________________________________________________
When sufficient injection cycles have been the completed (the total volume of additive required usually depends on Weights and Measures and/or company operating procedures), the operator should press the "STOP" key. The DanLoad 6000 prompts for the prover additive volume, i.e. the
1234567890123456789012345678901234567890
Additive calibration
Additive 1
K-factor 2600.00 / Gal
Vol (meter) 1869 cc in 31 cycles
Vol (prover) _______ cc
1234567890123456789012345678901234567890
If the operator enters a non-zero prover additive volume, the DanLoad 6000 computes, stores in
Setup and displays the new additive meter K-factor:
K new
= (K x Vol metered
) / Vol prover
The new K-factor computation can be bypassed by entering zero (or simply presses the "ENTER" key) when prompted for the prover additive volume.
The DanLoad 6000 deenergizes the additive's pump and block valve outputs (if configured), and prompts for an additive number so that the additive meter calibration process can be repeated for the same or another additive. The information from the last run are displayed until a further additive number is entered.
3.10.4
Multi-Stream Injection Mode
This paper describes the multi stream additive injection mode of the DanLoad 6000 Preset and addresses the following points :
#
#
#
Theory of Operation
Accuracy
Advantages
3 - 112 _________________________________________________________________ Setup
_________________________________________________________ DanLoad 6000 (v6.00)
# Theory of Operation
# General - The DanLoad 6000 Electronic Preset & Batch Controller can provide direct control of up to 6 additive streams plus a clean line flush stream via a multi stream additive panel. This functionality is available in firmware version 5.11 or above. It eliminates the need for “smart” microprocessor based additive injectors, thus providing the end user with an economical solution for load rack automation requiring additive injection of 1 or multiple additives.
There are 2 basic designs of a multi stream injection panel. Both designs use just one additive meter. The difference in design is :
# Type 1 - one has 1 additive on/off control valve with a block valve for each additive stream and the flush stream
# Type 2 - the other design has 1 additive on/off control valve for each additive stream and the flush stream and no block valves.
Therefore, a typical multi stream panel consists of 1 additive meter, 1 to 7 on / off control valves (6 for additive streams and 1 for flush) or 1 on / off control valve with
1 to 7 block valves (6 for additive streams and 1 for flush).
The main characteristic of a multi stream additive panel is the use of just one additive meter for two or more additive streams. In addition to being able to control, measure, and verify the additive process, the DanLoad 6000 Preset is able to properly account for each specific additive stream as well as the flush stream through the one additive meter. All of this is accomplished with the simple addition of 1 or 2 discrete I/O cards to the multi slot card cage of the DanLoad 6000.
#
#
Required I/O - The Multi Stream Injection Mode requires 1 high speed DC discrete input for the additive meter input, 1 to 7 additive ratio outputs (typically AC discrete output) to operate the additive on/off control valves, 1 to 6 AC discrete outputs for each additive block valve , and 1 AC discrete output for the clean line flush block valve if required. In addition to these I/O, the DanLoad must also have the necessary
I/O required for product loading (ie..control valve outputs, product pump output, additive pump outputs, meter input, RTD temperature input). The DanLoad has a discrete I/O capacity of 24 inputs and 28 outputs.
K-Factor per Additive - Additive volume is measured via an additive meter Kfactor per additive. This allows for maximum accuracy since viscosity varies for different additives and affects the meter’s K-factor.
Setup _________________________________________________________________ 3 - 113
DanLoad 6000 (v6.00) __________________________________________________________
#
#
#
#
Configuration - In addition to the normal configuration for typical loading, the
DanLoad 6000 requires each additive be configured for parameters such as additive pump output, additive ratio output, additive block valve output, additive meter input, additive meter K-factor, clean line flush output (PC # 399 - Flush Output), etc. The additive meter will be configured to the same input for each additive. Each additive’s injection method (PCs # 141, 146, etc.) should be set to “Control. The
flush pulses (PC # 425) is a configurable program code for entering the minimum number of additive meter pulses the DanLoad must read during the flush cycle. To disable the Flush Pulses alarm, set the minimum pulses to 0.
When the DanLoad sees two or more additive meters (PC # 381..396) configured as the same input, it automatically assumes the multi stream injection mode of operation and properly accounts for each additive according to the additive selected.
Therefore, the multi stream injection mode must have 2 or more additives configured.
Also, use of the multi stream injection mode precludes the use of the other injection modes available with the DanLoad.
Flush Pump Output - A flush pump might be required to insure enough pressure for the clean line flush to inject into the main product stream. There are two options for operating a pump dedicated to the flushing operation. Option 1 is to wire the flush pump in parallel with the Additive Clean Line Output (PC # 398). This runs the pump during the flush mode only. Option 2 is to wire the flush pump to Trip Output
#3 (PC # 317) which runs the pump for the entire batch.
Operation - When the START button is pressed to begin a batch, the DanLoad will check to see if an additive is selected. Only one additive can be selected at a time for the multi stream injection mode of operation. If more than one additive is selected, the DanLoad displays “additive failure” for each selected additive and does not allow the batch to start. Depending on the type of design of the injection panel, the control is as follows :
Type 1 (Panel w/ block valves and 1 additive on/off control valve) - The DanLoad will control the additive injection by first energizing the appropriate additive block valve output and pulsing the additive on/off control valve solenoid. As the end of the batch is reached and if clean line flush is configured, the DanLoad concludes the additive injection (reference clean line volume PC #138) and deenergizes the additive block valve and the additive on/off control valve solenoids (ie..closes the valves).
Then the flush block valve output (PC # 398 - Additive Clean Line Output) will be energized along with the flush output (PC # 399 - which is wired to the additive on/off control valve) to allow the flushing operation. If configured, the DanLoad will check the clean line pulses (PC # 425) at the end of the batch to verify the clean line flushing operation took place and alarm if necessary.
3 - 114 _________________________________________________________________ Setup
_________________________________________________________ DanLoad 6000 (v6.00)
#
#
#
Type 2 (Panel w/ 2 or more additive on/off control valves and no block valves) -
The DanLoad will control the additive injection by pulsing the appropriate additive on/off control valve solenoid. As the end of the batch is reached and if clean line flush is configured, the DanLoad concludes additive injection (reference clean line volume PC #138) by deenergizing the additive on/off control valve. Then the flush block valve output (PC # 398 - Additive Clean Line Output) will be energized along with the flush output (PC # 399 - which is wired to the additive on/off control valve) to allow the flushing operation. If configured, the DanLoad will check the clean line pulses (PC # 425) at the end of the batch to verify the clean line flushing operation took place and alarm if necessary.
Flush Pulses Alarm - At the end of a batch, if the DanLoad records fewer clean line flush pulses than the configured clean line flush pulses (PC # 425), the DanLoad will raise an internal alarm and display the message that has been configured for safety circuit #3 (PC # 254). To disable the Flush Pulses alarm, set the minimum pulses to 0. The DanLoad will record the actual number of clean line pulses at the end of each batch but will reset this register at the start of each batch. The flush pulses counter can be displayed on the Dynamic Data Display via data code # 223 on firmware versions 5.11 or above.
Calibrating the Additive Injectors - No additional electronics or handheld calibrators are required to calibrate each injector stream. Calibration is accomplished by using the DanLoad’s diagnostics to energize the discrete output wired to the additive solenoid valve which allows additive to flow into a test beaker. The
DanLoad’s dynamic data display is used to show the amount of additive measured by the DanLoad for that calibration cycle and is compared to the amount of additive in the test beaker. A new factor is calculated as follows : New Factor = (Metered
Volume / Beaker Volume) x Old Factor, with the result rounded to 2 decimal places.
The new factor is entered as PC # 142..167.
# Accuracy
The DanLoad 6000 is able to measure the injected additive with tremendous accuracy via a high resolution additive meter. At each step of the process the DanLoad constantly reads measured additive and adjusts the control cycle accordingly.
# Example : Based on an additive meter with a K-factor of 2600 PPG and a ratio of
0.4 gallons of additive per 1000 US gallons of product (400 ppm), there will be 25 injections of additive. Each injection will be 0.016 gallons (41.6 pulses per injection) for a total of 1040 pulses for the batch. At the completion of the batch, the DanLoad will typically be within ±1 pulse of the additive batch volume. This one pulse is equal to 0.000385 gallons.
Setup _________________________________________________________________ 3 - 115
DanLoad 6000 (v6.00) __________________________________________________________
# Advantages of Using DL6000 with Multi Stream Injection Mode vs. DL6000 with
“Smart” Injectors
In addition to cost savings, below are several advantages for using the DanLoad 6000 to directly control a multi stream additive injector panel.
# System installation is simplified and installation costs reduced due to less hardwiring requirements. An example is the elimination of the communication cable between the automation system and injector.
# System operation is simplified. The DanLoad 6000 directly controls the flow of product and additives and corrects for over or under injection. Configuration, calibration, alarm processing, diagnostics, etc. all take place at the DanLoad 6000.
Some possible causes of alarms due to interfacing automation systems and/or presets to “smart” injectors are eliminated.
# Reduces trouble-shooting and maintenance by utilizing one piece of electronics for both additive injection, measurement and control functions.
# Provides gross and net running product totalizers and additive running totalizers allowing for product and additive inventory management.
# Provides built-in reporting capabilities to facilitate product and additive inventory management.
# Provides multiple injection rates per additive stream via the DanLoad’s “Multi Rate” additive selection method (ie..five rates for each of six additive streams).
# Overall electronic preset and additive injector cost is reduced because of savings from not buying a “smart” injector.
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_________________________________________________________ DanLoad 6000 (v6.00)
Setup _________________________________________________________________ 3 - 117
DanLoad 6000 (v6.00) __________________________________________________________
3 - 118 _________________________________________________________________ Setup
_________________________________________________________ DanLoad 6000 (v6.00)
4.
5.
3.10.5
Multi Rate Additive Injection
The DanLoad 6000, using multiple recipies, has the capability of controlling multiple injection rates through a single additive injector. Typically, multiple additive injectors are required when different rates are needed when using the same additive. The DanLoad allows the user the capability of purchasing a minimum of 1 additive injector for a bay when the same additive with multiple rates are used in multiple recipies. Naturally, the DanLoad will support multiple injectors that require different rates when multiple additives are required.
Example: Additive injection using Multi-Rate selection and Control method.
1.
2.
Program Code (PC) Setup:
135 = 1 (Number of additives)
136 = Multi Rate (Selection method)
140 = 40 (Ratio Quantity. This value is ignored when Multi-Rate is selected).
141 = Control (Injection Method)
142 = 21 (Volume/Pulse or K factor)
143 = 0.4 (Additive per 1000)
480 = 2 (Number of recipies)
485 = x (Component 4 % or ratio quantity for recipe 1)
Determine the amount of additive injected per pulse:
Vol/pulse = ((PC 140) / 1000) x (PC 143)
3.
Determine the additive ratio:
Additive ratio = ((Vol/pulse) x 1000) / (Desired Additive per 1000)
Enter the new additive ratio into PC 485.
If another additive ratio is required, then use the calculation in steps 2 and 3 and enter the value into PC 491 (Component 4 % or ratio quantity for recipe 2).
Setup _________________________________________________________________ 3 - 119
DanLoad 6000 (v6.00) __________________________________________________________
Example:
1.
Additive injection using Multi-Rate selection and Meter method.
Program Code (PC) Setup:
135 = 1 (Number of additives)
136 = Multi Rate (Selection method)
140 = 40 (Ratio Quantity. This value is ignored when Multi-Rate is selected).
141 = Meter (Injection Method)
142 = 21 (Volume/Pulse or K factor)
143 = 0.4 (Additive per 1000)
480 = 2 (Number of recipies)
485 = x (Component 4 % or ratio quantity for recipe 1)
2.
Determine the amount of additive delivered per injection:
Vol/pulse = (Total additive injected) / (# of pulses)
3.
4.
Determine the additive ratio:
Additive ratio = ((Vol/pulse) x 1000) / (Desired Additive per 1000)
Enter the new additive ratio into PC 485.
5.
If another additive ratio is required, then use the calculation in steps 2 and 3 and enter the value into PC 491 (Component 4 % or ratio quantity for recipe 2).
In both examples above the DanLoad 6000 also computes the volume/pulse which is also known as
1 additive unit. This additive unit is used in additive error checking. If the delivered additive falls outside of PC 278 (Additive/1000 error limit) and has also exceeded the parameters of PC 272 and
PC 273 (low and high % of the ideal quantity at any point in a batch) the DanLoad 6000 will terminate loading and display an “Additive x failure” message, where x is the additive injector that failed.
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_________________________________________________________ DanLoad 6000 (v6.00)
3.11
Transaction Storage Overview
Data for multiple transactions composed of one or more batch deliveries is stored in non-volatile memory. Storage of transaction and batch delivery data is configured and enabled by program codes
834 through 837 and 840 through 901. Transaction storage MUST BE enabled and defined if either one or both of the following two cases exist.
# Case 1 A user defined Transaction Ticket will be printed on a pre-printed form. The print coordinates of selected variables are defined by program codes 920 through 981.
# Case 2 A host computer (Terminal Automation System) gathers data from the DanLoad
6000 and it is desired to provide backup storage of transaction data in case the host computer or host computer communications link fails.
*** OR ***
A host computer (Terminal Automation System) polls the DanLoad 6000 at long time intervals, such as once per day. For this type of operation, the host computer can upload all transaction data from the DanLoad 6000 once per day and then the transaction storage memory can be cleared or left intact.
If the transaction storage memory is cleared, the DanLoad 6000 reads the data for the next day beginning at transaction record 0000. If the transaction storage memory is left intact, the DanLoad 6000 reads the data for the next day beginning at the last read transaction record + 1.
It is not necessary to define the transaction / batch storage program codes 840 through 901 for any other case.
Text in this section uses standard programming and database terminology. You do not need to understand programming or database concepts to configure transaction storage. Examples are provided that relate the unique terminology to how data is placed and viewed on a printed page. If additional explanation is required, contact Daniel Automation Field Service Department or any person with computer programming experience.
Section 3.10.1 gives an example of transaction data storage definition and formatting a user defined transaction ticket. This example provides an overview of the required actions. Detailed information on the transaction data storage program codes and the user defined transaction ticket program codes is provided after the example. The procedures for implementing transaction storage and defining the format of a user defined transaction ticket are described below.
Section 3.10.2 discusses the default ticket formats available with the DanLoad 6000.
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DanLoad 6000 (v6.00) __________________________________________________________
3.11.1
Transaction Storage / Transaction Ticket Setup Procedure (Example)
Refer to Section 3.10.2 for the available preconfigured Standard Ticket Formats.
For the example, assume that the DanLoad 6000 controls gasoline octane blending (midgrade), high octane only, and low octane only gasoline loading to tanker vehicles. The example refers to the Transaction Ticket (Typical), Figure 3 - 13, the Transaction Storage Code Worksheet
(Example), Figure 3 - 14, and the Batch Storage Code Worksheet (Example), Figure 3 - 15.
The Transaction Ticket (Typical) was generated with a word processor program. The bold type indicates the pre-printed text in the ticket. The regular type indicates data that is obtained from the transaction storage file and the batch storage file in the DanLoad 6000. The transaction storage file can only contain data selected from the Transaction Storage Codes (TSC), Table 3 - 4 on page 3-
129, and the batch storage file can only contain data selected from the Batch Storage Codes (BSC),
Table 3 - 5 on page 3-131. If transaction data storage is defined and a user defined transaction ticket is not required, the print coordinates defined by program codes 920 through 955 and 960 through
982 can be ignored.
Steps performed:
1 Design the ticket format using available data defined by transaction storage codes and batch storage codes. Design the pre-printed text as desired.
2 Use a scale to measure and then mark the approximate row numbers and column numbers on the rough draft of the transaction ticket. The printed output from the DanLoad 6000 is normally 10 characters per inch on each line and 6 rows per inch vertically. The print font
(character style and size) is dependent on the data printer or other external device, such as a personal computer driving a printer.
3 Circle each printed variable generated by the DanLoad 6000. Near each circled variable, write the following code to describe the variable.
Type number, row, column, number of bytes stored in transaction or batch record, item multiplier
Example: Tnn, rrr, cc, b, m OR Bnn, rrr, cc, b, m
#
#
#
Type number T for TSC, B for BSC and TSC or BSC number rrr three-digit (leading zeros) row number on ticket cc two-digit (leading zeros) column number on ticket
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4
5
#
# b m
The number of bytes stored in the transaction or batch record. Obtain from the # bytes/format column in the Transaction Storage Codes
(TSC) table on page 3-129 or the Batch Storage Codes (BSC) table on page 3-131. Note: This number can be less than the number of characters in the formatted printout of the variable.
[multiplier] The number of flow meters defined (for TSC 23, 24,
25, 26) or the number of components defined (for BSC 10, 11, 12,
13, 14, 15). The multiplier is 1 for all other TSC's and BSC's.
Enter the TSC number, ticket row / column coordinates, and number of memory storage bytes required for the variable in the Transaction Record / Ticket Worksheet.
Start with the top TSC entry and calculate record offsets in the following manner.
(bytes times multiplier) plus offset equals the offset for the following line TSC.
In the example, [# bytes for T11 equals 4 times 1 (assumed multiplier)] plus 1 (offset for first entry) equals 5 which is entered as the offset for the next line TSC 12.
6 In the Record Length column, manually perform the bytes * m multiplication and write the product in the column. Sum all of the values or products in this column. The example sum is 120 bytes storage required in the transaction data storage record. Round this number to
150 bytes to allow for minor re-definition of data later. Enter the value 150 in program code
834 Transaction record length.
7
8
Enter the BSC number, ticket row / column coordinates, and number of memory storage bytes required for the variable in the Batch Record / Ticket Worksheet.
Start with the top BSC entry and calculate record offsets in the following manner.
(bytes times multiplier) plus offset equals the offset for the following line BSC.
In the example, [# bytes for B2 equals 2 times 1 (assumed multiplier)] plus 1 (offset for first entry) equals 3 which is entered as the offset for the next line BSC 7.
Setup _________________________________________________________________ 3 - 123
DanLoad 6000 (v6.00) __________________________________________________________
9 In the Record Length column, manually perform the bytes * M multiplication and write the product in the column. Sum all of the values or products in this column. The example sum is 18 bytes storage required in the batch data storage record. Round this number to 30 bytes to allow for minor re-definition of data later. Enter the value 150 in program code 836 Batch
record length.
Note
Ten memory pages (each page stores 8192 bytes) are allocated to store transaction records and batch records. Transaction storage pages are allocated by program code 835 Start page
and # pages and batch storage pages are allocated by program code 837 Start page and #
pages. If transaction storage is enabled, at least one page must be assigned for transaction storage records and at least one page must be assigned for batch storage records. The complete block of ten pages is identified by numbers 600 through 1510, where the last two digits (00 through 10) identify the number of pages allocated and the 6 through 15 part of the assignment indicates the start page. (Note: Memory pages 00 through 05 are used internally by the DanLoad 6000.)
Let's assume that at this tanker vehicle loading facility it is common to load three or four batch deliveries grouped into individual transactions.
Here are the known or assumed details:
#
#
#
Transaction record length
Batch record length
=
=
150
30
Maximum number of batches in each transaction is 6. Because the batches per transaction should never exceed 6, set program code 047 Batches/transaction = 6 at this time to limit the number of batches allowed per each transaction.
#
However, almost all transactions are composed of 4 batches. Typically 4 batches times 30 bytes each batch equals 120 bytes per each transaction stored in the batch storage record. (At the end of transaction, a 150 byte transaction record will also be stored.)
Let's assume that most transactions are composed of 4 batches. In this case, at each transaction close, 150 bytes are stored in the transaction file as the transaction record for the completed transaction nnnn. And 120 bytes are stored in the batch file as
FOUR batch records that make up the completed transaction nnnn.
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# Compare the value of the transaction record length and the sum of all batch records stored for each normal transaction.
1
2
Divide the smaller value by the larger value. In this example, divide 120 by
150. The result is 0.8.
Multiply the result (0.8) by 5. (Note: 5 is the median page count of the 10 pages used to store batch and transaction files.) The result of 0.8 times 5 is
4. If the result is a fraction, round the value up to a whole number. The value, 4, is the number of pages in either the transaction file or the batch file. The file is determined by the smaller value (numerator of the division) that was determined in step 1 above. In this example, 120 (the numerator) is the sum of the bytes in 4 batches (one transaction) so the number of pages calculated in this step (4) is assigned to the batch file.
3
4
Set program code 837 Start page and # pages to 1204 (for batch storage).
This indicates that the start page is 12 and 4 pages (12, 13, 14, 15) are assigned to the batch file.
The remaining 6 pages in the transaction storage group are allocated for transaction data as follows. Set program code 835 Start page and # pages to
606 (for transaction storage). This indicates that the start page is 6 and 6 pages (6, 7, 8, 9, 10, 11) are allocated to the transaction file.
5
6
7
8
Use the data entered in the Transaction Record / Ticket Worksheet and enter the transaction data record offsets, beginning at 1, in program codes 840 through 875, as defined.
Use the data entered in the Batch Record / Ticket Worksheet and enter the batch data record offsets, beginning at 1, in program codes 880 through 901, as defined.
[Optional, only if user defined transaction ticket is defined] Use the data entered in the Transaction Record / Ticket Worksheet and enter the transaction data print coordinates in program codes 920 through 955, as defined.
[Optional, only if user defined transaction ticket is defined] Use the data entered in the Batch Record / Ticket Worksheet and enter the batch data record print coordinates in program codes 960 through 981, as defined.
Setup _________________________________________________________________ 3 - 125
DanLoad 6000 (v6.00) __________________________________________________________
Transaction Ticket (Typical)
Figure 3-12
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_________________________________________________________ DanLoad 6000 (v6.00)
Transaction Record / Ticket Worksheet (Example)
Figure 3-13
Setup _________________________________________________________________ 3 - 127
DanLoad 6000 (v6.00) __________________________________________________________
Batch Record / Ticket Worksheet (Example)
Figure 3-14
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_________________________________________________________ DanLoad 6000 (v6.00)
The data contained in the Transaction Ticket (Typical), Figure 3 - 13, is described below.
Note: The upper area of the ticket contains data obtained from transaction storage codes and therefore, each defined line is a transaction storage line.
SHIPPER This number (up to eight-digits) is obtained from TSC-11 (Data item 1). This is the operator entry in response to Prompt #1 (program code 031). Assume that this prompt has been set to read "Enter shipper I.D. number".
CLIENT This number (up to eight-digits) is obtained from TSC-12 (Data item 2). This is the operator entry in response to Prompt #2 (program code 032). Assume that this prompt has been set to read "Enter client I.D. number".
TRANSACTION SEQUENCE NUMBER
The sequence number of the transaction obtained from TSC-2 (Transaction sequence number). This number (0 to 9999) is obtained from the internal transaction counter in the DanLoad 6000. The transaction sequence number is readable by program code
042 Transaction #.
RECIPE NUMBER / NAME
The recipe number (1 to 30) is obtained from TSC-3 (Recipe number). This number is maintained internally by the DanLoad 6000. The sequential recipe numbers are assigned to recipe names which have been defined by program codes in the recipe setup program code group (program codes 480 to 661).
The recipe name (up to 16 alpha-numeric characters) is obtained from TSC-4
(Recipe name). The name is obtained from the setup entry in program code 481
Recipe name (and similar program codes in the program code group 480 to 661).
Note: The example Delivery Ticket shows a slash (/) that visually separates the recipe number and recipe name. This (/) slash is part of the pre-printed text.
TRANSACTION CLOSING (DATE/TIME)
The date and time that the transaction is ended. This data is obtained from TSC-17
(Transaction end date and time). The date format is dependent of the configuration of program code 038 Date format and program code 039 Date separator. The time format is always in the hh:mm:ss form.
TRANSACTION OPENING (DATE/TIME)
The date and time that the transaction is started. This data is obtained from TSC-16
(Transaction start date and time). The date format is dependent of the configuration of program code 038 Date format and program code 039 Date separator. The time format is always in the hh:mm:ss form.
Setup _________________________________________________________________ 3 - 129
DanLoad 6000 (v6.00) __________________________________________________________
Batch data section of the Delivery Ticket (BATCH:) follows:
The parameters in this group are defined by batch storage codes.
In the example, we will assume that any tanker vehicle can only have a maximum of six compartments and that program code 047 Batches/transaction has been set to 6 to limit each transaction to no more than six batches. Therefore, we have designed to pre-printed Delivery Ticket with enough space to print up to six batch records (lines) in this area. If the number of batches per transaction is not limited by setup (program code 047) or by strict operating procedures, the number of batch records printed could over-print the lower area of the pre-printed Delivery Ticket.
SEQ # The batch sequence number is obtained from BSC-2 (Batch sequence number). All batches that are part of one transaction will have sequential numbers in the range of 0 to 9999. The batch sequence number is readable by program code 043 Batch number.
PRESET The batch preset quantity obtained from BSC-7. This quantity was entered by the local operator when the batch delivery operation was setup.
StandardGallons [OCTANE - HIGH]
The batch standard quantity, per component, obtained from BSC-11 (Component batch standard quantity). In this example, high octane gasoline was defined as
Component 1 at setup time with program codes 066 to 068. In this case, at setup time, we have set program code 067 Meter to 1 so that the high octane gasoline is measured by flow meter 1. This is important in this instance so that we can display the flow meter based TRANSACTION GROSS CLOSING / OPENING READING in the same format in the lower area of the Delivery Ticket.
StandardGallons [OCTANE - LOW]
The batch standard quantity, per component, obtained from BSC-11 (Component batch standard quantity). In this example, low octane gasoline was defined as
Component 2 at setup time with program codes 069 to 071. In this case, at setup time, we have set program code 070 Meter to 2 so that the low octane gasoline is measured by flow meter 2. This is important in this instance so that we can display the flow meter based TRANSACTION GROSS CLOSING / OPENING READING in the same format in the lower area of the Delivery Ticket.
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TEMP [OCTANE - HIGH]
The average temperature is obtained from BSC-12 (Component batch average temperature). Since the average temperatures are related to each component that has been defined, the order of printing on the line is component 1 temperature then component 2 temperature. In this case, the pre-printed labels OCTANE - HIGH and
OCTANE - LOW identify the corresponding component.
TEMP [OCTANE - LOW]
The average temperature is obtained from BSC-12 (Component batch average temperature). Since the average temperatures are related to each component that has been defined, the order of printing on the line is component 1 temperature then component 2 temperature. In this case, the pre-printed labels OCTANE - HIGH and
OCTANE - LOW identify the corresponding component.
Note: The data obtained from batch storage codes ends here. The remaining lower area of the
Transaction Ticket contains only data obtained from transaction storage codes and therefore each defined line is a transaction storage line.
TRANSACTION ADDITIVE GROSS VOLUMES
The injected additive gross volumes for the transaction are obtained from TSC-30 to
TSC-35 (Additive x transaction gross quantity). We have assumed for the example that all six additives have been setup for injection by program codes 380 to 398.
Therefore, we have allocated space to print the gross quantities for all six additives.
Transaction additive quantities are cumulative each transaction. This means that each additive will have only one quantity value. If accumulation of additive quantities by batch is required, BSC-16 to BSC-21 can be used to access these quantities. However, space on the report must be allocated to print a quantity value for each additive and each batch. Note: pre-printed additive labels in the example are ADD1, ADD2, etc., an actual transaction ticket could use the actual additive names in place of the generic place holders used in the example.
ALARMS Report space is allocated for up to two primary alarms that occur during the transaction. The alarm messages are obtained from TSC-28 (Primary alarm during transaction) and TSC-29 (Primary alarm during transaction). The alarm messages that can be printed are defined by various program codes in the alarms group program codes 220 to 275. Only Primary alarms are printed by TSC-28 and TSC-29. Two transaction storage codes are accessible to provide printing capability of up to two primary alarms that occur during a transaction.
Setup _________________________________________________________________ 3 - 131
DanLoad 6000 (v6.00) __________________________________________________________
BitMap The alarm bitmap is obtained from TSC-27 [Primary alarms during transaction
(bitmap)]. Note: Most organizations will probably not print the bitmap field on a pre-printed report. However, the alarm bitmap does provide an historical record of primary alarms that occur during transaction processing. The alarms bitmap usually has limited utility in a stand alone system because 1) occurrence of primary alarms indicates a hardware or operational problem that should be corrected immediately, and 2) interpretation of an alarms bitmap requires an understanding of the binary and hexadecimal numbering schemes. Section 3.10.6 contains information on interpreting the alarm bitmap.
TRANSACTION GROSS CLOSING READING
This gross quantity, per flow meter, obtained from TSC-25 (Gross meter totalizer at end of transaction). In this example, high octane gasoline was defined as
Component 1 at setup time with program codes 066 to 068. The low octane gasoline was defined as Component 2 at setup time with program codes 069 to 070. In this case, at setup time, we have set program code 067 Meter to 1 and program code 070
Meter to 2 so that the high octane gasoline is measured by flow meter 1 and the low octane gasoline is measured by flow meter 2. This is important in this instance so that we can display all quantities on the Delivery Ticket in the same order.
TRANSACTION GROSS OPENING READING
This gross quantity, per flow meter, obtained from TSC-23 (Gross meter totalizer at start of transaction). In this example, high octane gasoline was defined as
Component 1 at setup time with program codes 066 to 068. The low octane gasoline was defined as Component 2 at setup time with program codes 069 to 070. In this case, at setup time, we have set program code 067 Meter to 1 and program code 070
Meter to 2 so that the high octane gasoline is measured by flow meter 1 and the low octane gasoline is measured by flow meter 2. This is important in this instance so that we can display all quantities on the Delivery Ticket in the same order.
TOTAL GROSS TRANSACTION QUANTITY
This total quantity is obtained from TSC-18 (Transaction gross quantity). The quantity is calculated by the following formula.
TRANSACTION GROSS CLOSING READING (TSC-25) (all meters)
minus
TRANSACTION GROSS OPENING READING (TSC-23) (all meters)
equals
TOTAL GROSS TRANSACTION QUANTITY
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FLOW WEIGHTED AVERAGE TEMP.
This value is obtained from TSC-20 (Transaction average temperature). The value is calculated by the following formula.
sum of COMPONENT BATCH AVERAGE TEMPERATURE
(for all components) divided by the number of
COMPONENT BATCH AVERAGE TEMPERATURE values
DELIVERED Standard quantity AT 60 DEG F
This quantity is obtained from TSC-19 (Transaction standard quantity). This quantity is calculated by the following formula.
TOTAL GROSS TRANSACTION QUANTITY times the
COMBINED CORRECTION FACTOR equals
DELIVERED Standard quantity AT 60 DEG F
Note: The COMBINED CORRECTION FACTOR is the temperature correction factor in this case because pressure compensation is not applied.
DRIVER Space for the tanker vehicle driver to sign for receipt of product.
TERMINAL AUTHORIZATION
Space for the terminal supervisor or operator to sign for delivery of product.
Setup _________________________________________________________________ 3 - 133
DanLoad 6000 (v6.00) __________________________________________________________
3.11.2
Default Ticket Formats
Three default ticket formats are preconfigured in the DanLoad. Refer to program code 838 for a complete description of the Transaction Ticket Format. The basic formats are:
Format #1 -
Format #2 -
Format #3 -
Ticket without batch data
Ticket with batch data
Ticket with only batch data
See Figure 3-16 on the following page for an example of these formats.
Note: The first line under each format heading (numbers 1-8) and the very next line are used to indicate the column number (1-80) of the preconfigured ticket format. Transaction storage codes are in plain type. Batch storage codes are underlined. Field widths are indicated by dots to the right of the storage codes, even though the values may be right-justified within the fields.
Reference TSC and BSC codes on pages 3-129 to 3-131 for Field Identifier.
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Format 1 - Transaction sum m ary without batch data
1 2 3 4 5 6 7 8
12345678901234567890123456789012345678901234567890123456789012345678901234567890 (Column #)
1.. 5 2... 3. 4...............
18.... 19.... 20...
16............... 17...............
6............................... 11......
23....... 25....... 24....... 26....... <-- Assumes one meter only.
27..................
30........
31........
32........
33........
34........
35........
12345678901234567890123456789012345678901234567890123456789012345678901234567890 (Column #)
1 2 3 4 5 6 7 8
Format 2 - Transaction sum m ary with batch data
1 2 3 4 5 6 7 8
12345678901234567890123456789012345678901234567890123456789012345678901234567890 (Column #)
1.. 5 2... 3. 4...............
18.... 19.... 20...
16............... 17...............
6............................... 11......
23....... 25....... 24....... 26....... <-- Assumes one meter only.
27..................
30........
31........
32........
33........
34........
35........
2... 7..... 8..... 9..... 4.... 6..... 5.....
12345678901234567890123456789012345678901234567890123456789012345678901234567890
1 2 3 4 5 6 7 8
Format 3 - Batch data
1 2 3 4 5 6 7 8
12345678901234567890123456789012345678901234567890123456789012345678901234567890 (Column #)
1.. 5 2... 3. 4...............
2... 7..... 8..... 9..... 4.... 6..... 5.....
DanLoad Default Ticket Formats
Figure 3-15
Setup _________________________________________________________________ 3 - 135
DanLoad 6000 (v6.00) __________________________________________________________
3.11.3
Transaction Data Storage
The remaining sub-sections in the 3.10.x series contain detailed information on transaction data storage and user defined transaction tickets.
Transaction / batch data storage parameters are defined by program codes 834 to 838, 840 to 875, and 880 to 901. The function of these codes is independent from transaction ticket printing related program codes. However, if user defined transaction / batch tickets are printed, an interrelation between the different groups of program codes MUST BE established. Part of this interrelation between program codes is performed manually at setup time and part is established automatically internally by the DanLoad 6000. Program codes 920 to 981 specify the format of the printed tickets.
In addition, program codes 706, 707, and 709 control the actual printing and sequence numbering of transaction tickets.
All other program codes implemented in the DanLoad 6000, except those listed in the previous paragraph, are related to process monitor / control and manner of operation of the DanLoad 6000.
However, the transaction / batch storage codes and ticket printer control codes implement programming / database methods.
Definitions
Byte
Nybble
The term byte refers to a small space (8 binary bits) in computer memory used to store one alpha (letter, number, or special) character used as text only or two numeric (number) characters.
A nybble is 4 binary bits. A byte contains two nybbles.
Database Terminology (applicable to DanLoad 6000 batch and transaction storage)
Database
File
All of the static (unchanging) and dynamic (changing) data stored in the DanLoad
6000.
In this case, the transaction file and the batch file are database tables. Each file is a block of non-volatile (battery backed) memory that stores batch and transaction data in logical groups. The file (table) contains groups of similar type data that make up part of the database. The groups of data in the file are divided into columns and rows similar to data entered on paper. The columns are called fields and the rows are called records. The batch and transaction files are separate random access
(any data variable can be located with a pointer to (address of) the variable) files.
See Record definition below.
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Field A vertical column that contains similar type data. Each field contains one or more alpha-numeric characters. The Transaction and Batch File Organization table below indicates the field and record organization of both transaction and batch files. The field contents of a transaction record are defined by program codes 840 to 875. And the field contents of a batch record are defined by program codes 880 to 901. The transaction storage setup process allows the user to define multiple data items that are grouped as sub-fields in the User Defined field of the Batch Record and the
Transaction Record.
Record
Record Header
A row (horizontal string of alpha-numeric characters) that contains various types of data, divided into fields. Each of the up to ten-thousand batch records and up to tenthousand transaction records contains information on one completed batch loading
(in the batch file) or one completed transaction (in the transaction file). The length of each record in the transaction file is set to a fixed number of bytes by program code 834 Transaction record length. The length of each record in the batch file is set to a fixed number of bytes by program code 836 Batch record length. Note: The process of defining the contents of the user defined field of a batch record or transaction record define a template of the record contents. The actual alpha-numeric contents of each record is written into each record during or after a batch loading or transaction operation.
[Note: In the table below, all fields (columns) except the User Defined field
(column) are part of the record header.] Record header fields in each record contain information that is maintained and used internally by the DanLoad 6000. This information enables the DanLoad 6000 to know where to find each record and what data is contained in each record. The records are located by index numbers which are similar to page numbers in the index of a book. The record header fields for both transaction records and batch records are shown in the following table Transaction
and Batch File Organization. The record header fields are maintained internally by the DanLoad 6000.
When transaction / batch storage is enabled, a non-volatile memory block (file) is created for up to 10,000 user definable batch data records and up to 10,000 user definable transaction data records. A record is a row in a database table. Columns in the database table define data fields.
The table below shows the relationship between the data stored each transaction record (and file) and the separate data stored in each batch record (and file). Note that the transaction and batch records are stored in separate batch and transaction files. The table shows one transaction record (top) and one batch record (bottom) together for field comparison only.
Setup _________________________________________________________________ 3 - 137
DanLoad 6000 (v6.00) __________________________________________________________
Type of
Record 9
Transaction
>
Batch
>
Batch
Sequence
Number
Transaction and Batch File Organization
(Record Header Fields plus User Defined Field)
Transaction
Sequence
Number
Start
Batch
Number
Number of
Batches in
Transaction
Operating
Mode Status
Batch file key
Transaction file key
<yes>
<yes> <yes> <yes> <yes>
<yes>
User
Defined
<yes>
<yes>
Notes:
# The transaction and batch file keys are not stored in their respective records. The DanLoad
6000 maintains these index numbers internally.
# <yes> indicates that this field is stored in the corresponding record type.
<blank> indicates that the field is not applicable to the corresponding record type.
The fields contained in each record are defined below.
Batch Sequence Number (internal pointer to batch record)
The Batch Sequence Number is a sequential number between 0000 and 9999 that is maintained internally by the batch record counter in the DanLoad 6000. This number is not stored in any record field. However, because all batch deliveries and therefore batch numbers are sequential, the DanLoad 6000 can locate any batch record by setting the batch record counter.
Transaction Sequence Number (stored as part of batch record header)
The Transaction Sequence Number is a sequential number between 0000 and 9999 that is maintained internally by the transaction record counter in the DanLoad 6000. This number is not stored in transaction records. However, the current Transaction Sequence Number is stored in the record header of each batch record. Because all transactions and therefore transaction numbers are sequential, the DanLoad 6000 can locate any transaction record by setting the transaction record counter. The Transaction Record Number stored in the batch record header is used to group multiple batches into one transaction.
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Start Batch Number (stored as part of transaction record header)
The Start Batch Number is a number between 0000 and 9999 that is saved in a transaction record when the first batch delivery of the transaction is started. This number is stored in the transaction record header. This number, in conjunction with the Number of batches in
Transaction number is used to group one or more batch deliveries into one transaction.
Number of Batches in Transaction (stored as part of transaction record header)
The Number of Batches in Transaction is a number between 0001 and 9999 that is saved in a transaction record after the transaction is terminated. This number is stored in the transaction record. This number, in conjunction with the Start Batch Number is used to group one or more batch deliveries into one transaction.
Operating Mode (stored as part of transaction record header)
The Operating mode is a number obtained from the state of program code 025 Operating
mode at the start of the current transaction. The possible Operating Modes are listed below.
Operating Mode Number
0
1
2
Operating Mode
Auto
Manual
Stand-alone
Status (stored as part of transaction and batch record headers)
The Status is a number that identifies the current state of each record. The possible states are listed below.
Status Number Record Status
0
1
2 record is not allocated and does not contain valid data record is allocated, awaiting data from a batch loading or transaction in progress completed, the data is valid for the successfully completed batch loading or transaction
Setup _________________________________________________________________ 3 - 139
DanLoad 6000 (v6.00) __________________________________________________________
User Defined (data field that is not part of record header)
[Note: The User Defined field contains multiple data items (sub-fields) that are defined at setup time.] The complete User Defined field can be from 0 to 250 bytes in length. The length of this field is set to a fixed value (record length) for all transaction records by program code 834 Transaction record length and is independently set to a fixed value
(record length) for all batch records by program code 836 Batch record length. Selected data is placed in sub-fields of this field at setup time by program codes 840 through 875 for transaction records and program codes 880 through 901 for batch records. Data is selected by Transaction Storage Codes (TSC) for transaction records (file) and Batch Storage
Codes (BSC) for batch records (file). The two tables Transaction Storage Codes and Batch
Storage Codes contain information on the selectable data definitions.
During setup of transaction storage codes, the following two rules must be observed or the data will not be stored.
# Each data variable cannot overlay another data variable in storage. Data variables must be placed end to end with no overlap.
# Any data variable cannot extend past the last byte of the record as defined by program code 834 for transaction records or program code 836 for batch records.
The following example of the User Defined portion of a batch record illustrates application of these rules. Assume that program code 836 is set to 50 (batch record length is fixed at
50 bytes).
1 2 3 4 5
12345678901234567890123456789012345678901234567890 < OFFSET
aabbttTTPPPPcccccccccccccccc < good record
PPPP < bad record
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The OFFSET is the position in the 50-byte record length set by program code 836. If program code 836 where set to 0, no memory space is allotted and no data is stored. Data storage is enabled by setting program code 836 to any value between 1 and 250. Very small values in this variable are not meaningful because of the limitation of data variable storage.
Example of good record shows the following assigned data storage.
Program
Code
880
881
882
883
Variable
Unit address
Storage Length (bytes)
2 (aa)
Batch sequence number
Transaction sequence number
Temperature
2 (bb)
2 (tt)
2 (TT)
884
889
Pressure 4 (PPPP)
Component gross quantity
4 * number of components defined (cccccccccccccccc)
File Pointer + Number of
Bytes in Variable
1 + 2 bytes
(9 start next at byte 3)
3 + 2 bytes
(9 start next at byte 5)
5 + 2 bytes
(9 start next at byte 7)
7 + 2 bytes
(9 start next at byte 9)
9 + 4 bytes
(9 start next at byte 13)
13 + (4 * 4 bytes)
(9 start next at byte 29)
A transaction consists of one or more batch deliveries of a single recipe and additive selection combination. Process data for transactions is stored by the DanLoad 6000 and can be accessible, depending on the configuration of several program codes.
Setup _________________________________________________________________ 3 - 141
DanLoad 6000 (v6.00) __________________________________________________________
Program Code
696
697
706
707
Transaction Data Access Program Codes
Function
Enables printing of the PREDEFINED STANDARD Batch Summary
Report on one of up to four selectable printers.
Enables printing of the PREDEFINED STANDARD Transaction
Summary Report on one of up to four selectable printers.
Enables printing of a USER DEFINED Transaction Ticket on a one of up to four selectable printers.
Enables selection and printing of a USER DEFINED Transaction Ticket on one of up to four selectable printers. The selection and re-printing function is enabled by manual entry of the transaction sequence number in the Reprint transaction ___ display. The Reprint transaction ___ display is accessible by the second selection in the Program Mode
Menu.
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The following tables contain information on Transaction Storage Codes (TSC) and Batch Storage
Codes (BSC). A description of the data in the tables follows the tables.
1 Addr
2 Tr seq #
3 Recipe #
4 Recipe name
5 Side
6 Prompt 1
7 Prompt 2
8 Prompt 3
9 Prompt 4
10 Prompt 5
11 Data item 1
12 Data item 2
13 Data item 3
14 Data item 4
15 Data item 5
16 Start date
17 End date
18 Gross
19 Std
20 Temp
21 Pres
22 Dens *
TSC Number and
Display
Transaction Storage Codes (TSC) Table 3 - 4
Record Offset
Program
Code
Ticket
Coordinates
Program Code
Time Saved # bytes/format
931
932
933
934
927
928
929
930
935
936
937
938
939
940
941
920
921
922
923
924
925
926
851
852
853
854
847
848
849
850
855
856
857
858
859
860
861
840
841
842
843
844
845
846 start trns start trns start trns start trns start trns start trns start trns start trns start trns end trns start trns start trns start trns start trns start trns start trns start trns end trns end trns end trns end trns end trns
2/nnn
2/nnnn
2/nn
16/(a16)
1/n
32/(a32)
32/(a32)
6/
6/
32/(a32)
32/(a32)
32/(a32)
4/nnnnnnnn
4/nnnnnnnn
4/nnnnnnnn
4/nnnnnnnn
4/nnnnnnnn
4/nnnnnn
4/nnnnnn
2/nnn.n
4/
4/
Reference
DUART address
PC 042 internal register
PC 481...
DC 001
PC 031
PC 032
PC 033
PC 034
PC 035 entry for PC 031 entry for PC 032 entry for PC 033 entry for PC 034 entry for PC 035
PC 038, 039
PC 038, 039
PC 457
Table continues on next page.
Setup _________________________________________________________________ 3 - 143
DanLoad 6000 (v6.00) __________________________________________________________
Transaction Storage Codes (TSC) Table 3 - 4 (continued)
TSC Number and
Display
23 Start gross
Record Offset
Program
Code
862
Ticket
Coordinates
Program Code
942
Time Saved start trns
# bytes/format Reference
24 Start std
25 End gross
26 End std
27 Alarm bit map
28 Prim alarm
29 Temp alarm
30 Add 1
31 Add 2
32 Add 3
33 Add 4
863
864
865
866
867
868
869
870
871
872
943
944
945
946
947
948
949
950
951
952 start trns end trns end trns end trns end trns end trns end trns end trns end trns end trns
4 * # of meters/ nnnnnnnnn
4 * # of meters/ nnnnnnnnn
4 * # of meters/ nnnnnnnnn
4 * # of meters/ nnnnnnnnn
10/(a20)
10/(a40)
10/(a40)
4/nnnnnnn.nn
4/nnnnnnn.nn
4/nnnnnnn.nn
4/nnnnnnn.nn
34 Add 5
35 Add 6
36 Op mode
37 Gross units
38 Std units
873
874
875
876
877
953
954
955
956
957 end trns end trns authorize trns authorize trns authorize trns
4/nnnnnnn.nn
4/nnnnnnn.nn
1/n
6/nnnnnn
6/nnnnnn
PC 025
* The component 1 backup density/gravity is stored/printed. The individual batch densities/gravities are not averaged.
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BSC Number and
Display
1 Addr
2 Ba seq #
3 Tr seq #
4 Temp
5 Pres
6 Dens
7 Preset
8 Gross
9 Std
10 Comp gross
11 Comp std
12 Comp temp
13 Comp dens
14 Comp pres
15 Comp %
16 Add 1
17 Add 2
18 Add 3
19 Add 4
20 Add 5
21 Add 6
22 Op mode
880
881
882
883
884
885
886
887
888
889
Batch Storage Codes (BSC) Table 3 - 5
Record Offset
Program
Code
Ticket
Coordinates
Program Code
Time Saved # bytes/format
960
961
962
963
964
965
966
967
968
969 start batch start batch start batch end batch end batch end batch start batch end batch end batch end batch
890
891
892
893
894
895
896
897
898
899
900
901
970
971
972
973
974
975
976
977
978
979
980
981 end batch end batch end batch end batch end batch end batch end batch end batch end batch end batch end batch authorize trns
2/nnn
2/nnnn
2/nnnn
2/nnn.n
4/nnnn.n
4/nnnn.n
4/nnnnnn
4/nnnnnn
4/nnnnnn
4 * # of comp/ nnnnnn
4 * # of comp/ nnnnnn
2 * # of comp/ nnn.n
4 * # of comp/ n.nnnn
4 * # of comp/ nnnn.n
2 * # of comp/ nnn.n
4/nnnnnnn.nn
4/nnnnnnn.nn
4/nnnnnnn.nn
4/nnnnnnn.nn
4/nnnnnnn.nn
4/nnnnnnn.nn
1/n
Reference
DUART address
PC 043
PC 042
DC 132
DC 134
DC 133
DC 102
DC 002
DC 003
DC 072, 078, 084,
090
DC 073, 079, 085,
091
DC 075, 081, 087,
093
DC 107, 109, 111,
113
DC 108, 110, 112,
114
DC 122, 123, 124,
125
DC 115
DC 116
DC 177
DC 118
DC 119
DC 120
PC 025
Setup _________________________________________________________________ 3 - 145
DanLoad 6000 (v6.00) __________________________________________________________
The tables above contain the following data.
TSC / BSC Number and Display
This column contains the identification number and text displayed when the Record Offset
Program Code is addressed.
Record Offset Program Code
This column contains the program code that defines the byte offset (1 to 250) within the user defined area of each transaction or batch record.
Ticket Coordinates Program Code
This column contains the program code that defines the row and column coordinates to print the data on a user defined transaction ticket. This function is described below in the User
Defined Transaction Ticket section.
Time Data is Saved
This column contains the time, in the transaction time sequence, when the data variable is saved.
2
3
4
5
6
Step
1
7
State
Authorize transaction
[authorize trns]
Start transaction
[start trns]
Authorize batch
[authorize batch]
Start batch
[start batch]
Batch in progress
End batch
[end batch]
End transaction
[end trns]
Normal Transaction Sequence
Action
Select recipe
(single recipe setup defaults to recipe # 1)
Select additives (if defined)
Enter preset quantity for first batch to load
(go to Step 4)
Enter preset quantity to load
(same as Step 2 for first batch load)
Press START push-button to start any batch load
OR
Press START push-button to restart a suspended batch loading before preset quantity is delivered
Loading is in progress
Preset quantity has been delivered [return to step 3 if multiple batch loads are grouped in this transaction]
OR
Press STOP/PRINT push-button [restart batch load (go to step 4) if allowed or return to step 3 if multiple batch loads are grouped in this transaction]
Press STOP/PRINT push-button with no load in progress
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Sequence Steps 3 through 6 are repeated for multiple batch loads that are grouped into one transaction.
# bytes/format
This column contains the number of bytes required to store the data variable in the transaction or batch record and the format of the data printed on a User Defined Transaction
Ticket. Note that alpha-numeric data, such as the Recipe name and Prompt # is stored in a standard ASCII string without NULL terminator (00 byte). Numeric data is stored in packed binary (two decimal digits per byte). Fixed format characters, such as decimal points and date/time field separators, are not stored but are maintained internally by the DanLoad 6000.
Several data values are stored and can be printed in groups that are dependent on the number of flow meters or number of components defined by the system setup. Examples are:
Transaction Storage Code 23 Start Gross, program code 862
Four bytes in printable format nnnnnnnn times the number of flow meters defined. Each field is printed on one line with one space between each field.
nnnnnnnn nnnnnnnn nnnnnnnn < example shows three flow meters
Batch Storage Code 10 Comp gross, program code 889
Four bytes, each in printable format nnnnnn, times the number of components defined.
Each field is printed on one line with one space between each field.
nnnnnn nnnnnn nnnnnn < example shows three components
Reference
This column contains an addressable program code (PC nnn), data code (DC nnn), or other readable point, such as DUART address from address selection switches on DUART, for reading the variable. This reference is not the source of the data variable. But, the reference refers to an addressable point where the variable can be read.
Setup _________________________________________________________________ 3 - 147
DanLoad 6000 (v6.00) __________________________________________________________
3.11.4
Relation Between Batch Storage and Transaction Storage Variables
Three batch storage codes and transaction storage codes reference identical data as indicated in the following table.
Batch Storage Code
1 Addr
3 Tr seq #
22 Op mode
Com m on Storage Codes
Transaction Storage Code
1 Addr
2 Tr seq #
36 Op mode
Reference
DUART address
PC 042
PC 025
A storage variable can only be defined one time in a batch storage record or a transaction storage record. In addition, any one variable can only be assigned one set of print coordinates for a user defined Transaction Ticket. Therefore, all batch and transaction variables, with the exception of the three variables listed above, can only appear once on a Transaction Ticket.
Relation Between Various Batch Storage Codes
Batch storage codes are related to other batch storage codes in the following manner.
Batch Storage Code
4 Temp
5 Pres
6 Dens
8 Gross
9 Std
Batch Storage Code (BSC) Relations
7 Source Batch Storage Code
Average of BSC 12 Comp temp for all defined com ponents in the batch.
Average of BSC 14 Comp pres for all defined com ponents in the batch.
Average of BSC 13 Comp den for all defined com ponents in the batch.
Sum of BSC 10 Comp gross for all defined com ponents in the batch.
Sum of BSC 11 Comp std for all defined com ponents in the batch.
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3.11.5
Relation Between Transaction Storage Codes / Batch Storage Codes / Program
Codes
Transaction storage codes are related to other transaction storage codes and batch storage codes in the following manner.
Transaction Storage Code (TSC) Relations
Transaction Storage Code 7 Source Transaction Storage Code
6 Prompt 1
6 Prompt 2
7 Prompt 3
8 Prompt 4
9 Prompt 5
18 Gross
19 Std
20 Temp
21 Pres
22 Dens
30 Add 1
31 Add 2
32 Add 3
33 Add 4
34 Add 5
35 Add 6
Program code 031 <prompt #1> text for which the operator entered response is 11 Data item 1 during transaction setup.
Program code 032 <prompt #2> text for which the operator entered response is 12 Data item 2 during transaction setup.
Program code 033 <prompt #3> text for which the operator entered response is 13 Data item 3 during transaction setup.
Program code 034 <prompt #4> text for which the operator entered response is 14 Data item 4 during transaction setup.
Program code 035 <prom pt #5> text for which the operator entered response is 15 Data item 5 during transaction setup.
Sum of 25 End gross m inus 23 Start gross for each defined flow m eter. (Sum of BSC 8 Gross for all batches in the transaction.)
Sum of 26 End std m inus 24 Start std for each defined flow m eter.
(Sum of BSC 9 Std for all batches in the transaction.)
Average of BSC 4 Temp for all batches in the transaction.
Average of BSC 5 Pres for all batches in the transaction
Program code 454 Component 1 backup density/gravity. The individual densities/gravities are not averaged.
Sum of BSC 16 Add 1 for all batches in the transaction
Sum of BSC 17 Add 2 for all batches in the transaction
Sum of BSC 18 Add 3 for all batches in the transaction
Sum of BSC 19 Add 4 for all batches in the transaction
Sum of BSC 20 Add 5 for all batches in the transaction
Sum of BSC 21 Add 6 for all batches in the transaction
Setup _________________________________________________________________ 3 - 149
DanLoad 6000 (v6.00) __________________________________________________________
The following table describes the relationship between the quantity total accounting for batches and transactions.
Com ponent1
Batch Quantity Totals
Com ponent2 Com ponent3 Com ponent4
10 Comp gross 10 Comp gross 10 Comp gross 10 Comp gross
BSC 8 Gross is the sum of all defined BSC 10 Comp gross quantities in the batch.
11 Comp std 11 Comp std 11 Comp std 11 Comp std
BSC 9 Std is the sum of all defined BSC 11 Comp standard quantities in the batch.
M eter3
(PC-067)
M eter2
(PC-070)
Transaction Quantity Totals
M eter4
PC-073)
M eter1
(PC-076)
25 End gross
23 Start gross
25 End gross
23 Start gross
25 End gross
23 Start gross
25 End gross
23 Start gross
TSC 18 Gross is the sum of all defined TSC 25 End gross m inus TSC 23 Start gross m eter quantities in the transaction. This value is equal to the sum of all BSC 8 Gross quantity accum ulations for the transaction.
26 End std
24 Start std
26 End std
24 Start std
26 End std
24 Start std
26 End std
24 Start std
TSC 19 Std is the sum of all defined TSC 26 End std m inus TSC 24 Start std m eter quantities in the transaction. This value is equal to the sum of all BSC 9 Standard quantity accum ulations for the transaction.
Batch and Transaction Quantity Totals Accounting
Batch and transaction quantity accumulations are for deliveries of one recipe which is: single component quantity without additives, single component quantity with additives, blend quantity without additives, or blend quantity with additives.
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Components are permanently assigned to flow meters by program codes 067, 070, 073, and 076.
The component assignment in the table above is an example only. The example shows that any component can be assigned to any flow meter. The table shows that batch quantities are accumulated per component and the sum of all component quantity accumulations is added to obtain the total batch quantity accumulations (BSC 8 Gross and BSC 9 Std). The table also shows that transaction quantities are accumulated per flow meter and the sum of all flow meter accumulations is added to obtain the total transaction quantity accumulations (TSC 18 Gross and TSC 19 Std). The method of quantity accumulation allows access to both component quantities, for batches, and flow meter quantities, for transactions, for user defined Transaction Tickets and terminal automation systems.
It is obvious that the only quantity accounting device in any tanker vehicle loading installation is the flow meter. The quantity accounting per component is performed by the DanLoad 6000 control program.
As explained later in the Transaction Ticket Configuration section, the component to flow meter assignments determine the print format for multiple components [batch data (BSC 10 / 11 / 12 /
13 / 14 / 15)] and flow meters [transaction data (TSC 23 / 24 / 25 / 26)]. Therefore, if the listing order of multiple batch quantity totals must match the listing order of transaction totals, overall system design and setup can be important for user defined Transaction Tickets.
3.11.6
Transaction Ticket Configuration Overview
Selected transaction / batch data can be printed on a pre-printed form. The form can be used as a loading ticket or transaction report. This section contains information on configuration of a user defined transaction ticket. An example transaction ticket, Figure 3 - 13, is used to illustrate the example. The bold text signifies the pre-printed part of the form. The regular text signifies the data variables obtained from transaction storage codes or batch storage codes.
User configurable transaction tickets can be printed on personal computer style data printers. Or the tickets can be transmitted to, and archived in, a personal computer or similar processing device.
User configurable transaction tickets are completely independent from the standard format Batch
Summaries and Transaction Summaries. Therefore, user definable transaction tickets can be printed regardless of the print status of Batch Summaries and Transaction Summaries. Data Logging
Section 4.4.1 contains information on Batch Summaries and Transaction Summaries.
The reason for the user defined transaction tickets capability is to permit batch and transaction loading data to be printed on a pre-printed loading ticket (transaction Bill of Lading). The process of defining the format of the printed transaction ticket is easy. However, some planning is required to insure that the ticket layout is as desired and that the ticket contains the required data.
Setup _________________________________________________________________ 3 - 151
DanLoad 6000 (v6.00) __________________________________________________________
3.11.7
Transaction Ticket Layout Planning
Although printing user defined data on an existing pre-printed ticket form is certainly possible, it is usually easier to plan the layout of the required printed data from the DanLoad 6000 and then design the pre-printed form to fit the printed data format. The data from the DanLoad 6000 is obtained from transaction storage codes (TSC) that have been defined for the transaction storage record and batch storage codes (BSC) that have been defined for the batch storage record. A word processor program for a personal computer can generate an example form similar to the example
Transaction Ticket, Figure 3 - 13. Otherwise, the form can be designed with paper and pencil.
Remember that multiple batch data in one transaction prints on consecutive lines. Quantity data from transaction storage codes 23 / 24 / 25 / 26 prints variable length lines dependent on the number of flow meters defined. And data from batch storage codes 10 / 11 / 12 / 13 / 14 / 15 prints variable length lines dependent on the number of components defined.
The DanLoad 6000 outputs standard ASCII characters to the printer. The printer determines the appearance (font) of the printed data. Virtually all personal computer style printers default to
Courier 10 font. These characters are printed 10 cpi (characters per inch) and 6 lines per inch.
Most printers allow manual selection of Courier 12 font which prints characters at 12 cpi and 8 lines per inch. Fonts smaller than Courier 12 are usually not suitable for this type of report.
After the required data for the Transaction Ticket has been selected from the transaction storage file and the batch storage file, the print coordinates should be defined and a test printout generated on blank paper. Review the test printout. Check for space for the pre-printed areas of the form. Check for a clear area of approximately 1-inch (2.5 cm) along the left margin to allow for holes and storage in a ring binder. Adjust the print coordinates of data items as required so that the data and spacing appears correct on the paper. After adjustments have been made, manually enter the data to be pre-printed with a color pen. You may need to consult with a print shop at this time to determine if the space allotted for the pre-printed area of the form is sufficient for the desired preprinted text.
The format of a Transaction Ticket is very flexible. However, the following rules are applicable to format design.
# Any transaction line (row) of the Transaction Ticket can only contain transaction data. In other words, if a line of the Transaction Ticket contains a variable assigned by transaction storage codes 840 through 875, then any other variable displayed on that line must also be assigned by transaction storage codes 840 through 875.
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#
#
#
Any batch line (row) of the Transaction Ticket can only contain batch data. In other words, if a line of the Transaction Ticket contains a variable assigned by batch storage codes 880 through 901, then any other variable displayed on that line must also be assigned by batch storage codes 880 through 901.
Transaction storage codes 23 / 24 / 25 / 26 assign quantity data storage space in memory for flow meter quantities in the following format.
Meter_1_quantity Meter_2_quantity Meter_3_quantity Meter_4_quantity
The quantity values for each configured flow meter are stored in sequence and will be printed in this sequence if any of these four transaction storage codes is assigned print coordinates on the Transaction Ticket. The values are right justified with leading zeros suppressed. A minimum of one horizontal space is open between each accumulator value, dependent on the number of digits in the value.
Batch storage codes 10 / 11 / 12 / 13 / 14 / 15 assign quantity, temperature, pressure, density, and quantity percentage data storage space in memory for components in the following format.
Component_1_value Component_2_value Component_3_value Component_4_value
The values for each configured component and variable type are stored in sequence and will be printed in this sequence if any of these four transaction storage codes is assigned print coordinates on the Transaction Ticket. The values are right justified with leading zeros suppressed. A minimum of one horizontal space is open between each accumulator value, dependent on the number of digits in the value.
During planning of the Transaction Ticket, we need to know a few things about the configuration of the DanLoad 6000 in order to design a Transaction Ticket properly. The following program codes have either direct or indirect effect on the data can be printed on the Transaction Ticket.
# Program code 025 Operating mode
Defines the operating mode for the DanLoad 6000. The operating mode determines how transaction and batch records are archived in their respective files. [Operating mode is accessible by TSC 36 and BSC 22]
# Program code 031 through 035 Prompt for data item #x
The actual text entries for prompts can be printed. The eight-digit operator entries in response to these prompts can also be printed. [Prompt test is accessible by TSC 6 to 10]
Setup _________________________________________________________________ 3 - 153
DanLoad 6000 (v6.00) __________________________________________________________
#
#
#
#
#
#
#
#
#
#
#
#
Program code 038 Date format and 039 Date separator
Determine the format for printing the date. [Date is accessible by TSC 16 and TSC 17]
Program code 047 Batches/transaction
Limits the number of batches in each transaction. [Important for user defined transaction tickets]
Program code 067 / 070 / 073 / 076 Meter
The component to flow meter assignments determine the order for printing component values
(quantities) for transaction storage codes 23 / 24 / 25 / 26.
Program code 080 Preset/delivery type
Determines the gross or standard engineering units for BSC-7 Preset quantity
Program code group 135 through 168 Additive injection
Determine the maximum number of additive values (Volumes) that can be printed.
[See TSC 30 to 35 and BSC 16 to 21]
Program code group 220 through 268, 274, 275 Alarms
Determine the primary alarm assignments that are available for printing. Only primary type alarms can be printed. [See TSC 27 / 28 / 29]
Program code 343 Auto/manual change-over
Determines mode of operation which effects the transaction and batch storage data files.
Program code 344 Primary alarm reset
Determines when primary alarms are reset by an external input.
Program code group 380 through 398 Additive injection
Determines how additive injection volumes are accumulated. [See TSC 30 to 35 and BSC
16 to 21]
Program code group 426 through 479 Temperature/Pressure/Density
Sets the process variable engineering units for temperature, pressure, and density. If any of these values are printed, the pre-printed engineering units labels must match the internally used engineering units. [See TSC 20 / 21 / 22]
Program code group 480 through 661 Recipes
Defines the recipe names and associates these names with internally maintained recipe numbers. Both recipe names and or recipe numbers can be printed. [See TSC 3 and 4]
Program code group 663 through 673 Data Communications Parameters
Defines the serial data port parameters for interface to a serial input printer or other data acquisition device.
3 - 154 _________________________________________________________________ Setup
_________________________________________________________ DanLoad 6000 (v6.00)
#
#
#
#
#
#
#
Program code 696 Batch summary
Defines printer interface for the STANDARD pre-formatted batch summary report. This report is different from the batch data printed a user defined Transaction Ticket.
Program code 697 Transaction summary
Defines printer interface for the STANDARD pre-formatted transaction summary report.
This report is different from the transaction data printed in the user defined Transaction
Ticket.
Program code 706 Transaction ticket
Defines printer interface for the user defined Transaction Ticket described in this section.
Program code 707 Transaction ticket reprint
Defines printer interface for re-printing Transaction Tickets manually from the Reprint transaction display in Program Mode.
Program code 709 Sequence numbers
Enables printing of form sequence numbers (0 to 9999) unique for each printer. This feature allows organization and audit tracking of all forms printed on all printers.
Program code group 834 through 877, 880 through 901
Control and define storage of transaction storage variables and batch storage variables in the transaction and batch files. Each variable must be stored in its respective file to enable access to the variable for printing in the Transaction Ticket.
Program code group 920 through 957, 960 through 982
Define the row and column coordinates, for each transaction and/or batch variable, on the printed Transaction Ticket.
Setup _________________________________________________________________ 3 - 155
DanLoad 6000 (v6.00) __________________________________________________________
3.11.8
Alarm BitMap
The alarm bitmap is normally not printed on transaction tickets. However, comparison of alarm activity for several loading operations can be a useful diagnostic tool.
For the following description we presuppose that the reader does not have programming experience but does have some knowledge of number base systems. The common base 10 number system uses digits 0 through 9 to indicate the value of each digit position. The position decimal weight increases by 1 power of 10 for each position change in the leftward direction from the decimal point. The
DanLoad 6000, like all digital computers, uses the base 2 number system which uses digits 0 and
1 to indicate the value of each position. The position binary weight increases by 1 power of 2 for each position change in the leftward direction from the binary point. A third number base system, the base 16 (hexadecimal) number system is used solely to make the binary (base 2) number system more readable and manageable for people. The hexadecimal number system uses digits 0 to 9, a, b, c, d, e, f. The a through f digits are symbols that are place holders for decimal digits
10 through 15. The symbols serve only as single character place holders to represent possible numbers in the number system. The bitmap as the name implies is binary based. Each bit stands for one unique alarm. Each bit can be 0 (no alarm occurred) or 1 (alarm occurred). The bitmap is transmitted and read as hexadecimal for ease of use by people. The relation between internal storage of the bitmap and representation is presented below.
BitMap Representation
0000000000 7 bytes
<through 9 > ffffffffffffffffffff 7 hex digits
00000000000000000000
<through 9 > ffffffffffffffffffff
0 <through 9 > f
8 4 2 1
Description ten 8-bit bytes (two hexadecimal digits per byte) twenty 4-bit hexadecimal digits each 4-bit digit
(nybble) the bit weight
(hexadecimal) for each 4-bit nybble
3 - 156 _________________________________________________________________ Setup
_________________________________________________________ DanLoad 6000 (v6.00)
6
7
8
4
5
2
3
0
1 b c
9 a d e f
BitMap Character / Bit Weight Translation
Printed
Character
(1 of 20)
Bit
Weight
8
Bit
Weight
4
Bit
Weight
2
Bit
Weight
1
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
Note: The bit is set TRUE if the corresponding alarm occurs during the transaction. The combination of TRUE alarms determines the character printed.
Setup _________________________________________________________________ 3 - 157
DanLoad 6000 (v6.00) __________________________________________________________
The alarm bitmap is described on the following pages. The Alarm BitMap for Position:
000000000000000000000 table indicates the character position and the bit weight within each character that is set TRUE when the alarm was active during the transaction. The alarm bitmap is stored, by assignment of TSC 27, as 10 bytes with two-digits in each byte. Each character position contains indicators (bits) for 4 alarms. Since each alarm is independent from other alarms, the occurrence of no alarm or any combination of from 1 to 4 alarms assigned to each character position will determine what character is printed in each position of the bitmap. The characters that can be printed in each character position are 0 through 9, a, b, c, d, e, f. This is the hexadecimal numbering system. The bitmap is read from right to left for both character position and bit position.
Example: 2 1
09876543210987654321 < bitmap character position number
8421 < bit weights any character position
(example for character position 12)
Read the printed bitmap with the aid of the following tables.
# The leftward 4 character positions (17 through 20) are always zeros because alarms are not assigned to these positions.
# Any non-zero character printed indicates that an alarm occurred during the transaction.
Determine the character position, the rightward character is 1 the leftward character is 20.
# Find the corresponding Character Position in the Alarm BitMap for Positions:
00000000000000000000 table below.
# Use the BitMap Character / Bit Weight Translation table to determine which bits were set
TRUE.
# If the printed character is 1, 2, 4, or 8, then only one alarm in that character position group was set TRUE.
# If the printed character is 3, 5, 6, 9, a, or c, then two of the alarms in that character position group were set TRUE.
# If the printed character is 7, b, d, or e, then three of the alarms in that character position group were set TRUE.
# If the printed character is f, then all four of the alarms assigned to that character position were set TRUE.
3 - 158 _________________________________________________________________ Setup
_________________________________________________________ DanLoad 6000 (v6.00)
Alarm BitM ap for Positions: 00000000000000hhhhhh
Alarm
Character
Position
Prim ary/secondary internal tem perature too high/low
Flow rate too low m eter 1
Flow rate too low m eter 2
Flow rate too low m eter 3
Flow rate too low m eter 4
Flow rate too high m eter 1
Flow rate too high m eter 2
Flow rate too high m eter 3
Flow rate too high m eter 4
Unable to close valve m eter 1
Unable to close valve m eter 2
Unable to close valve m eter 3
Unable to close valve m eter 4
Valve closed early m eter 1
Valve closed early m eter 2
Valve closed early m eter 3
Valve closed early m eter 4
Tim ed-out - no flow detected m eter 1
Tim ed-out - no flow detected m eter 2
Tim ed-out - no flow detected m eter 3
Tim ed-out - no flow detected m eter 4
Unauthorized flow exceeds lim it m eter 1
Unauthorized flow exceeds lim it m eter 2
Unauthorized flow exceeds lim it m eter 3
Note: The BitMap representation in the title line shows the character positions on this page as hhhhhh. The 0's in the BitMap can be any valid character and are described on other pages of the table.
6
6
6
6
5
5
5
5
3
3
3
3
4
4
4
4
2
2
2
2
1
1
1
1
1
2
4
8
1
2
4
8
1
2
4
8
4
8
1
2
1
2
4
8
1
2
4
8 t
Bit
W eigh
Setup _________________________________________________________________ 3 - 159
DanLoad 6000 (v6.00) __________________________________________________________
Alarm BitM ap for Positions: 00000000hhhhhh000000
Alarm
Character
Position
Unauthorized flow exceeds lim it m eter 4
Pulse security error m eter 1
Pulse security error m eter 2
Pulse security error m eter 3
Data m em ory full
Com m s failure channel A
Com m s failure channel B
Tem perature failure m eter 1
Tem perature failure m eter 2
Tem perature failure m eter 3
Tem perature failure m eter 4
Density failure com ponent 1
Density failure com ponent 2
Density failure com ponent 3
Density failure com ponent 4
Pressure failure m eter 1
Pressure failure m eter 2
Pressure failure m eter 3
Pressure failure m eter 4
Additive 1 failure
Additive 2 failure
Additive 3 failure
Additive 4 failure
Additive 5 failure
Note: The BitMap representation in the title line shows the character positions on this page as hhhhhh. The 0's in the BitMap can be any valid character and are described on other pages of the table.
12
12
12
12
11
11
11
11
9
9
9
9
10
10
10
10
8
8
8
8
7
7
7
7
1
2
4
8
1
2
4
8
1
2
4
8
4
8
1
2
1
2
4
8
1
2
4
8 t
Bit
W eigh
3 - 160 _________________________________________________________________ Setup
_________________________________________________________ DanLoad 6000 (v6.00)
Additive 6 failure
Unable to m aintain blend
Unable to close block valve 1
Unable to close block valve 2
Unable to close block valve 3
Unable to close block valve 4
Circuit 1 alarm
Circuit 2 alarm
Circuit 3 alarm
Circuit 4 alarm
Circuit 5 alarm
Circuit 6 alarm
Circuit 7 alarm
Circuit 8 alarm
Storage m em ory full
Power failure
Alarm BitM ap for Positions: 0000hhhh000000000000
Alarm
Character
Position
1
2
4
8
4
8
1
2
1
2
4
8
1
2
4
8 t
Bit
W eigh
Character positions: hhhh0000000000000000 not used in software version 3.0
13
13
13
13
15
15
15
15
14
14
14
14
16
16
16
16
17 to 20
Note: The BitMap representation in the title line shows the character positions on this page as hhhh. The 0's in the BitMap can be any valid character and are described on other pages of the table.
Setup _________________________________________________________________ 3 - 161
Unit: _______
Date: _______
Transaction
Storage Code
Transaction Record / Ticket Worksheet
Row
Ticket
(PC 920 to 955)
Column
PgmCode
Row/Col
Record
(PC 840 to 875)
Length
(bytes * #) Offset
PgmCode
Offset
1
Unit: _______
Date: _______
Batch
Storage Code
Batch Record / Ticket Worksheet
Row
Ticket
(PC 960 to 982)
Column
PgmCode
Row/Col
Length
Record
(PC 880 to 902)
(bytes * #) Offset
PgmCode
Offset
1
DanLoad 6000 (v6.00) __________________________________________________________
3.12
Component Size Inputs
In the manual operating mode, the authorized [batch] quantity can be determined automatically based on the state of up to four discrete inputs, each one corresponding to a possible tank or compartment size, known as "compartment size inputs". With compartment size inputs configured (program code
341), it is often only necessary for the operator to select the compartment size via a multi-way selector switch and press the "ENTER" and "START" keys, or even just the "START" key (see "start method", program code 342). The same functionality can be achieved quite easily in the automatic operating mode via automation system programming, and is simplified by the fact that the states of the safety circuit inputs are included in the response to the Request Status (12h) command. Refer to the DanLoad 6000 Comm Spec.
In order to authorize a batch, one compartment size input, indicating the actual compartment size, should be closed prior to entering a preset quantity or simply pressing the "ENTER" key. If the
"ENTER" key is pressed without having keyed-in a preset quantity, the authorized quantity entered is the compartment size. If a preset quantity is keyed-in prior to pressing the "ENTER" key, the authorized quantity entered is the minimum of the compartment size and the keyed-in preset quantity, i.e:
Authorized qty = min(Compartment size per closed inputs or User-entered preset qty (if any))
Note the "if any" condition on the user-entered preset quantity; if a preset quantity is not keyed-in, the compartment size corresponding to the lowest-numbered compartment size input that is closed is used. For this reason, compartment sizes should be configured (see recipe 28, program codes 644 to 647) from smallest to largest in ascending order. If none of the compartment size inputs is closed, it is not possible to authorize a batch even if a preset quantity is keyed-in, i.e. it is necessary to select the compartment size even if a preset quantity is to be keyed-in.
The number of compartment size inputs (program code 341) can be configured (0 to 4). Zero means that compartment size inputs are not being used. Safety circuits 4 thru 8 inputs serve double as compartment size inputs. If one or more of them is used as a compartment size input, the corresponding safety circuit cannot be used and its alarm action (program codes 257, 259, 261, 263) should be set to "Off". The compartment sizes are configured via recipe 28's component percentages. Program codes 349/350/351/352 are used to define the physical discrete compartment size input and program codes 644/645/646/647 are used to define the physical compartment size in product units for the associated input. The actual compartment size value is calculated by the
DanLoad as the value, entered in program codes 644/645/646/647, times 100. The maximum preset quantity (program code 078) should not be smaller than the largest configured compartment size.
If compartment size inputs are used, the number of recipes (program code 480) must not exceed 26.
3 - 164 _________________________________________________________________ Setup
_________________________________________________________ DanLoad 6000 (v6.00)
If compartment size inputs are used, additional pre-authorization verification of the compartment size/preset quantity (in the manual operating mode) and verification of the loaded quantity while a batch is in progress (in any operating mode) can be enabled via the level input (program code 374) and the hatch input (program code 375). The processing associated with the level input was developed for a specific user, and as such may not provide as much flexibility as you would normally expect from the DanLoad 6000; care should be taken to understand the processing fully before deciding to use this capability. Refer to the relevant program codes (374, 375 and 650 thru 653) for more information.
3.13
Cutoff (End of Day Processing)
#
#
The DanLoad 6000 runs a cutoff (end of day processing) every 24 hours based on the configured cutoff hour (program code 710). When the time (hour) is equal to the configured cutoff hour, the
DanLoad 6000...
# Waits for any batch is progress to end. (Note: A DanLoad 6000 transaction may span two cutoff periods.)
# Saves the previous cutoff data, i.e. cutoff date and time, previous cutoff date and time, meter, component and recipe gross and standard running totalizers and additive running totalizers.
Saves the new cutoff data.
Prints the totalizer data log if it is enabled (program code 705) and the DanLoad 6000 is in the manual operating mode (program code 25).
# Prints the thruput data log if it is enabled (program code 708) and the DanLoad 6000 is in the manual operating mode (program code 25).
The totalizer and thruput data logs can be reprinted (if they are enabled and the DanLoad 6000 is in the manual operating mode) using the "Reprint cutoff" option in the program mode menu. Both data logs show the date and time at which they were printed as well as the date and time of the cutoff.
The DanLoad 6000 can reprint the totalizer and thruput data logs only for the most recently completed cutoff, i.e. it does not "archive" cutoff data.
Setup _________________________________________________________________ 3 - 165
DanLoad 6000 (v6.00) __________________________________________________________
3.14
Set Contrast / Backlighting
Access to the Set Contrast / Backlighting display is via the Set contrast/backlighting selection of the
Program Mode Menu, Figure 3 - 1. This display provides the method to change the current contrast and backlighting settings for either the local or remote LCD panel.
8
9
8
9
Set Contrast / Backlighting Display
Figure 3 - 16
If only the local display is present, it is preselected and indicated. Use the 8 and 9 arrow keys to adjust the contrast level. A value of 0 is minimum contrast, a value of 15 is maximum contrast.
Use the ALT+8 and ALT+9 keys to adjust the backlight level. A value of 0 is backlight off, a value of 7 is maximum backlight intensity.
3 - 166 _________________________________________________________________ Setup
_________________________________________________________ DanLoad 6000 (v6.00)
3.15
# Configuration
The DanLoad 6000 contains 22 program codes (6 “global” and 4 “per meter”) and 4 data codes (1 per meter) that are associated with Calibration Monitoring. 19 program codes (3 “global” and 4 “per meter” are in the “Blending” setup group. 3 program codes (all “global”) are in the “Recipe” setup group and are configured via Recipe 30 comp 1%, comp 2% and comp 3%. Calibration Monitoring related program and data codes are as follows:
# "731/ 737/ 743/ 749 CALMON analysis method".
# "Fuzzy". Calibration monitoring analysis incorporated “Fuzzy” logic with four inputs and one output. This is the recommended setting.
# "Heuristic". Analysis operation using a Heuristic method.
#
CALMON - Turbine Meter Calibration Monitoring for the DanLoad 6000
Electronic Preset
"753 CALMON error limit" (0 to 255): The number of "bad meter analyses" per
CALMON reset count (program code 754) calibration monitoring analyses above which a calibration failure alarm is raised for the meter during monitoring. The default value is 25.
# "754 CALMON reset count" (0 to 9999): The “total analyses”, “good meter analysis” and “bad meter analyses” counters are zeroed every CALMON reset count” calibration monitoring analyses during monitoring. A calibration failure alarm is raised for the meter if there are no "good meter analyses" in "CALMON reset count" calibration monitoring analyses during monitoring. This is also the number of attempts to auto-detect the number of blades (if necessary) and acquire a calibration sample before a calibration failure alarm is raised for the meter during calibration.
The default value is 50.
# 755 Calib fail alarm action": The calibration failure alarm action. The default value is "Primary". Select one of the following:
#
#
#
#
"Off". The alarm is disabled.
"Info".
"Secondary".
“Primary".
Setup _________________________________________________________________ 3 - 167
DanLoad 6000 (v6.00) __________________________________________________________
#
#
#
#
#
"757/ 762/ 767/ 772 Number of blades" (0 to 50): The number of magnetic blades
(or buttons) on the meter for calibration monitoring purposes. 0 disables calibration monitoring for the meter. Any other value enabled calibration monitoring for the meter. 1 indicates that the number of blades should be auto-detected by the "MPMC" prior to acquiring a calibration sample. The default value is zero, i.e. calibration monitoring disabled for the meter. In order to use the calibration monitoring feature it is recommended that this value must be set to 1, if the information on number of magnetic blades or buttons is not available.
"758/ 763/ 768/ 773 Max max char dev" (0 to 65535): The maximum characteristic deviation computed during a calibration monitoring analysis above which a "bad meter" result may be indicated, i.e. the "bad meter" counter may be incremented. The default value of 100 detects a 10% blade bent corresponding to an average K-factor change of 0.3%.
"759/ 764/ 769/ 774 Max tot char devs" (0 to 65535): The total characteristic deviation computed during a calibration monitoring analysis above which a "bad meter" result may be indicated, i.e. the "bad meter" counter may be incremented. The default value of 400 detects a 10 % blade bent corresponding to an average K-factor change of 0.3% or multiple bent blades, bent by a smaller magnitude.
"760/ 765/ 770/ 775 Calibration sample": The current calibration sample status.
This program code can be used to force acquisition of a new calibration sample. The default value is "Not acquired", i.e. calibration sample not acquired. Select one of the following:
# "Not acquired". The calibration sample has not been acquired or is invalid.
Calibration sample is requested if the number of blades is greater than 0.
# "Acquired". The calibration sample has been acquired and is valid.
Set this program code to “Not Acquired” to allow the MPMC to acquire or re-acquire calibration sample.
"656 Recipe 30, Comp 1 % (Max sample Instability)" The sample instability (% x 100) computed during a calibration monitoring analysis above which a "bad meter" result may be indicated, i.e. the "bad meter" counter may be incremented. During the initial start-up this value should be 150 (i.e 1.5 %)
3 - 168 _________________________________________________________________ Setup
_________________________________________________________ DanLoad 6000 (v6.00)
#
#
#
#
"657 Recipe 30, Comp 2 % (Max frequency Instability)"The frequency instability
(% x 100) computed during a calibration monitoring analysis above which a "bad meter" result may be indicated, i.e. the "bad meter" counter may be incremented.
During the initial start-up this value should be set to 250 (i.e 2.5 %)
"658 Recipe 30, Comp 3 % (Monitoring frequency band)" The frequency band as a % of high flow rate at which a monitoring sample is acquired. A monitoring sample is not acquired if the meter frequency is above or below the monitoring frequency band. During initial start up this value should be set to 00.10 (i.e 10 %).
"Data code 219/220/221/222. Mtr Calib status". The current calibration sample status for meter 1
#
#
0 Calibration sample "Not acquired".
1 Calibration sample "Acquired".
Configure this dynamic data code as item 5 so that the flow rate and the current status for the meter is visible.
Calib fail alarm action". The calibration failure alarm action. The default value is
"Primary". Select one of the following:
#
#
#
#
"Off". The alarm is disabled.
"Info". When an alarm is reported...
"Secondary". When an alarm is reported...
"Primary". When an alarm is reported...
Setup _________________________________________________________________ 3 - 169
DanLoad 6000 (v6.00) __________________________________________________________
# Operation
Calibration sample acquisition
The DanLoad 6000 auto-detects the number of blades, if necessary, and acquires a calibration sample, which characterizes the meter, when the flow rate reaches the highest configured flow rate during an authorized load. The status of the calibration sample (“Acquired” or “Not acquired”) may be viewed in the dynamic data display. In order to acquire a calibration sample perform the following :
# Set the program code 757 "Number of blades" to the number of magnetic blades (or buttons) on the meter if known or set it to 1 if unknown.
#
#
Set program code 760 "Calibration sample" to "Not Acquired".
Preset and start a load.
When the batch reaches its high flow section, the DanLoad tries to acquire a “Calibration sample”.
The status of the calibration sample may be viewed in the dynamic data display. The status of the calibration sample in the dynamic data display changes to “Acquired” when a calibration sample is acquired by the DanLoad 6000. The calibration sample may be viewed from the “Calmon status” screen on the DanLoad.
Monitoring sample acquisition
The DanLoad 6000 acquires monitoring samples on subsequent loads and determines the monitoring characteristic of the meter
CALMON analysis
A comparison of calibration characteristic and monitoring characteristic results in the monitoring sample being classified as "Good", "Bad" or "Unsure". The DanLoad 6000 reports calibration alarms depending on the sample classification and “Calmon error limit” and “Calmon reset count”.
3 - 170 _________________________________________________________________ Setup
_________________________________________________________ DanLoad 6000 (v6.00)
CALMON Status Screen
The calmon status screen contains information on the “Calibration sample”, the “Monitoring sample” and “Calmon analysis”. Following information may be obtained from a characteristic sample:
# Sample frequency: The frequency in Hz at which the characteristic sample was acquired.
# Frequency instability: Flow rate in-stability during acquisition of a characteristic sample. This value indicates accelerating or decelerating flow, or pulsating flow.
# Mean blade deviation: A value indicating machine inaccuracies of blade spacing and inaccuracies in blade angles.
# Sample instability: A value indicating the condition of the bearing such as damaged or dry bearings.
# Total characteristic deviations: Calculated after acquiring a monitoring sample, it is the sum of individual blade ratio deviations from the calibration sample.
# Maximum characteristic deviation: Calculated after acquiring a monitoring sample, it is the maximum of the blade ratio deviation from the calibration sample, among the individual blade ratio deviations.
The characteristic deviations indicate conditions such as single or multiple bent blades or broken blades.
# Good count: The number of good meter analyses. The number of good meter analyses are zeroed for every "CALMON reset count" calibration monitoring analyses.
# Bad count: The number of bad meter analyses. The number of bad meter analyses are zeroed for every "CALMON reset count" calibration monitoring analyses.
# Reset count: is the number of times “Calmon reset count” calibration monitoring analysis was performed.
# Individual characteristic. The “Calmon status” screen also contains the characteristic of each individual blade samples. The number of samples contained in this screen depends on the number of blades on the meter.
Setup _________________________________________________________________ 3 - 171
DanLoad 6000 (v6.00) __________________________________________________________
# Alarm bitmap. is a 16 bit MPMC alarm bitmap since the DanLoad was last reset.
The alarm bitmap includes 4 types of “Calibration monitoring alarms”. The
DanLoad raises a “Calibration failure” alarm for any “Calibration monitoring” alarm reported by the CALMON process.
The following table describes the “Alarm bitmap” that is displayed on the DanLoad 6000
“Alarm bitmap” field.
Bit #
11
12
13
14
15
9
10
7
8
5
6
3
4
0
1
2
Alarm Flags
Description
Pulse security error meter 1
Pulse security error meter 2
Program memory checksum
RAM check
Stack overflow
Unexpected interrupt
Calibration failure meter 1.
Calibration failure meter 2.
I/O port error
Invalid command (command code or command length).
Calibration sample could not be acquired meter 1.
Calibration sample could not be acquired meter 2.
Monitoring sample could not be acquired meter 1.
Monitoring sample could not be acquired meter 2.
Calibration checksum invalid meter 1.
Calibration checksum invalid meter 2.
Bit 0 is the LSB and bit 15 is the MSB. Alarms corresponding to bits 6,7 and 10, 11, 12,13,14 and
15 are raised by the CALMON process.
3 - 172 _________________________________________________________________ Setup
_________________________________________________________ DanLoad 6000 (v6.00)
# Description of Calibrating Monitoring Alarms
There are 4 types of alarms reported, per meter, by the CALMON process. These alarms are:
# "Calibration sample could not be acquired ": "CALMON reset count" attempts were made to auto-detect the number of blades (if necessary) and acquire a calibration sample. This condition usually occurs when a steady flow velocity is not maintained during calibration sample acquisition.
# "Monitoring sample could not be acquired": A single good meter analysis per
"CALMON reset count" calibration monitoring analyses could not be made. This condition is usually caused by either worn or dry bearings, unstable or pulsating flow or debris in the line.
# "Calibration failure": The number of times bad meter analyses per "CALMON reset count" exceeded "CALMON error limit". This condition is usually caused by bent or broken turbine meter blades or worn bearings or dry bearings.
# "Calibration checksum invalid": Alarm is raised during monitoring indicating that the calibration characteristic stored in battery backed memory changed after the calibration sample was "acquired". This condition may be caused by a failure of the non-volatile RAM. This alarm may also be raised if MPMC tries to acquire a monitoring sample for a meter for which a calibration sample has not been
"acquired".
Calibration monitoring for a meter is disabled following an alarm and may be enabled again by the master.
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DanLoad 6000 (v6.00) __________________________________________________________
The following table is a list of calibration failure alarms reported by the MPMC and the probable cause for these alarms.
Calibration Failure Alarms
Calibration sample could not be acquired.
Monitoring sample could not be acquired.
Calibration failure.
Calibration checksum invalid.
Probable Causes
Unstable or pulsating flow. Worn or dry bearings.
Blade count indeterminate.
Debris in the liquid line.
Unstable or pulsating flow. Worn or dry bearings.
Debris in the liquid line.
Bent or broken blade.
Worn or dry bearing.
Nonvolatile RAM failure.
MPMC tried to acquire a monitoring sample for a meter for which a calibration sample has not been acquired.
The following table is a list of common conditions that are responsible for meter calibration failures and the Characteristic values that are affected by these conditions.
Conditions for Calibration Failures on
Liquid Turbine Meters
Bent or broken blades.
Machine inaccuracies of blades or blade angles.
Unstable flow
Debris in liquid line, possibly trapped upstream.
Worn or dry bearings or pulsating flow.
Characteristic Values Affected
Total characteristic deviations, Maximum characteristic deviation, Mean blade deviation.
Mean blade deviation
Frequency instability.
Frequency instability, Sample instability.
Sample instability.
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3.16
Configuration Parameter Groups
The tables located in Appendix A are provided as a guide to the various program codes (parameters) that determine the configuration of the DanLoad 6000. These tables provide aid in determining if all required program codes have been correctly configured. Refer to drawings BE-18204 Device
Linkages - DanLoad 6000 and DE-18201 Program Code to Device Assignments - DanLoad 6000, located in Appendix E for help in understanding the parameter groups.
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This section contains information on operation of the DanLoad 6000 Preset during batch delivery and multiple batch delivery transactions. Operation of the DanLoad 6000 is defined by program codes. Program codes consist of a three-digit identification number, a name, and a value or selection. Program codes are configured during the setup procedure described in Section 3 - Setup.
Section 6 - Program Code Definitions contains additional information on the function of all program codes.
The DanLoad 6000 is used to control and measure the delivery of liquid products to tanker vehicles.
Single components or from two to four components can be blended and delivered. Delivery of a single component, either sequentially or simultaneously with other components, is called a load.
A batch consists of one or more component loads.
A batch is defined as the delivery of one single product or a blend consisting of two to four components, with or without additives. A single batch delivery may constitute a transaction, that is no more batches will be delivered to this client at this time. A batch delivery begins when the user
/ operator presets a quantity to be delivered and initiates the delivery. A batch delivery can be suspended and restarted at any time if the following two limitations are met. All the permissive circuits are closed (no active permissive alarm condition) and the Remaining quantity is greater than the value set in program code 079 Minimum preset qty. The batch delivery is terminated when the last pulse from the flow meter is detected and the batch delivery cannot be restarted due to one of the conditions mentioned above.
#
#
#
A transaction is defined as one or more batch deliveries that are grouped together for accounting purposes. Transactions are logically the delivery of one or more batches to one client, which would be the case in multiple batches delivered to multiple compartments in a tanker vehicle. The
DanLoad 6000 allows the operator to define the batch deliveries that comprise a transaction. A transaction is terminated if any of the following conditions occur.
Loss of power to the DanLoad 6000.
An end transaction command is received from the terminal automation system.
The STOP/PRINT key is pressed and a delivery operation is not in progress. If a batch delivery is temporarily suspended by pressing the STOP/PRINT key, and it is desired to continue the batch delivery, the ENTER and START key press sequence will restart the batch delivery. If while the batch delivery is suspended, the STOP/PRINT key is pressed, the transaction is terminated and either the Recipe Selection Display, the Additive Selection
Display, or the Loading Display is presented to the user / operator, depending on the system configuration.
Operation _______________________________________________________________ 4 - 1
DanLoad 6000 (v6.00) __________________________________________________________
A new batch delivery which will be part of a new transaction must be defined before a product or blend of products can be delivered. The batch delivery procedure is described in Section 4.2. Batch delivery control parameters are preset by the user / operator. The method of delivering and calculating the quantity the batch delivery are dependent on the preset configuration of the DanLoad
6000. The steps listed below indicate the sequence for initiating a batch delivery. Some or all of the steps are bypassed if the feature is not implemented.
1
2
A recipe selection: Performed automatically if only one recipe is defined or performed manually if two or more recipes are defined. The recipe defines the single product or multicomponent blending characteristics of the batch delivery. (Section 6 - Program Codes 480
to 661).
An additive selection: Required if additive injection selection method program code 136
Selection method is set to Prompt and the additive is selected program code 143 / 148 / 153
/ 158 / 163 / 168 Available.
3 Entry of one to five data items: Each data item can be from zero to eight numeric digits, data items are used by terminal automation systems for batch / transaction accounting purposes (Section 6 - Program Codes 030 to 037).
All of the batch delivery parameters must be preset before a batch delivery can begin. A transaction must share all of these parameters for all associated batch deliveries. Therefore, a transaction is restricted to one or more batch deliveries of a single product or a single blend of components which have preselected additive injection parameters. A transaction cannot include multiple recipes, or various additive injection combinations.
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__________________________________________________________ DanLoad 6000 (v6.00)
4.1
Physical Configuration
The display panel, status indicators, and keypad that are mounted in the operator control panel provide operator interface with the instrument.
Desired functions are controlled via command entries at the keypad in response to displayed data and prompt messages.
4.1.1
Displays and Controls
A LCD (Liquid Crystal Display) panel and three (red, green, yellow) LED (Light Emitting
Diode) status indicators are provided.
4.1.1.1
LED Status Indicators
The three LED status indicators are visible through the vertical window located to the right of the
LCD display panel. During normal operation of the DanLoad 6000 in the Manual mode (not connected to a terminal automation system) the yellow indicator is OFF (manual operating mode).
The green indicator is ON if power is applied to TB2 terminal 1 on the power supply board. This power usually comes from the permissive power circuit and is not present unless the safety circuits are enabled. The yellow and red LED’s are pulsed on/off for one second on power-up/reset of the
DanLoad 6000.
The indicators provide the following status information.
Operation _______________________________________________________________ 4 - 3
DanLoad 6000 (v6.00) __________________________________________________________
LED Status Function
AUTO/MANUAL
(yellow) OFF The DanLoad 6000 is operating in the Manual mode (program code 025
Operating mode). (Note: Local operation is identical in either of these two modes.)
ON The DanLoad 6000 is operating in the Auto mode (linked to a host computer and operating as a slave unit) (program code 025 Operating mode).
FLASHING
#
#
#
(Two short pulses every two seconds) Case internal temperature is too high or the keypad/display is disconnected or power is removed from the keypad/display.
(One short pulse every two seconds) The condition that cased the alarm has returned to normal state. The DanLoad 6000 should be powered-up or reset to continue using the keypad/display.
(Rapid flashing) Power failure or low power condition.
PERMISSIVE POWER
(green) ON The permissive power circuit is closed (normal state when a batch delivery is in progress). The function of the green LED indicator is dependent on the state of the permissive circuit, located on the power supply module, and is not programmable.
OFF The permissive power circuit is open. This indicates an abnormal state which is due to permissive power failure or failure of one or more permissive circuits wired in series (wired AND) with the permissive power source (the function of the green LED indicator is dependent on the state of the permissive circuit and is not programmable).
ALARM STATUS
(red) ON A primary alarm is active (see Section 4.5 for information on alarm action).
OFF All alarms are inactive (normal state).
FLASHING A secondary alarm is active (see Section 4.5 for information on alarm action).
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4.1.1.2
LCD Alpha-numeric / Graphic Data Display
The LCD data display has a back-lighting feature for ease of reading in low ambient light conditions.
The intensity of the back-lighting is controlled by the intensity level of ambient light (program
codes 355 to 360).
Data is displayed in up to three basic formats during normal batch delivery setup and delivery operations. These three display formats are:
# Recipe Selection Display
This display is presented to the user / operator if more than one recipe has been defined. If only one recipe has been defined, that recipe is selected automatically and the Recipe
Selection Display is not presented to the operator. Information on recipe selection and an example of this display are provided below in this section.
# Additive Selection Display
This display is presented to the user / operator if one or more additives have been defined and the additive prompt option, program code 136 Selection method set to Prompt. In the case where additives have been defined and made available, program code 143 / 148 / 153 / 158
/ 163 / 168 Available set to Yes, injection of all additives is always turned off and each additive must be manually enabled via operator interaction. If no additives have been defined, the Additive Selection Display is not presented to the operator. Information on additive injection selection and enabling and an example of this display are provided below in this section.
# Loading Display
This display is always presented to the user / operator to provide data feedback during definition of a batch delivery operation and during delivery of the batch or group of batches
(transaction). Information on batch loading and an example of this display are provided below in this section.
# Dynamic Data Display
This display can be manually selected when the loading display is active. This data is particularly useful during batch loading and meter proving.
Operation _______________________________________________________________ 4 - 5
DanLoad 6000 (v6.00) __________________________________________________________
4.1.1.3
Keypad
The numeric / function keypad provides the method for the user / operator to select recipes and additives, enter the desired preset quantity, and control batch deliveries. Some key functions are only applicable to setup of the DanLoad 6000 while in the Program Mode. These special functions are not used in normal batch delivery operations and therefore are not covered in this section. The keypad layout is indicated in Figure 4 - 1.
Keypad Layout
Figure 4 - 1
Note
The Weights and Measures switch is the lockable and sealable pushbutton switch located in the upper left corner of the keypad.
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__________________________________________________________ DanLoad 6000 (v6.00)
Key Function
0 thru 9
ENTER
CLEAR numeric digits for data entry accept the manually entered value and continue reject the manually entered value and continue
SELECT toggle the Off / On option for each defined additive
9 scroll down, move the select box to the next item in the Recipes Selection Display or the Additive
Selection Display
8
START scroll up, move the select box to the previous item in the Recipes Selection Display or the
Additive Selection Display initiate the batch loading operation after batch setup data has been entered
STOP/PRINT stop the batch loading operation and print batch and / or transaction report, if enabled program
W&M access to the Program Mode for modification of non-restricted program codes and system data the Weights and Measures security switch
Key Functions (Batch Delivery)
Figure 4 - 2
Key functions applicable to batch delivery operations are listed in Figure 4 - 2. The description of the batch delivery procedure in Section 4.2 contains in-context information of the function of the various keys. The program key and the Weights and Measures switch are not used during normal batch deliveries. However, the user / operator should be familiar with the functions of the program key and Weights and Measures switch.
Operation _______________________________________________________________ 4 - 7
DanLoad 6000 (v6.00) __________________________________________________________
#
#
Program key
The program key is used, while operating in the Loading Mode and no batch delivery is in progress, to access the Program Mode. This action is accomplished by pressing the ALT key and while maintaining the ALT key depressed, simultaneously press the ENTER /
program key. The Enter passcode _________ prompt is displayed on the message line at this time. The response is for the user / operator to enter their predefined passcode (one to nine digits). If a passcode is not entered within thirty seconds or if an invalid passcode is entered, the message Invalid passcode is displayed on the message line. Press the CLEAR key to re-display the normal loading prompt, Enter preset quantity. Section 3 - Setup and
Section 6 - Program Code Definitions contain information on operation of the Program
Mode.
Weights and Measures security switch
Several parameters, accessible as program codes in the Program Mode, have direct effect on the validity and accuracy of the batch quantity calculations. These parameters were specified during the setup procedure to have Weights and Measures attributes. Parameters with the Weights and Measures attributes set have three levels of protection to restrict modification of their values or options settings. A valid user passcode must be entered, the user must have supervisor privilege, and the Weights and Measures switch must be open
(in the extended position). If the drift pin through the spring loaded switch actuator is visible, the switch is open. During normal operation, this switch should be closed and wire sealed in the closed position.
Additional information on the Program Mode and the function of the Weights and Measures switch is located in Section 3 - Setup and Section 6 - Program Code Definitions.
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4.2
Batch Delivery Procedure
This sub-section contains a description of normal operation of the DanLoad 6000 during batch data entry, batch delivery, and termination of a batch delivery. The description covers operation of the
DanLoad 6000 in either the Stand-alone mode or the Manual mode. Operation in both of these modes is identical from the user / operator viewpoint. Operation of the DanLoad 6000 as a slave device to a terminal automation system is installation dependent and is covered in the DanLoad 6000
Communications Specification, Part Number 9-6000-674.
It is assumed at this point that the DanLoad 6000 is in the idle state, that is no batch delivery is in progress and no transaction is open. If two or more recipes have been setup, the Recipe Selection
Display is displayed at the start of the transaction. If only one recipe has been setup, the single recipe is assumed to the active recipe and the Recipe Selection Display is not shown. When a recipe is selected, the availability of each recipe component is checked. The 068 / 071 / 074 / 077
Available parameter for all recipe components, located in the Component parameters group, must be set to Yes. In the case of sequential blending, the sum of the selected component percentages specified by program code 486 / ... / 660 Sequence to load parameter of the recipe, must be 100.
In the case of in-line blending, the sum of the percentages of all four components in the recipe must be 100. An example of the Recipe Selection Display is provided below.
Recipes mm/dd/yy hh:mm
Regular Gasoline
Premium Gasoline
Diesel
Kerosene
Recipe Selection Display (Typical)
Figure 4 - 3
Operation _______________________________________________________________ 4 - 9
DanLoad 6000 (v6.00) __________________________________________________________
To select the product (recipe) for delivery from the Recipe Selection Display by using the 9 or 8 key to position the select box over the desired product (recipe), then press the ENTER key.
If one or more additives have been setup and program code 136 Selection method is set to Prompt, the Additive Selection Display is presented to the user / operator for selective enabling of each additive. The transaction is authorized after the recipe and additive(s) are selected. However, the transaction does not start until the START key is pressed to initiate the first batch.
While operating in the Automatic mode, additive injection is controlled by the terminal automation system. While operating in the Stand-alone mode or the Manual mode, additive injection is dependent on the option selected for program code 136 Selection method and related factors described below.
# 136 Selection method = External (default selection) All configured additives are injected if an external enable contact closure is closed.
# 136 Selection method = Prompt The Additive Selection Display is presented to the operator for manual selection of each additive before the start of each transaction. (Note: In AUTO mode, at least one of the additive delivery enable program codes 143 / 148 / 153 / 158 / 163
/ 168 Available, must be set to yes to enable presentation of the Additive Selection Display.)
# 136 Selection method = Inputs Any configured additive is injected if the corresponding external enable contact closure (program code 382 / 385 / 388 / 391 / 394 / 397 Selection
input) for that particular additive is closed.
# 136 Selection method = Recipe Additive 1 to 6 is selected automatically for the corresponding recipe 1 to 6. The additive n's ratio output (if configured) is cycled when the corresponding recipe number is being delivered.
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__________________________________________________________ DanLoad 6000 (v6.00)
The selected recipe is indicated in the top line of the Additive Selection Display. An example of the
Additive Selection Display is illustrated below.
Additive Selection Display
Figure 4 - 4
To select the additive from the Additive Selection Display use the 9 or 8 keys to position the select box over the desired additive, then press the SELECT key to toggle the option from Off to On (or from On to Off if an entry error is made). Press the ENTER key after all desired (zero to six) additives have been enabled for injection into the delivered stream.
Operation _______________________________________________________________ 4 - 11
DanLoad 6000 (v6.00) __________________________________________________________
The Loading Display is presented to the user / operator at this time. The Loading Display allows the user / operator to enter the preset quantity to be delivered and to monitor the delivery of the batch and transaction. An illustration of the Loading Display is provided below.
Loaded 0
+)))),
* *
* *
* *
* *
.))))-
Loading Display
Figure 4 - 5
The Loading Display, Figure 4 - 5, illustrates several alpha-numeric and numeric fields related to batch deliveries and a graphic representation of the batch delivery receiving tank. The fields contained in the Loading Display are described below.
# Recipe name (Premium Gasoline) field contains the name of the current recipe manually selected by the operator or automatically selected if only one recipe is defined. In the example, this field indicates Premium Gasoline which was defined as the recipe name in program code 481 / ... / 655 Recipe name parameter located in the Recipes parameters group and selected with the Recipe Selection Display.
# Date and time (mm/dd/yy hh:mm) fields contain the current date and time. The format of the date is specified by program code 038 Date format and program code 039 Date
separator program codes. The time is always indicated in the format hh:mm in the range of
00:00 to 23:59. The date and time entries are adjusted via the Program Mode Menu > Set
date and time selection. See Section 3 - Setup for date and time modification instructions.
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__________________________________________________________ DanLoad 6000 (v6.00)
#
#
#
#
#
#
#
Loaded field contains the batch quantity of the delivered product. The value in this field is incremented in quantity units until either the preset quantity is reached or the delivery is suspended or terminated.
Preset field contains the batch quantity to deliver which is manually entered by the user / operator in response to the Enter preset quantity prompt shown on the message line of the display panel.
Remaining field contains the batch quantity that has not yet been delivered during a batch delivery. (Preset quantity minus loaded quantity equals remaining quantity)
Transaction total field contains the total accumulated quantity for the delivery transaction.
A delivery transaction can consist of one batch delivery or multiple batch deliveries.
Product units mnemonic (Gal) field contains the engineering units label used in the display panel and in reports. The mnemonic is entered by program code 218 Product units mnemonic. Although the default entry is “Gal”, any six-character label may be entered. Note that this selection is a display label only and does not affect the quantity unit scaling of the flow calculations. See Section 6 - Program Code Definitions for additional information.
Bar graph percentage display is the rectangle displayed on the right side of the display panel.
This display is a bar graph representation of the quantity percentage loaded to the receiving tank. As the Loaded quantity is incremented and the Remaining quantity is decremented, the bar graph percentage is proportionately shaded in black. The black shading represents the Loaded quantity and the unshaded portion represents the Remaining quantity. The number located at the top of the tank indicates the percentage of the Preset quantity that has been Loaded. The normal range of this number is 0% to 100%. However, percentages greater than 100 percent are indicated for a delivery quantity in excess of 100 percent of the preset quantity.
Message line is the bottom line of the display panel and is used to display various status messages to the user / operator. The content and meaning of the messages are explained below in the Controlling the Batch Delivery section.
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DanLoad 6000 (v6.00) __________________________________________________________
# Component # n/n (not shown) is displayed below the Loaded field only if more than one component has been defined for delivery (sequential blending). This field contains the following information.
# Component # Component identification, as shown or the alpha-numeric
Component ID assigned in the Component parameters group, program codes 065 to 077.
# n/n The sequence number of the component / total number of components in the recipe, obtained from program code 486
/ ... / 660 Sequence to load and recipe definition located in the
Recipes group, program codes 480 to 661.
4.2.1
Controlling the Batch Delivery
If a data item prompt or prompts were defined during the setup procedure the prompts will be displayed during batch delivery setup. Data item prompts accept user / operator numeric entries of up to five eight-digit numeric values that are saved in transaction storage memory or printed in data log in manual or stand-alone modes. In auto mode, data items are communicated to a terminal automation system for transaction accounting purposes. Data item entries are not used internally by the DanLoad 6000. Data item prompts are messages that are presented on the message line of the display panel when the Loading Display is first shown. These prompt messages are defined during setup with program codes 030 to 036.
The general format of a data prompt message is:
Enter data item #1 ________
However, note that the message shown above is a default entry which can be changed to a meaningful prompt message during setup. Actual messages that could be displayed are: Enter order
number:, Enter driver number:, Enter trailer number:, etc. The response is to enter the desired number, from one to eight digits and then press the ENTER key. If program code 036 Prompt
time-out (s) has been defined, and no entry is made within the time-out time period, the Recipe
Selection Display will be redisplayed to allow restarting the batch delivery setup procedure. If an error is made during the numeric entry, press the CLEAR key and reenter the number. If an invalid number is entered and accepted, press the STOP/PRINT key to terminate and re-start the transaction. If an entry is not required, press the ENTER key to continue. After all one to five data items have either been entered or bypassed, the Loading Display as shown in Figure 4 - 5, with the
Enter preset quantity prompt is presented to the user / operator.
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If data item entries have not been defined in the setup procedure, the Loading Display is presented as shown in Figure 4 - 5, with the Enter preset quantity prompt displayed.
The quantity to deliver is entered with the numeric keypad. If an entry error is made, press the
CLEAR key to reset the entry and start again. If the entry is correct, press the ENTER key to accept the entry and continue. If the selected recipe component percentages and components specified by program code 486 / ... / 660 Sequence to load program code do not equal 100 percent, the message Invalid recipe (percentages) is displayed on the message line at this time. This setup error condition can be corrected by selecting the Program Mode > Setup Menu > Recipes program codes and revising either the percentages of the individual components specified by the loading sequence and / or the loading sequence program code. If the entered value is less than the value of program code 079 Minimum preset qty, the message Invalid entry - less than minimum is displayed on the message line of the display panel. Press the CLEAR key to reset the entry and start again.
If the entered value is greater that the value of program code 078 Maximum preset qty, the message
Invalid entry - more than maximum is displayed on the message line of the display panel. Press the
CLEAR key to reset the entry and start again.
If the manual entry passes the high and low preset quantity validation checks, the Preset and
Remaining field values are set to the entered value, the Delivered value is set to zero, and the message Press START when ready or STOP to cancel is displayed on the message line of the display panel. If the STOP/PRINT key is pressed at this time, the batch delivery that is setup is aborted.
The message Please wait is displayed on the message line of the display panel and then the Recipe
Selection Display is re-displayed to allow reentry of a new batch delivery definition. Any open transaction is also terminated by this action.
The green LED ON indicates that the environment is safe for the loading operation. If all permissive circuits are not in the safe state, the corresponding alarm message (Connect safety circuit, etc.) is displayed.
The following message sequence is displayed on the message line of the display panel during a normal batch delivery operation.
# Open block valve - press ENTER
#
This message and operator entry is only required if the selected unit type is Seq.(manual)
(manual sequential blender).
Opening block valve
The block valve for the component is being opened.
Operation _______________________________________________________________ 4 - 15
DanLoad 6000 (v6.00) __________________________________________________________
#
#
#
#
#
#
Line pack delay
The pump for the component is running and the loading line is being packed.
Ramping up to high flow rate
The flow control valve or valves are opening in stages to increase the flow rate to the maximum predefined flow rate.
Load in progress
The batch delivery is in progress in a normal manner.
Ramping down to low flow rate
The flow control valve or valves are closing in stages to decrease the flow rate to the predefined low flow rate.
Shutting valve
All open flow control valves are closed. Block valves are closed if the unit is not a manual sequential blender.
Close block valve - press ENTER
This message and operator entry is only required if the selected unit type is Seq.(manual)
(manual sequential blender).
The following tasks are performed during the batch delivery operation.
# The display panel shows the preset quantity, the delivered quantity (incrementing), the transaction quantity (incrementing), and the remaining quantity (decrementing). These accumulators indicate either gross or standard quantities dependent on the setup parameters.
# Up to four delivery flow rates can be defined for each flow meter / flow control valve combination. The DanLoad 6000 always attempts to deliver the product at the maximum defined flow rate except during low flow startup and shutdown times. The rate of flow is controlled automatically without interaction with the user / operator. If the highest defined flow rate cannot be maintained for some reason, the DanLoad 6000 will set the flow rate at the next highest maintainable flow rate, which is selected in the setup, and periodically attempt to increase the flow rate to the maximum defined flow rate.
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#
#
#
#
#
#
Up to six additives can be injected into the delivered batch. The ratio of the quantity of each additive to the delivered batch quantity is automatically controlled.
All permissive inputs are monitored continuously for abnormal conditions. An open permissive circuit will cause the green LED indicator to turn OFF, indicating no permissive power, cause an alarm message to appear on the message line of the display panel and may suspend the batch delivery, depending on the defined control parameters.
All process variables are monitored continuously and compared to limit setpoints. Abnormal process conditions will cause an alarm and the corresponding message to appear on the message line of the display panel and may suspend the batch delivery, depending on the defined control parameters.
Real-time process input data and calculated process data, such as real-time flow rates, average temperatures, etc., can be monitored by the Dynamic Data Display window which is displayed in the center area of the Loading Display. The SELECT key is pressed to activate the Dynamic Data Display window. The 9 and 8 arrow keys are used to change display pages (one to four display pages, with four data items in each display page - for a total of up to sixteen different items, can be predefined). The CLEAR key removes the
Dynamic Data Display window and re-displays the standard Loading Display.
The batch delivery can be temporarily suspended by pressing the STOP/PRINT key. The batch delivery can be restarted if the quantity remaining to deliver is greater than the minimum preset quantity and all permissive circuits are closed, indicating that the system is safe and ready for batch delivery.
If a power failure occurs during a batch delivery operation, the DanLoad 6000 saves the date and time of the power failure in non-volatile memory and indicates this in a message on the first display presented when power is restored to the instrument.
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DanLoad 6000 (v6.00) __________________________________________________________
#
#
The DanLoad 6000 ramps down to the low flow rate (or stop rate for an in-line blending application) at a configurable quantity from the end of a batch. The valves are finally commanded to close (fully), i.e. the “final trip point” is reached, based on the average value of the five most recently taken “valve closure pulse samples” for the component/valve combination. A valve closure pulse sample is the number of pulses between commanding the valve to close (deenergizing the valve solenoids) and the flow rate dropping to zero (zero flow rate being defined as 2.5 seconds without a single pulse being recorded). If the batch terminates normally, i.e. flow is stable at the low flow rate at the final trip point and there is no alarm (such as “unable to close valve”), a new valve closure pulse sample is taken and a new average is computed to be used for the next batch. NOTE: If the low flow stop quantity is too small it may not be possible for the flow rate to stabilize at the low flow rate, i.e.
within the deadband, prior to reaching the final trip point, in which case the flow control valve closure sample for that batch will not be used. NOTE 2: The valve closure pulse samples are stored in non-volatile (battery-backed) memory. NOTE 3: The valve closure number of pulses depends on line pressure (particularly for hydraulically operated flow control valves, which close more slowly when line pressure is low) and the repeatability of the low flow rate (particularly with two-stage flow control valves).
When the DanLoad 6000 is in the idle / ready state, the Loading Display is presented to the user / operator with the prompt Enter preset quantity. The previously delivered quantity is indicated in the Loaded field and the Remaining field indicates 0. The Loading Display remains in this state until the user / operator initiates a new batch delivery (part of the open transaction) by entering the quantity to be delivered. Or the open transaction is closed by pressing the STOP/PRINT key without a batch delivery in progress.
Each delivered batch quantity total will be combined in the transaction delivered total until the STOP/PRINT key is pressed when a delivery is not in progress.
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4.3
Additive Injection
#
#
Additives can be automatically injected into the delivered product or component blend. The additive volume in relation to the delivered product volume is usually very small, typically less than four percent of the delivered quantity. The basic features of the additive injection operations are listed below.
# Directly control the injection of one to six additives (or no additive). Additive injection is quantity based and determined by the configured ratio, program code 140 / 145 / 150 / 155
/ 160 / 165 Ratio qty, of the preset batch quantity and the quantity of additive injected, which is controlled by program code 139 / 144 / 149 / 154 / 159 / 164 Additive control
meters. The quantity of additive to inject is reset at the start of each batch delivery operation.
Therefore, additive injection is based on batch quantity and not transaction quantity.
However, the same additive or additives selection applies to all batches that are part of a transaction.
# Allow one additive to be selected automatically based on the selected recipe number 1 to 6.
Delivery of recipe 1 to 6 activates injection of the corresponding additive, 1 to 6. Different injection methods (additive injector types) for each logical additive are also permitted.
# Allow additives to be selected from the terminal automation system and / or a discrete selection input for each additive and manual selection with the keypad while viewing the
Additive Selection Display.
# Provide multiple injection rates (concentrations) per additive via the “Multi Rate” additive selection method.
# (Option) Accumulate and / or verify the quantity totals with data logging of the injected additives.
# (Option) Deliver a clean line quantity, without additive injection, at the end of each loading operation. Additive injection ratio is maintained correctly with or without clean line loading implemented.
(Option) Inhibit additive injection for part of a batch load.
The DanLoad 6000 can be configured to provide either an AC or DC control output to selfcontrolled or automatic additive injection systems that require a one-to-one drive signal. In addition, either an AC or DC status input (default Safety circuit #4) can detect an alarm condition from the additive injector.
Operation _______________________________________________________________ 4 - 19
DanLoad 6000 (v6.00) __________________________________________________________
4.4
Data Logging
This sub-section contains information on the data logging and reporting capabilities of a DanLoad
6000 equipped with an optional DUART board. The data logging feature allows the DanLoad 6000 to generate an audit trail for documentation of operation of the loading system. The function provides a cost effective manual backup documentation system for use if the terminal automation system fails.
The program codes listed below, with the exception of program codes 709 and 710, are used to enable or disable automatic logging of the corresponding data. Program code 709 is used to enable or disable printing of data log sequence numbers on each data log. The sequence numbers are printer sequential. If multiple printers are attached to the DanLoad 6000, sequence numbering for each printer is independent.
Program Code Log Function
703
704
705
706
707
708
709
710
696
697
698
699
700
701
702
Batch summary
Transaction summary
Alarm log
Power fail log program mode entry/exit
W&M switch opened/closed
Program value change log
Configuration summary
Crash memory summary
Totalizers
Transaction ticket
Transaction ticket reprint
Thruput
Sequence numbers
Cutoff hour
Code operated switch attributes are found in Section 6.21.
Data logging usually involves sending the enabled reports / data to a common 80-column dot matrix printer. However, data logs can be sent to a personal computer or any other data logging device that can handle serial input ASCII data with a CR (carriage return) and LF (line feed) at the end of each line of data.
Data is sent from the DanLoad 6000 to the printer or logging device as each event occurs. This method of operation is called event logging. Logs are not stored in the DanLoad 6000. However, if the DanLoad 6000 detects that the printer or logging device is off-line, logs are held in memory until either the printer / logging device becomes on-line, then the stored logs are printed or the log memory is full. The action taken if the data logging memory becomes full is specified by program code 235 Data logging alarm action.
4 - 20 ______________________________________________________________ Operation
__________________________________________________________ DanLoad 6000 (v6.00)
Several DanLoad 6000's can share one data printer or logging device. Printer sharing requires a special device that accepts the serial data link from each DanLoad 6000 and provides one serial data link to the printer.
The text language of the data logs is specified by program code 028 Language.
4.4.1
Example Data Logs
An example of each type of data log associated with normal batch deliveries and transactions is provided below. The Crash memory summary log is described in Section 4.5 - Fault Analysis /
Correction. A brief description of the contents of each field follows the data log example.
Batch Summary
1 2 3 4 5 6 7 8
12345678901234567890123456789012345678901234567890123456789012345678901234567890
9999 <- Data log sequence number (program code 709)
Unit 999 XXXXXXXX 99:99:99 -- Batch Summary
Transaction 9999 Side 9 Recipe #1 IDXXXX <-- transaction data
Enter data item #1 99999999
ENTER ORDER NUMBER 99999999
XXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXX 99999999
XXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXX 99999999
XXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXX 99999999
Batch 9999 Preset 999999 Gross 999999 Std 999999 <-- batch data
Started XXXXXXXX 99:99:99 Stopped XXXXXXXX 99:99:99
Gross Std Temp Dens Pres
Gal Gal Deg C lb/ft3 psi <-- from PC's 029, 427, 428, 429
Component #1 IDX 999999 999999 -999.9 9999.9 9999.99 <-- Component data
Component #2 IDX 999999 999999 -999.9 9999.9 9999.99
Component #3 IDX 999999 999999 -999.9 9999.9 9999.99
Component #4 IDX 999999 999999 -999.9 9999.9 9999.99
XXX <- Additive units per program code 44.
Additive #1 9999999.99
Additive #2 9999999.99
Additive #3 9999999.99
Additive #4 9999999.99
Additive #5 9999999.99
Additive #6 9999999.99 <- Scale depends on additive units (program code 44).
12345678901234567890123456789012345678901234567890123456789012345678901234567890
1 2 3 4 5 6 7 8
Operation _______________________________________________________________ 4 - 21
DanLoad 6000 (v6.00) __________________________________________________________
#
#
#
A batch summary is generated automatically at the end of each batch delivery or when power is restored after a power outage occurred during a batch delivery. The fields contained in the Batch
Summary are described below.
# Unit The unit address obtained from the DIP switch settings on the optional
DUART board.
# Transaction A sequential numeric value, generated internally for identification of each transaction.
Side
Recipe ##
The loading island side where the delivery was made.
The name of the recipe that controlled the delivery.
<Enter data item #1>
Up the five data prompts and corresponding manually entered numeric data.
The number of lines printed is dependent on the number of data prompts defined by program code 030 Number of data item prompts. Data item prompts are re-defined by the alpha-numeric entries for parameters 031 to
035 (03x Enter data item #x). The corresponding values, printed to the right of the prompt messages, are the manual entries from the start of the batch delivery.
# Batch A sequential numeric value, generated internally for identification of each batch delivery, this row (record) also contains the gross quantity delivered and the standard quantity delivered (sum of all components).
4 - 22 ______________________________________________________________ Operation
__________________________________________________________ DanLoad 6000 (v6.00)
#
#
#
#
#
#
#
Preset
Gross
Std
Started
The preset quantity obtained from the batch data entry.
The accumulated gross quantity for the composite batch delivery.
The accumulated standard quantity for the composite batch delivery.
Date and time the delivery started.
Stopped Date and time the delivery stopped.
Component #
One row (record) for each delivered component, with the following data indicated:
# Gross quantity delivered of this component, the engineering units label is obtained from program code 029 Product Units.
# Standard quantity delivered of this component, the engineering units label is obtained from program code 029 Product Units.
# Average temperature of this component (negative values are indicated), the engineering units label is obtained from program code
427 Temperature units.
# Average density of this component, the engineering units label is obtained from program code 428 Density units.
# Average pressure of this component, the engineering units label is obtained from program code 429 Pressure units.
Additive # The units and format in which additive volumes are display and printed.
Operation _______________________________________________________________ 4 - 23
DanLoad 6000 (v6.00) __________________________________________________________
Transaction Summary
Unit nnn mm/dd/yy hh:mm:ss -- Transaction Summary
Transaction nnnn Side n Recipe ## aaaaaa Gross nnnnnn Std nnnnnn
Started mm/dd/yy hh:mm:ss Stopped mm/dd/yy hh:mm:ss
Enter data item #1 nnnnnnnn
Enter data item #2 nnnnnnnn
Enter data item #3 nnnnnnnn
Enter data item #4 nnnnnnnn
Enter data item #5 nnnnnnnn
Start End Start End
gross gross std std
Meter 1 totalizer nnnnnnnnn nnnnnnnnn nnnnnnnnn nnnnnnnnn
Meter 2 totalizer nnnnnnnnn nnnnnnnnn nnnnnnnnn nnnnnnnnn
Meter 3 totalizer nnnnnnnnn nnnnnnnnn nnnnnnnnn nnnnnnnnn
Meter 4 totalizer nnnnnnnnn nnnnnnnnn nnnnnnnnn nnnnnnnnn
A transaction summary is generated automatically at the end of each transaction consisting of one or multiple batch deliveries or when power is restored after a power outage occurred while a transaction is in progress. The fields contained in the Transaction Summary are described below.
# Start gross / End gross
Start std / End std
The gross and standard quantitys are indicated for each active flow meter
(Meter m totalizer).
#
#
Alarm
Unit nnn mm/dd/yy hh:mm:ss -- Alarm aaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaa
An alarm log is generated automatically when an alarm condition is detected for alarms which have the alarm action attribute set to Primary or Secondary. The fields contained in the Alarm log are described below.
# Unit The unit address obtained from the DIP switch settings o the optional
DUART board.
<time>
<message>
Date and time that the alarm condition was detected.
Alarm message, messages are indicated in Section 4.5.
4 - 24 ______________________________________________________________ Operation
__________________________________________________________ DanLoad 6000 (v6.00)
Power Failure Date and Time
Unit nnn mm/dd/yy hh:mm:ss -- Power failed mm/dd/yy hh:mm:ss
A power failure log is generated automatically when power is restored to the DanLoad 6000. The fields contained in the Power failure log are described below.
# Unit The unit address obtained from the DIP switch settings on the optional
DUART board.
# <time> The current date and time and the date and time that power was removed from the DanLoad 6000.
Program Mode Entry and Exit
Unit nnn mm/dd/yy hh:mm:ss -- User aaaaaaaaaaaaaaaa entered program mode
Unit nnn mm/dd/yy hh:mm:ss -- User aaaaaaaaaaaaaaaa exited program mode
#
#
A program mode entry / exit log is generated automatically whenever the program mode is entered or exited. The fields contained in the program mode entry/exit log are described below.
# Unit The unit address obtained from the DIP switch settings on the optional
DUART board.
<time>
User
Date and time of the event.
The user / operator name obtained from program code 002 / ... / 023 User ID parameter entry.
Operation _______________________________________________________________ 4 - 25
DanLoad 6000 (v6.00) __________________________________________________________
Weights and Measures Switch
Unit nnn mm/dd/yy hh:mm:ss -- Weights and measures switch opened
Unit nnn mm/dd/yy hh:mm:ss -- Weights and measures switch closed
#
#
A weights and measures switch log is generated automatically whenever the state of the weights and measures switch, located on the operator control panel, is changed. The fields contained in the
Weights and measures switch log are described below.
# Unit The unit address obtained from the DIP switch settings on the optional
DUART board.
<time>
<message>
Date and time of the event.
The message Weights and measures switch opened or
Weights and measures switch closed.
#
#
Program Code Value Changed
Unit nnn mm/dd/yy hh:mm:ss -- Program Code Value Changed
User aaaaaaaaaaaaaaaa Value 480 Number of recipes 5
A program code value changed log is generated automatically whenever a program code value is changed for a program code which has the Data logging attribute set to Yes. (Note: This attribute
defaults to Yes for all program codes during initial startup (cold start). The fields contained in the
program code value changed log are described below.
# Unit The unit address obtained from the DIP switch settings on the optional
DUART board.
<time>
User
Date and time of the event.
The user / operator name obtained from program code 002 / ... / 023 User ID parameter entry.
# Value The program code number and name followed by the current program code value.
4 - 26 ______________________________________________________________ Operation
__________________________________________________________ DanLoad 6000 (v6.00)
Totalizers
The totalizers data log is generated automatically every 24 hours per the "cutoff hour"
(program code 710) or on demand (for the last cutoff) from the program mode menu.
1 2 3 4 5 6 7 8
12345678901234567890123456789012345678901234567890123456789012345678901234567890
9999 <- Data log sequence number.
Unit 999 XXXXXXXX 99:99:99
-- Totalizers XXXXXXXX 99:99:99 <- Langauge dependent text and cutoff date and time.
Gross Std <- Language dependent text.
XXX XXX <- Configured units mnemonic.
XXXXX 999999999 999999999 <- Configured meter ID and gross and std totalizers.
XXXXX 999999999 999999999
XXXXX 999999999 999999999
XXXXX 999999999 999999999 <- Depending on configured # meters (max. 4).
XXXXXXXXXXXXXXXX 999999999 999999999 <- Configured component ID and gross and std totalizers.
XXXXXXXXXXXXXXXX 999999999 999999999
XXXXXXXXXXXXXXXX 999999999 999999999
XXXXXXXXXXXXXXXX 999999999 999999999 <- Depending on configured # components (max. 4).
XXXXXXXXXXXXXXXX 999999999 999999999 <- Configured recipe ID and gross and std totalizers.
XXXXXXXXXXXXXXXX 999999999 999999999
XXXXXXXXXXXXXXXX 999999999 999999999
XXXXXXXXXXXXXXXX 999999999 999999999
XXXXXXXXXXXXXXXX 999999999 999999999
XXXXXXXXXXXXXXXX 999999999 999999999
XXXXXXXXXXXXXXXX 999999999 999999999
XXXXXXXXXXXXXXXX 999999999 999999999
XXXXXXXXXXXXXXXX 999999999 999999999
XXXXXXXXXXXXXXXX 999999999 999999999
XXXXXXXXXXXXXXXX 999999999 999999999
XXXXXXXXXXXXXXXX 999999999 999999999
XXXXXXXXXXXXXXXX 999999999 999999999
XXXXXXXXXXXXXXXX 999999999 999999999
XXXXXXXXXXXXXXXX 999999999 999999999
XXXXXXXXXXXXXXXX 999999999 999999999
XXXXXXXXXXXXXXXX 999999999 999999999
XXXXXXXXXXXXXXXX 999999999 999999999
XXXXXXXXXXXXXXXX 999999999 999999999
XXXXXXXXXXXXXXXX 999999999 999999999
XXXXXXXXXXXXXXXX 999999999 999999999
XXXXXXXXXXXXXXXX 999999999 999999999
XXXXXXXXXXXXXXXX 999999999 999999999
XXXXXXXXXXXXXXXX 999999999 999999999
XXXXXXXXXXXXXXXX 999999999 999999999
XXXXXXXXXXXXXXXX 999999999 999999999
XXXXXXXXXXXXXXXX 999999999 999999999
XXXXXXXXXXXXXXXX 999999999 999999999
XXXXXXXXXXXXXXXX 999999999 999999999
XXXXXXXXXXXXXXXX 999999999 999999999 <- Depending on configured # recipes (max. 30).
XXX <- Configured additive units mnemonic.
Additive #1 99999.9999 <- Language-dependent text and totalizer (format depends on additive units).
Additive #2 99999.9999
Additive #3 99999.9999
Additive #4 99999.9999
Additive #5 99999.9999
Additive #6 99999.9999 <- Depending on configured # additives (max. 6).
12345678901234567890123456789012345678901234567890123456789012345678901234567890
1 2 3 4 5 6 7 8
Operation _______________________________________________________________ 4 - 27
DanLoad 6000 (v6.00) __________________________________________________________
Thruput
The thruput data log is generated automatically every 24 hours per the "cutoff hour"
(program code 710) or on demand (for the last cutoff) from the program mode menu.
1 2 3 4 5 6 7 8
12345678901234567890123456789012345678901234567890123456789012345678901234567890
9999 <- Data log sequence number.
Unit 999 XXXXXXXX 99:99:99
-- Thruput XXXXXXXX 99:99:99 - XXXXXXXX 99:99:99 <- Language dependent text and start and end dates and times.
Gross Std <- Language dependent text.
XXX XXX <- Configured units mnemonic.
XXXXX 999999999 999999999 <- Configured meter ID and gross and std totalizers.
XXXXX 999999999 999999999
XXXXX 999999999 999999999
XXXXX 999999999 999999999 <- Depending on configured # meters (max. 4).
XXXXXXXXXXXXXXXX 999999999 999999999 <- Configured component ID and gross and std totalizers.
XXXXXXXXXXXXXXXX 999999999 999999999
XXXXXXXXXXXXXXXX 999999999 999999999
XXXXXXXXXXXXXXXX 999999999 999999999 <- Depending on configured # components (max. 4).
XXXXXXXXXXXXXXXX 999999999 999999999 <- Configured recipe ID and gross and std totalizers.
XXXXXXXXXXXXXXXX 999999999 999999999
XXXXXXXXXXXXXXXX 999999999 999999999
XXXXXXXXXXXXXXXX 999999999 999999999
XXXXXXXXXXXXXXXX 999999999 999999999
XXXXXXXXXXXXXXXX 999999999 999999999
XXXXXXXXXXXXXXXX 999999999 999999999
XXXXXXXXXXXXXXXX 999999999 999999999
XXXXXXXXXXXXXXXX 999999999 999999999
XXXXXXXXXXXXXXXX 999999999 999999999
XXXXXXXXXXXXXXXX 999999999 999999999
XXXXXXXXXXXXXXXX 999999999 999999999
XXXXXXXXXXXXXXXX 999999999 999999999
XXXXXXXXXXXXXXXX 999999999 999999999
XXXXXXXXXXXXXXXX 999999999 999999999
XXXXXXXXXXXXXXXX 999999999 999999999
XXXXXXXXXXXXXXXX 999999999 999999999
XXXXXXXXXXXXXXXX 999999999 999999999
XXXXXXXXXXXXXXXX 999999999 999999999
XXXXXXXXXXXXXXXX 999999999 999999999
XXXXXXXXXXXXXXXX 999999999 999999999
XXXXXXXXXXXXXXXX 999999999 999999999
XXXXXXXXXXXXXXXX 999999999 999999999
XXXXXXXXXXXXXXXX 999999999 999999999
XXXXXXXXXXXXXXXX 999999999 999999999
XXXXXXXXXXXXXXXX 999999999 999999999
XXXXXXXXXXXXXXXX 999999999 999999999
XXXXXXXXXXXXXXXX 999999999 999999999
XXXXXXXXXXXXXXXX 999999999 999999999
XXXXXXXXXXXXXXXX 999999999 999999999 <- Depending on configured # recipes (max. 30).
XXX <- Configured additive units mnemonic.
Additive #1 99999.9999 <- Language-dependent text and totalizer (format depends on additive units).
Additive #2 99999.9999
Additive #3 99999.9999
Additive #4 99999.9999
Additive #5 99999.9999
Additive #6 99999.9999 <- Depending on configured # additives (max. 6).
12345678901234567890123456789012345678901234567890123456789012345678901234567890
1 2 3 4 5 6 7 8
4 - 28 ______________________________________________________________ Operation
__________________________________________________________ DanLoad 6000 (v6.00)
Configuration Summary
1 2 3 4 5 6 7 8
12345678901234567890123456789012345678901234567890123456789012345678901234567890
9999 <- Data log sequence number (program code 709)
Unit 999 XXXXXXXX 99:99:99
**************************************** Security parameters
User 1
001 Passcode *********
002 User ID DanLoad 6000
003 Supervisor privilege Yes
User 2
004 Passcode *********
005 User ID
006 Supervisor privilege No
.
.
.
024 Supervisor privilege No
9999 <- Data log sequence number (program code 709)
Unit 999 XXXXXXXX 99:99:99
**************************************** Unit parameters
Unit parameters
025 Operating mode Manual
.
.
026 Unit type Seq. (auto)
027 Valve type Std digital
.
etc.
etc.
etc.
12345678901234567890123456789012345678901234567890123456789012345678901234567890
1 2 3 4 5 6 7 8
Operation _______________________________________________________________ 4 - 29
DanLoad 6000 (v6.00) __________________________________________________________
4.5
Alarm Analysis / Correction / Diagnostic Tests
#
#
This sub-section contains information on the analysis and correction of common fault conditions that can occur during batch delivery operations.
# Alarm messages and causes of the alarm messages are described in Section 4.5.1. Additional information on alarm parameters and other parameters in located in Section 6 - Program
Code Definitions.
Diagnostic tests, available in the Program Mode, are described in Section 4.5.2.
A Crash memory log is automatically generated, if enabled, if a processor memory error is detected. Section 4.5.3 contains information on this error log.
Crash memory logs should be saved and the log occurrence reported to:
Daniel Measurement and Control
Daniel Measurement Services
Telephone: (281) 897-2900
FAX: (281) 897-2901
After-hours emergency answering service: Electronics: (713) 468-4096
Automation: (713) 464-5715
General information on all alarm conditions and messages is provided on the following pages.
Additional information on alarms is provided in the Alarms group, program codes 220 to 279, and the I/O Parameters group, program codes 280 to 379, in Section 6.
Note
Primary alarms are reset by logging-on with your passcode to activate the Program Mode.
Then use the 9 (down arrow) (depending on the firmware version) to select Alarm reset.
Press the Enter key to clear individual alarms. After alarms have been cleared, press EXIT
(ALT+CLEAR) to return to the Loading Mode.
Secondary alarms are reset automatically after the time period set by program code 220
Secondary alarm reset (secs) has elapsed.
4 - 30 ______________________________________________________________ Operation
__________________________________________________________ DanLoad 6000 (v6.00)
4.5.1
Alarm Messages
Flow rate too low meter #
221 Low flow alarm action
222 Minimum flow rate
223 Low flow time (secs)
Notes:
#
Default
Primary
100
10
Range
Off
Info
Secondary
Primary
0 to 99999
5 to 999
In the alarm message, # is the actual flow meter number (1, 2, 3,
4).
# The flow rate units for program code 222 Minimum flow rate are determined by the corresponding program code 171 / 182 / 193 /
204 Nominal K-factor for the flow meter (GPM, LPM, dLPM,
BPH, LBH, KGH).
# This alarm is triggered by problems in the component pumping circuit, flow control valve circuit, flow meter preamplifier, or flow meter sensor.
Operation _______________________________________________________________ 4 - 31
DanLoad 6000 (v6.00) __________________________________________________________
4.5.1
Alarm Messages (continued)
Flow rate too high meter #
224 High flow alarm action
225 Maximum flow rate
226 High flow time (secs)
Notes:
#
Default
Primary
660
10
Range
Off
Info
Primary
0 to 99999
5 to 999
In the alarm message, # is the actual flow meter number (1, 2, 3,
4).
# The flow rate units for program code 225 Maximum flow rate are determined by the corresponding program code 171 / 182 / 193 /
204 Nominal K-factor for the flow meter (GPM, LPM, dLPM,
BPH).
# This alarm is triggered by problems in the component pumping circuit, flow control valve circuit, or flow meter circuit.
4 - 32 ______________________________________________________________ Operation
__________________________________________________________ DanLoad 6000 (v6.00)
4.5.1
Alarm Messages (continued)
#
#
Unable to close valve meter #
--- Overrun limit alarm action
227 Overrun limit qty
Notes:
#
Default
Primary
2.0
Range
<none>
0.0 to 99.9
In the alarm message, # is the actual flow meter number (1, 2, 3, 4).
The alarm action is internally set to Primary.
This alarm is triggered by problems in the flow control valve circuit. program code 086 / 092 /098 / 104 Low flow stop qty too small, unstable flow rate during low flow stop, K-factor to small (insufficient pulse rate input for frequency calculation), flow control valve jammed OPEN by debris or mechanical failure.
# After valve is repaired or adjusted, the DanLoad 6000 will need to deliver a minimum of three batches in order to determine the valve closure time.
Valve closed early meter #
228 Underflow alarm action
Default
Off
Range
Off
Primary
0.0 to 99.9
#
#
229 Underflow limit qty
Notes:
5.0
In the alarm message, # is the actual flow meter number (1, 2, 3, 4).
This alarm is triggered by problems in the flow control valve circuit.
Operation _______________________________________________________________ 4 - 33
DanLoad 6000 (v6.00) __________________________________________________________
4.5.1
Alarm Messages (continued)
Timed-out - no flow detected meter #
230 No flow time-out alarm action
Default
Primary
231 No flow time-out (secs)
Notes:
#
5
In the alarm message, # is the actual flow meter number (1, 2, 3, 4).
Range
Off
Info
Secondary
Primary
1 to 99
# This alarm is triggered by problems in the flow meter circuit (bad preamplifier or pulse input wiring), pump circuit, the component block valve circuit, or the flow control valve circuit, failure of meter pulse board or main processor board.
#
#
Unauthorized flow exceeds limit meter #
--- Unauthorized flow limit alarm action
232 Unauthorized flow limit qty
Notes:
#
Default
Primary
10
In the alarm message, # is the actual flow meter number (1, 2, 3, 4).
The alarm action is internally set to Primary.
Range
<none>
0.0 to 99.9
This alarm is triggered by problems in the block valve or flow control valve circuit, such as a mechanical failure (bad O-rings, etc.) of the valve or pulsation of the product caused by multiple arms, valves, pumps in the same circuit in use at the same time. The alarm is also triggered if either the normally closed or normally open stem switches (stem switches 1 and 2, respectively) or both, are configured (program codes
294 and 295 for valve 1, etc.).
# After valve is repaired or adjusted, the DanLoad 6000 will need to deliver a minimum of three batches in order to determine the valve closure time.
# See Section 3 and Section 6 for additional information.
4 - 34 ______________________________________________________________ Operation
__________________________________________________________ DanLoad 6000 (v6.00)
4.5.1
Alarm Messages (continued)
#
#
Pulse security error meter #
--- Pulse security alarm action
233 Error limit (levels B and C)
234 Reset count (pulses)
Notes:
#
Default
Primary
0
10000
Range
<none>
0 to 255
0 to 65535
In the alarm message, # is the actual flow meter number (1, 2, 3, 4).
The alarm action is internally set to Primary.
The pulse security level B is determined by an electronic module installed on the meter pulse input board. Reference British standard IP 252 or API standard MPMS Chapter 5, Section 5 and program code descriptions in
Section 6.13 of this manual.
# This alarm is triggered by pulse comparison errors between two pulse train inputs from a single flow meter. Causes of errors are A / B input pulse trains reversed, preamplifier failure, wiring failure.
# Program code 233 Error limit (pulses) must be set to 0 (zero) to disable this function if dual pulse security is not implemented.
Operation _______________________________________________________________ 4 - 35
DanLoad 6000 (v6.00) __________________________________________________________
4.5.1
Alarm Messages (continued)
Data logging memory full
235 Data logging alarm action
Default
Info
Range
Info
Primary
Notes:
# This alarm is triggered when the data logging memory becomes full. This condition is usually caused by the data logging printer being off-line, out of paper, or otherwise not available. The data logging function is enabled or disabled by the Data logging parameters.
Comm failure channel x
236 Time-out ch. A (s)
237 Time-out ch. B (s)
Note:
#
Default
10
10
Range
0 to 300
0 to 300
These program codes set the time-out in seconds for communication channels A and B alarms. Zero (0) disables the alarm(s).
4 - 36 ______________________________________________________________ Operation
__________________________________________________________ DanLoad 6000 (v6.00)
4.5.1
Alarm Messages (continued)
Temperature failure meter #
238 Temperature failure alarm action
239 Minimum temperature
240 Maximum temperature
Default
Primary
-40.0
110.0
Range
Off
Info
Primary
-999.9 to
999.9
-999.9 to
999.9
Notes:
#
#
In the alarm message, # is the actual flow meter number (1, 2, 3, 4).
This alarm is triggered by a failure in the RTD temperature input assigned to the indicated flow meter. Temperature inputs are assigned by program codes
318 / 321 / 324 / 327 Meter x temp input. Some causes of this alarm are: temperature of product out-of-range (can be caused by faulty product heater or product remaining in heater too long a time), failure of RTD or failure of wiring to RTD/
# Fixed temperature values used in case of failure of the live temperature inputs are set by program codes 434 / 437 / 440 / 443 Backup temperature. These fixed temperature values are assigned to components, however, the DanLoad
6000 relates the current component flow to the current flow meter. The alarm
meter # indicates a specific RTD input.
Operation _______________________________________________________________ 4 - 37
DanLoad 6000 (v6.00) __________________________________________________________
4.5.1
Alarm Messages (continued)
Density failure component #
241 Density fail alarm action
242 Minimum density/gravity
243 Maximum density/gravity
Default
Primary
9.9999
9.9999
Notes:
#
#
In the alarm message, # is the actual component number (1, 2, 3, 4).
This alarm is triggered by a failure in the density input assigned to the indicated component.
Range
Info
Primary
-9.9999 to
9.9999
-9.9999 to
9.9999
Pressure failure meter #
--- Pressure failure alarm action
244 Minimum pressure
245 Maximum pressure
Default
Primary
0.00
0.00
Range
<none>
0.0 to
9999.99
0.0 to
9999.99
Notes:
#
#
In the alarm message, # is the actual flow meter number (1, 2, 3, 4).
This alarm is triggered by a failure in the pressure input assigned to the indicated flow meter. Possible causes include; input pressure out of range, the method other than “Off” has been configured and the required input is not configured, or the pinch back method will not allow the flow control valve to be properly closed due to insufficient pressure when flowing at the low flow rate.
4 - 38 ______________________________________________________________ Operation
__________________________________________________________ DanLoad 6000 (v6.00)
4.5.1
Alarm Messages (continued)
Additive # failure
--- Additive error alarm action
246 Additive error limit
247 Additive feedback count
271 Unauthorized additive flow volume
272 Prod/add -%
273 Prod/add +%
278 Additive per 1000 error limit
0
0
1
Default
Primary
3
0
0.0000
Range
<none>
1 to 99
0 to 9999
0.0000 to
99999.9999
0 to 99
0 to 99
1 to 99
Notes:
#
For the “M ech” and “Handshake” injection methods this is the maximum number of pulses by which the actual feedback pulse count can differ from the ideal feedback pulse count before an additive failure alarm is raised. The ideal feedback pulse count is based on the additive feedback count (program code 247), or is 1 (internal default, independent of configuration) for the “Handshake” injection method.
#
Program code 247 Additive feedback count is the expected number of feedback pulses per additive ratio cycle for the “M ech” additive injection method, e.g. 1 for Titan PAC-3
“confirmation pulse”, 2 for Hydrolec injector. The number of seconds within which the additive feedback input must go on and off again after the additive ratio output has been energized for the “Handshake” additive injection method, e.g. 5 (per Mapco).
#
Program code 278 Additive per 1000 error limit is the number of ratio quantities worth of additive by which the actual quantity of additive can differ from the ideal volume of additive at any point in a batch before the DanLoad 6000 checks for a “low additive” or “high additive” condition (program codes 272 and 273).
#
Each additive failure alarm has a single character alphanumeric “reason code” which can be accessed as a data code value, e.g. in the dynamic data display or via an automation system.
Data code 233 is the additive failure reason code for additive 1, etc. The possible additive
failure reason codes are as follows:
“M ”
“F”
M ultiple additives authorized in multi-stream injection mode.
Feedback input count error for “M ech” or “Handshake” injection method (program codes 246 and 247).
Ratio output timer expired for “Handshake” injection method (program code 247).
“T”
“U” Unauthorized additive flow for “M eter” and “Control” injection methods (program code 271).
Low additive (or no additive) based on configured additive per 1000 (program codes “L”
“H”
272 and 278).
High additive based on configured additive per 1000 (program codes 273 and 278).
The additive failure reason codes are cleared (reset) when a batch is started or restarted.
Operation _______________________________________________________________ 4 - 39
DanLoad 6000 (v6.00) __________________________________________________________
4.5.1
Alarm Messages (continued)
#
#
Component X block valve not closed
--- Block valve close fail alarm action
248 Block valve time (s)
Notes:
Default
Primary
10
In the alarm message, X is the actual component number (1, 2, 3, 4).
Range
<none>
0 to 99
This alarm is triggered by a failure in the corresponding block valve control circuit indicating that the block valve has not closed after the component has been deselected. The position of the block valve is sensed by program code 401 / 403 /
405 / 407 Block value input, corresponding to one of four component block valves.
Component block valves are controlled by program codes 400 / 402 / 404 / 406
Block valve output.
4 - 40 ______________________________________________________________ Operation
__________________________________________________________ DanLoad 6000 (v6.00)
4.5.1
Alarm Messages (continued)
Ground detector open
249 Circuit 1 alarm action
250 #1 Ground detector open
Default
Secondary
7 message
Range
Off
Info
Secondary
Primary
1 to 32 characters
Notes:
# General permissive input, message specified by program code 250 # 1 Ground
detector open can be modified.
# This alarm is triggered by an open circuit sensed on the discrete input assigned to program code 345 Safety circuit 1.
Overspill detector open
251 Circuit 2 alarm action
252 #2 Overspill detector open
Default
Secondary
7 message
Range
Off
Info
Secondary
Primary
1 to 32 characters
Notes:
# General permissive input, message specified by program code 252 #2
Overspill detector open can be modified.
# This alarm is triggered by an open circuit sensed on the discrete input assigned to program code 346 Safety circuit 2.
Operation _______________________________________________________________ 4 - 41
DanLoad 6000 (v6.00) __________________________________________________________
4.5.1
Alarm Messages (continued)
Permissive power failure
253 Circuit 3 alarm action
254 #3 Permissive power failure
Default
Secondary
7 message
Range
Off
Info
Secondary
Primary
1 to 32 characters
Notes:
# General permissive input, message specified by program code 254 #3
Permissive power failure can be modified.
# This alarm is triggered by an open circuit sensed on the discrete input assigned to program code 347 Safety circuit 3.
Additive injection failure
255 Circuit 4 alarm action
256 #4 Additive injection failure
Default
Secondary
7 message
Range
Off
Info
Secondary
Primary
1 to 32 characters
Notes:
# General permissive input, message specified by program code 256 #4 Additive
injection failure can be modified.
# This alarm is triggered by an open circuit sensed on the discrete input assigned to program code 348 Safety circuit 4.
4 - 42 ______________________________________________________________ Operation
__________________________________________________________ DanLoad 6000 (v6.00)
4.5.1
Alarm Messages (continued)
Arm down side 1
257 Circuit 5 alarm action
258 #5 Arm down side 1
Default
Secondary
7 message
1
Range
Off
Info
Secondary
Primary
1 to 32 characters
0 to 2 265 Circuit 5 type
Notes:
# Side assignable permissive input, message specified by program code 258 #5
Arm down side 1 can be modified.
# This alarm is triggered by an open circuit sensed on the discrete input assigned to program code 349 Safety circuit 5. The side detect function is controlled by program code 265 Circuit 5 type which senses the swing arm side based on the option selection of program code 312 Side detect method.
# The permissive input can be set to be side independent or to be dependent on either side.
Operation _______________________________________________________________ 4 - 43
DanLoad 6000 (v6.00) __________________________________________________________
4.5.1
Alarm Messages (continued)
Arm down side 2
259 Circuit 6 alarm action
260 #6 Arm down side 2
Default
Secondary
7 message
2
Range
Off
Info
Secondary
Primary
1 to 32 characters
0 to 2 266 Circuit 6 type
Notes:
# Side assignable permissive input, message specified by program code 260 #6
Arm down side 2 can be modified.
# This alarm is triggered by an open circuit sensed on the discrete input assigned to program code 350 Safety circuit 6. The side detect function is controlled by program code 266 Circuit 6 type which senses the swing arm side based on the option selection of program code 312 Side detect method.
# The permissive input can be set to be side independent or to be dependent on either side.
4 - 44 ______________________________________________________________ Operation
__________________________________________________________ DanLoad 6000 (v6.00)
4.5.1
Alarm Messages (continued)
Walkway down side 1
261 Circuit 7 alarm action
262 #7 Walkway down side 1
Default
Secondary
7 message
1
Range
Off
Info
Secondary
Primary
Up to 32 characters
0 to 2 267 Circuit 7 type
Notes:
# Side assignable permissive input, message specified by program code 262 #7
Walkway down side 1 can be modified.
# This alarm is triggered by an open circuit sensed on the discrete input assigned to program code 351 Safety circuit 7. The side detect function is controlled by program code 267 Circuit 7 type which senses the swing arm side based on the option selection of program code 312 Side detect method.
# The permissive input can be set to be side independent or to be dependent on either side.
Operation _______________________________________________________________ 4 - 45
DanLoad 6000 (v6.00) __________________________________________________________
4.5.1
Alarm Messages (continued)
Walkway down side 2
263 Circuit 8 alarm action
264 #8 Walkway down side 2
Default
Secondary
7 message
2
Range
Off
Info
Secondary
Primary
Up to 32 characters
0 to 2 268 Circuit 8 type
Notes:
# Side assignable permissive input, message specified by program code 264 #8
Walkway down side 2 can be modified.
# This alarm is triggered by an open circuit sensed on the discrete input assigned to program code 352 Safety circuit 8. The side detect function is controlled by program code 268 Circuit 8 type which senses the swing arm side based on the option selection of program code 312 Side detect method.
# The permissive input can be set to be side independent or to be dependent on either side.
Memory check failed
The DanLoad 6000 continuously calculates and verifies CRC-16 checksums on critical blocks of memory containing data such as totalizers, calibration factors and flow rates and temperature calculation parameters. If a checksum does not verify correctly, the
DanLoad 6000 raises a “Memory check failed” primary alarm; this problem should be reported to Daniel Customer Service. Additionally, there are two situations in when a
“Memory check failed” alarm is raised, both of which are “harmless” and can be ignored:
1.
2.
Flow meter pulses entering the unit during power-up or reset. Operator action:
Reset the alarm and continue to use the unit.
Batch started after having modified calibraton factors or flow rates via automation system communications without having reset the unit. Operator action: Reset the alarm, power-up/reset the unit and continue to use the unit.
4 - 46 ______________________________________________________________ Operation
__________________________________________________________ DanLoad 6000 (v6.00)
Storage memory full
274 Storage alarm action
Default
Off
Range
Off
Primary
Note:
# A storage alarm (“Storage memory full”) is raised when enabled (“Primary”) and starting a new transaction or batch in the manual operating mode would overwrite an old transaction or batch (in transaction storage memory) also loaded in the manual operating mode.
Power failure
275 Power failure alarm action
Default
Off
Range
Off
Primary
Note:
# A power fail alarm (“Power failure”) is raised on power-up when the alarm is enabled (“Primary”) and a power failure or “crash” occurred during a batch, i.e. the DanLoad 6000 was reset during a batch. Following a power failure during a batch, the batch preset quantity is available (Dynamic Data Display) via data code 245, the batch gross and standard quantities via data codes 130 and 131, and the batch remaining quantity via data code 246.
Unable to ramp down
276 Ramp down alarm action
Default
Primary
Range
Off
Primary
0 to 9999 277 Ramp down time (secs)
Notes:
#
4
Program code 276 selects the response to an Unable to ramp down alarm when the DanLoad 6000 cannot reduce the flow rate to a defined lower flow rate within the time period specified by program code 277 sets the time limit for attempt to ramp down flow rate before triggering an Unable to ramp down
alarm.
# When Primary is selected (default) for program code 276, the ramp down alarm function is enabled.
Operation _______________________________________________________________ 4 - 47
DanLoad 6000 (v6.00) __________________________________________________________
Calibration failure meter X
755 Calib fail alarm action
Default
Primary
Range
Off
Info
Secondary
Primary
Note:
# This program code sets the calibration failure alarm action for calibration monitoring. Selections include “Off” which disables the alarm, “Info”,
“Secondary” and “Primary”.
The alarm indicates that the flow meter may be out of calibration. Refer to section 3.15 CALMON -Turbine Meter Calibration Monitoring for the
DanLoad 6000 Electronic Preset.
MPMC X failure
756 FPO
757 Number of blades
Notes:
Default
0
0
Range
0-2
0-50
The MPMC X failure is a primary alarm and is raised when the DanLoad 6000 has been configured to use one or both of the MPMC’s features, i.e. factored pulse outputs or calibration monitoring, and a batch is started or restarted and the DanLoad detects the failure of (or non-existence of) the required MPMC board on the indicated meter pulse board X.
FPO is the factored pulse output of the “smart” 4-ch. Meter pulse board on which to generate factored pulses according to the configured FPO basis (program code 752).
The number of magnetic blades (or buttons) on the meter is for calibration monitoring purposes. Zero (0) disables calibration monitoring for the meter. Any other value enables calibration monitoring for the meter. One (1) indicates that the number of blades should be auto-detected by the MPMC prior to acquiring a calibration sample. Zero (0) disables calibration monitoring for the meter.
4 - 48 ______________________________________________________________ Operation
__________________________________________________________ DanLoad 6000 (v6.00)
4.5.1
Alarm Messages (continued)
Primary display failure
Secondary display failure
--- Display failure alarm action
Notes:
#
Default
Primary
Range
<none>
This alarm is triggered if the keypad/display has been disconnected or the internal temperature of the keypad/display enclosure is too high. Power is removed from the keypad/display and the upper (yellow) LCD indictor pulses twice every two seconds. When the condition that caused the alarm no longer exists, the upper (yellow) LED is pulsed once every two seconds. The DanLoad
6000 should be powered-up/reset to continue using the keypad/display.
Maximum batches on transaction
--- Maximum number of batches exceeded alarm action
Notes:
#
Default
Primary
Range
<none>
This message is displayed when an attempt is made to start a batch and the maximum number of batches per transaction (which is configurable via program code 047 Batches/Transaction) has already been loaded. The new batch is not started.
Side not authorized
--- Unauthorized swing arm configuration alarm action
Notes:
#
Default
Primary
Range
<none>
This message is displayed when an attempt is made to start a batch on a new side
(swing arm configurations) when the transaction on the old side has not been ended, e.g. by pressing the STOP key.
Operation _______________________________________________________________ 4 - 49
DanLoad 6000 (v6.00) __________________________________________________________
4.5.2
Diagnostic Tests
RAM (random access memory) diagnostics are run continuously while power is applied to the
DanLoad 6000. The RAM diagnostic and several other diagnostics are described in this section.
Several of the diagnostic tests are designed for maintenance troubleshooting and have limited use for operations personnel. However, the operations personnel should be aware of the reaction of the instrument to some types of failures. These failure indications are described in this sub-section.
A group of diagnostic tests are accessible for manual execution via the Diagnostics selection in the
Program Mode Menu. Access to the Program Mode Menu is described in Section 4.1.1.3. When the Diagnostics selection is activated, the Diagnostics Menu shown below in displayed.
9
8
Diagnostic Menu
Figure 4 - 6
4 - 50 ______________________________________________________________ Operation
__________________________________________________________ DanLoad 6000 (v6.00)
The following selections in the Diagnostics Menu are available.
# Firmware Versions
The firmware versions of the program for the two CPU's and the message EPROM is displayed. The power failure message indicating the date and time of the last power failure is also displayed.
# RAM tests
The passed / failed results of the RAM tests is displayed. If a RAM test fails at any time, all discrete outputs are OPENED, causing all flow control valves and block valves to close and all pumps to stop running. The cause of the failure must be corrected before the
DanLoad 6000 can be used. (Note: The contents of RAM are not modified by the diagnostic tests.)
# Keypad
A prompt message Press key to test ... is displayed. The name of any key pressed is displayed beside the prompt message. Multiple keys can be pressed until the EXIT
(ALT+CLEAR) key is pressed to re-display the Diagnostics Menu.
# Display
The display backlighting level is stepped at one second intervals through the indicated numeric level range of 0 to 7. The display contrast level is stepped at one second intervals through the indicated numeric level range of 0 to 15. The local display panel and if connected, the remote display panel are checked. Both the backlighting and the contrast levels are restored to their current settings on exit from the display. (Note: Contrast and backlighting can be manually adjusted via the Set contrast/backlighting selection of the
Program Mode Menu.)
Operation _______________________________________________________________ 4 - 51
DanLoad 6000 (v6.00) __________________________________________________________
# Inputs/Outputs
The Input/Outputs diagnostic display indicated below is shown. This display is used to view the current live values of the selected input or output point.
Inputs / Outputs Diagnostic
Figure 4 - 7
The 9 and 8 arrow keys are used to move the flashing underline cursor to the desired line.
The 0 to 9 numeric keys are used to enter any valid input or output number up to the maximum number for that type of input or output. Press the ENTER key to continue. The value of the selected input is displayed. The flashing cursor remains on the same line and other inputs of the same type may be viewed. The input value corresponds to the selected input point. The state of a control output can be changed by entering the control output number, pressing the ENTER key, and then when the flashing cursor is positioned at the state field, press either the 0 key (to turn the output OFF, or the 1 key to turn the output
ON, as applicable. The output may be repeatedly toggled at this time with the 0 key and the
1 key or may be left in the desired state by pressing the ENTER key with the desired state displayed. (Note: #pulses is an accumulated pulse count, A/D value is a four-digit hexadecimal number, state is 0 or 1 as described above.)
4 - 52 ______________________________________________________________ Operation
__________________________________________________________ DanLoad 6000 (v6.00)
# DUART
Serial ports COM1 and COM2 are tested under program control by running the two channels in local loopback mode. The three-digit address with leading zeros (000 to 255), selected by the DIP switch on the module is displayed. A nnn% errors result of the test for each channel is displayed. (Note: Channel A = COM1, Channel B = COM2.)
The diagnostic tests are performed on the channels configured 'Not used'. Channel A is tested first, then channel B is tested. If a channel is configured, the word 'BUSY' is displayed and diagnostic tests are not performed. The diagnostic tests are described below.
Local loopback The type SCN2681 DUART in the DanLoad 6000 is tested by the channel 'X' mode register 2. The DanLoad 6000 transmits 256 characters (0 through
255) looped back to the receive circuit. A result of 129/256 indicates that
129 out of the 256 characters where transmitted and received properly. The correct result is 256/256. If the DUART is not installed or failed completely, the word 'ERROR' is displayed.
External loopback A hardware loopback connector is connected to the RS-232 / RS-485 port.
The test function and results are identical as those of the local loopback test.
Ch-A (RS-485)
RX+
1
RX-
2
TX+
3
TX-
4
.))))))))3)))))))))*
.)))))))))))))))))))-
RX
5
Ch-B (RS-232)
CTS
6
TX
7 8 9
COM
10 baud rates data formats
Loopback Connector Pinout (Reference Drawing CE-12693)
All eight possible baud rates (from lowest speed to highest speed) are setup and tested. The following ten test characters are used: 00h, 01h, 02h, 04h,
08h, 10h, 20h, 40h, 80h, and FFh. The example pass/fail map PPPPPPPF indicates that the lowest seven baud rates passed and the highest baud rate failed.
Parity bits, stop bits, and data bits are setup and tested. The pass/fail map indicates the results of the test. For example: PFP indicates that the parity test passed, the stop bits test failed, and the data bits test passed.
Operation _______________________________________________________________ 4 - 53
DanLoad 6000 (v6.00) __________________________________________________________
Interrupts The RxRDY (receive ready), FFULL (receive buffer full), and TxRDY
(transmit ready) interrupts are tested. The pass/fail map indicates the results of the test. For example: FPF indicates that the RxRDY interrupt test failed, the FFULL interrupt test passed, and the TxRDY interrupt test failed.
DUART Ports Diagnostic
Figure 4 - 8
# LAN
The LAN port is tested under program control. The address (0 to 255), selected by the DIP switch settings on the module is displayed. The current value in the read only Diagnostic
Status Register and the current value in the read/write Configuration Register are displayed.
The values are two-digit hexadecimal numbers. Note: The Arcnet/Lan port option is not available on the DanLoad 6000.
LAN Port Diagnostic
Figure 4 - 9
4 - 54 ______________________________________________________________ Operation
__________________________________________________________ DanLoad 6000 (v6.00)
# Crash analysis
A “crash” is an unrecoverable hardware, software or configuration error detected by the program. The symptom of a “crash” is that the unit resets itself, i.e. the display goes dark
(briefly) as if the unit had been powered off and on again; if product is flowing when this happens, a “memory check failed” alarm may be raised since the pulse count checksum cannot be verified. If a crash occurs, the program saves crash information so that the cause can be determined. Perform the following steps:
- Go into Diagnostics | Crash anaylsis in program mode and write down the four columns of figures before the unit is powered-off again, since powering off the unit may cause CPU-2 crash information to be overwritten. (The unit generates a CPU-2 crash error code “FADE” whenever it is powered-off.) NOTE: Press the “CLEAR” key to zero the four columns of figures so that you can find out when a new crash occurs.
1234567890123456789012345678901234567890
Crash memory CPU 1 CPU2
Stk ptr/prog ctr 4793/2085 7e9d/821e
Int mask/int mask 1 004c/0063 0043/00c9
WSR/tsk pg 0000/0002 000f/0005
Error code/task adr 0000/e742 fff7/83bc
Press ALT+CLEAR to exit
1234567890123456789012345678901234567890
- Select Diagnostics | Firmware versions in program mode and write down the three firmware version numbers, e.g. v5.60. The crash analysis cannot be interpreted
without the firmware version numbers.
- Contact Daniel Customer Service or your local representative or expert with the crash analysis and firmware version number information.
The crash analysis in the same format as the Crash memory summary log, Section 4.5.3, is displayed. See the description of the Crash memory summary log for details.
A Crash memory summary log indicates an unrecoverable error detected by the control program.
This feature is a general purpose detector / logger for critical hardware and software error conditions.
The Crash memory summary log should be saved for use in main processor troubleshooting.
If program code 704 Crash memory summary is set On and the data printer is available, a Crash
memory summary log is printed by the logging printer. The example below indicates the format of the log.
Operation _______________________________________________________________ 4 - 55
DanLoad 6000 (v6.00) __________________________________________________________
Crash Memory Summary
Unit nnn mm/dd/yy hh:mm:ss -- Crash Memory Summary
CPU #
Stk ptr/prog ctr 47n3/2085
Int mask/int mask 1 004c/0063
WSR/task 0000/0002
Error code/task adr 0000/e742
#
#
The fields contained in the Crash memory summary log are described below.
# CPU # The # is either 1 (indicating CPU 1 problem) or 2 (indicating CPU 2 problem).
# Unit The unit address obtained from the setting of the address DIP switches on the
DUART board, range is 0 to 255.
<time> Date and time of the event.
Stk ptr/prog ctr
The hexadecimal values of the stack pointer and the program counter.
#
#
#
#
#
Int mask/int mask 1
The hexadecimal values of the interrupt mask and the interrupt mask 1.
WSR/task The Window Select Register / multi-task task number.
Error code/task adr
The hexadecimal identifier of the critical error code / the address of the active task.
Print configuration
The configuration summary data log (a report showing all program code values) can be printed from the diagnostics menu in the manual operating mode. The data log must be enabled (program code 703). The data log is quite big, and should typically only be printed when the unit is not needed for a while and the data logging device is not busy.
Show memory
Data memory is displayed. The display shows the memory address with data in both hexadecimal and ASCII formats.
4 - 56 ______________________________________________________________ Operation
__________________________________________________________ DanLoad 6000 (v6.00)
This section contains information on flow meter proving using methods specified in API standards and English measurement units. The general information applies to other standards and measurement units as well. Meter proving is the procedure for determining a meter factor for a rack flow meter. Calibration is the procedure for determining a volume of the meter prover and is not covered in this manual.
Details are provided on manual meter proving by the prover tank method and the master meter method. The pipe prover method is usually used for proofs of large capacity flow meters in pipeline or tanker ship loading service and is not covered in this manual. Meter proving determines the accuracy of the flow measurement and therefore the accuracy of quantity and cash accounting for delivered products. It is strongly recommended that you read this section, all local, regional, and country standards, and all company standards applicable to your installation and meter proving, before proving a rack meter or a master meter.
Typical forms used during the meter proving procedure are provided at the end of this section. These forms can be copied or used as a guide for development of forms for your organization.
Note
The flow meter proving procedures described in this section and the typical meter proof forms
(Figure 5 -2, Figure 5 -3) are primarily provided to describe the DanLoad 6000 program codes that affect meter proving and flow measurement accuracy. The method of meter proving and the typical form may require changes before use in your organization. Consult the flow measurement accounting department of your organization before conducting flow meter proofs.
#
#
A prover tank is a field standard measure which is designed and calibrated by a laboratory that can provide calibration traceability to the Weights and Measures Office of the National Bureau of
Standards. The calibrated prover tank can be used in either or both of the following meter proof methods.
Used periodically to prove individual rack meters.
Used periodically to prove a master meter. Then the master meter is used to prove the individual rack meters.
Flow Meter Proving ______________________________________________________ 5 - 1
DanLoad 6000 (v6.00) __________________________________________________________
The primary American Petroleum Institute standards applicable to meter proving are:
Manual of Petroleum Measurement Standards (MPMS)
#
#
Chapter 4 - Proving Systems
Chapter 12 - Calculation of Petroleum Quantities
# Section 2 - Instructions for Calculating Liquid Petroleum Quantities
Measured by Turbine or Displacement Meters
(contains Tables A-1 and A-2 - Correction Factors for Steel)
# Chapter 11.1 - Volume Correction Factors
Table 6 - Reduction of Volume to 60 degrees Fahrenheit
Against API Gravity at 60 degrees Fahrenheit
Table 24 - Reduction of Volume to 60 degrees Fahrenheit
Against Specific Gravity 60/60 degrees Fahrenheit
These standards supersede API Standards 1101, 2531, 2533, and 2534 and are widely used in the
USA and several other countries. The volume reduction tables 6 and 24 are also designated: ASTM
D 1250, API Standard 2540, and IP 200.
Every flow meter is a unique device. The manufacturer fabricates each flow meter so that it meets design specifications. However, differences within normal fabrication tolerances produce apparently identical flow meters that generate slightly different pulses per volume unit (K-factor).
The nominal K-factor [average number of pulses per each volume unit (such as a gallon) that are generated by a flow meter] is stamped on the flow meter nameplate. For example, by design the
Daniel 4-inch LR turbine meter should produce 23.0 pulses per each gallon measured. After manufacture, each LR turbine meter is proved with water flow at the factory. This initial meter proof of the new flow meter may produce an actual K-factor for that flow meter of 23.403 pulses per gallon measured. This initial meter proving is normally the only time that the flow meter Kfactor is determined by a meter proof. After a meter has been installed on-site, additional meter proofs may be used to determine meter factors. Over the lifetime of a meter, its meter factor may change due to variations in flow rates, viscosities, wear, and other causes. However, the K-factor will always remain the same. The K-factor is the gross adjustment factor and the meter factor is the fine adjustment factor. The DanLoad 6000 uses a mathematical combination of the K-factor and the meter factor to adjust the volume accumulation totalizers to match the actual volume that has flowed through the meter.
5 - 2 ______________________________________________________ Flow Meter Proving
__________________________________________________________ DanLoad 6000 (v6.00)
In addition to the type of flow meter and installation design, the product being measured, temperature of the product being measured, the flow rate, and, to a lesser extent, the pressure of the product being measured may also affect the accuracy of the flow measurement. (Note: The pressure effect on the volume of low vapor pressure hydrocarbon liquids, such as gasoline, diesel, kerosine, and fuel oil is usually negligible when these liquids are handled at low pressures (less than 100 PSIG) and is ignored in many tanker vehicle loading installations. Pressure compensation and back-pressure control should always be implemented in LPG loading configurations.)
Flow meters can be proved as often as desired. Many organizations have regulations governing the frequency of meter proofs. These regulations are often based on date, volume of flow through the meter, and / or number of loading operations use the meter. If your organization does not have such regulations, each meter should be proved periodically and the proof results compared with previous proof results to determine if more frequent or less frequent proofs are required.
The terminology used in this section is defined below and is based on the definitions in the API standards.
Term
Gross volume
Definition
The indicated volume times the meter factor derived from a meter proving of the flow meter at a specific flow rate. This is a volume measurement. This volume is displayable as Dynamic Data Element - Mtr m grs load in the
DanLoad 6000 and is used to determine the volume measured by the rack meter during meter proving.
Calculation: gross volume = indicated volume times meter factor
Gross standard volume
The gross volume corrected to standard temperature and pressure. This is a quantity measurement.
Calculation: Gross standard volume = gross volume times C
TLM
(correction factor for the effect of temperature on the liquid in the meter) times C (correction factor for the effect of
PLM pressure on the liquid in the meter)
Indicated volume (also called meter registration) The change in the flow meter reading that
Occurs during a product flow measurement operation. This is a volume measurement.
Calculation: indicated volume = end reading minus start reading
Flow Meter Proving ______________________________________________________ 5 - 3
DanLoad 6000 (v6.00) __________________________________________________________
Term
K-factor
Master meter
Meter factor
Definition
The pulses per volume unit, such as gallon, generated by a pulse (System
factor) output type flow meter. The K-factor is also called the system factor.
The nominal value is determined by flow meter design and factory water flow calibration and is indicated on the flow meter nameplate. The K-factor is a physical characteristic of the flow meter and is a fixed number.
A master meter is a turbine meter or positive displacement meter that has been proved previously with a tank prover. The master meter is temporarily connected in series with a rack meter to be proved so that all flow passes through both meters. A volume of liquid is passed through both meters and the volume measured by the master meter is considered to be 'correct'. The difference between the volume measured by each meter determines the meter factor for the rack meter. The API standard recommends that a minimum volume of 10,000 volume unit increments are accumulated during a meter proof and that the minimum duration of a meter proof run be five minutes.
The DanLoad 6000 can display delivered quantities in hundredths of volume units, such as vvv.vv gallons. A proof run of 100.00 volume units may be sufficient to satisfy the 10,000 volume unit requirement. Meter proof deliveries of 1500 to 2000 whole volume units are more common.
A number used internally by the DanLoad 6000 in flow calculations to correct the indicated volume (final flow meter registration minus initial flow meter registration) to the observed gross volume (actual flow meter throughput at operating conditions). The meter factor value is near 1.0000
and rounded to four decimal places.
5 - 4 ______________________________________________________ Flow Meter Proving
__________________________________________________________ DanLoad 6000 (v6.00)
Term
Pipe prover
Definition
A pipe prover is a calibrated pipe section that contains a sphere made of an elastomer material and a sphere detector switch located at each end of the calibrated pipe section. The pipe prover has two basic configurations, bidirectional or uni-directional. As the names imply, the sphere can pass in either direction or only one direction, respectively. The sphere detector switches are used to start and stop an external prover counter which can be connected to a high resolution pulse output from the DanLoad 6000. A meter proof is performed by directing all flow through a flow meter in series with the pipe prover calibrated pipe section and accumulating the raw pulses generated by the flow meter while the prover sphere moves from the start pulse count gate switch and the stop pulse count gate switch. Since the precise volume of the calibrated section of the pipe prover is known, the flow meter pulse output corresponds to that precise volume, and each volume unit can be calculated.
Quantity (Example: gross standard volume)
The resulting amount of product measured after compensation for operational temperature and pressure, usually indicated in one of the following units: gallons, barrels, liters, cubic meters.
Tank prover A tank prover is a fixed or portable graduated tank that is calibrated to contain a precise known volume of liquid. The tank bottom and sides are reinforced so that the weight of the liquid in the tank does not distort the tank.
The graduated sight gauge(s) permit determination of the exact volume of liquid in the tank. The minimum capacity of the tank must be equal to the volume that passes through the flow meter in one minute. The recommended capacity of the tank is 1-1/2 to 2 times the volume that passes through the flow meter in one minute. For example, if the maximum operational flow rate of a flow meter is 600 GPM, the minimum prover tank capacity is 600 gallons, and the recommended prover tank capacity between 900 and 1200 gallons.
Volume (Example: indicated volume; gross volume)
The actual space occupied by the product measured, usually indicated in one of the following units: gallons, barrels, liters, cubic meters.
Flow Meter Proving ______________________________________________________ 5 - 5
DanLoad 6000 (v6.00) __________________________________________________________
5.1
General Considerations
Program codes that affect the flow measurement accuracy of the DanLoad 6000 may be restricted from modification by the Weights & Measures attributes of those program codes. If these program codes are set to ON, the value of the program codes can only be changed when the Weights &
Measures switch is set OPEN. Therefore, before a flow meter can be proved, the front panel
Weights & Measures switch must be set OPEN (extended position).
A DanLoad 6000 can deliver up to four components and each component can be delivered at up to four different flow rates. The lowest defined flow rate for a component is the component's 'low flow
rate'. The highest defined flow rate for a component is the component's 'high flow rate' which is also called the 'normal flow rate'. Any other defined flow rates for a component are called 'fall back
flow rates' or 'intermediate flow rates'. Each of the component / flow rate combinations has a unique meter factor for a total of sixteen possible meter factors. Installations with less than four flow meters and less than four flow rates will have fewer meter factors.
The meter factors for each component must be determined and entered in the order shown below.
Component p meter factor 1 Lowest defined flow rate.
Component p meter factor 2 Next higher flow rate if more than one flow rate is defined.
Component p meter factor 3 Next higher flow rate if more than two flow rates are defined.
Component p meter factor 4 Highest flow rate if four flow rates are defined.
The component number p is 1 to 4. The reason for determining meter factors in this order is to prevent any inaccuracies at any lower flow rate from affecting the accuracy of the meter factor for a higher flow rate. Because meter proving is performed during batch delivery, startup and shutdown volumes delivered at low flow start rate and low flow stop rate, are included in the total proof batch.
Therefore, any volume measurement errors occurring during low flow rate times will be compensated in the total proving batch.
In some organizations it is acceptable to use only a low flow and high flow meter factor even when one or two fall back flow rates are defined. In these cases, the rack meter is proved at the low and high flow rate and the meter factor for the high flow rate is also entered as the meter factor for one or two fall back flow rates.
During meter proving, various parameter values may need to be changed. All associated parameters are not located in the same Setup Menu sub-group. To access a parameter when the Setup Menu is active, enter the three-digit program code number. The selected parameter is then displayed. Verify or change the value of the parameter as desired. Then press the EXIT (ALT + CLEAR) key to re-display the Setup Menu and select the next parameter or continue.
5 - 6 ______________________________________________________ Flow Meter Proving
__________________________________________________________ DanLoad 6000 (v6.00)
Each meter proving run can only determine one meter factor for one component (flow meter) / flow rate combination. Each component defined by the DanLoad 6000 configuration is associated with a meter number by program codes 067 / 070 / 073 / 076 Meter. Each flow meter is automatically assigned a fixed input number (1 to 4) dependent on the pulse meter card slot location and on-board switch settings. For example: Component number 1 may be associated with the fixed input for meter number 3.
Unique meter proving recipes should be setup to define each single component for use in controlling the block valves of a multi-component blending system during meter proving.
Example:
Select an undefined recipe number higher than the last defined operational recipe and set that recipe to deliver 100 percent of component 1, set the next recipe to delivery 100 percent of component 2.
Setup from one to four recipes (one for each component) that permit selection and proof delivery of each component without any blending. The setup could appear as follows.
Example meter proof recipes for a blender system:
Recipe 10:
535 Prove Gasoline
536 Component 1 %
537 Component 2 %
538 Component 3 %
539 Component 4 %
540 Sequence to load
Recipe 11:
541 Prove Diesel
542 Component 1 %
543 Component 2 %
544 Component 3 %
545 Component 4 %
546 Sequence to load
=
=
=
=
1XXX
=
=
=
=
2XXX
100
0
0
0
0
100
0
0
(Continue to define a third recipe for component 3 and a forth recipe for component 4 meter proofs if required.)
Flow Meter Proving ______________________________________________________ 5 - 7
DanLoad 6000 (v6.00) __________________________________________________________
The gross loaded volume, with the current meter factor applied, that the DanLoad 6000 measures during the delivery operation must be displayable after a meter proof is completed. The following data element codes are available for this purpose.
Data Code Default Program Code Description
103 Mtr 1 grs load
104 Mtr 2 grs load
105 Mtr 3 grs load
106 Mtr 4 grs load
689
____
____
____
Dynamic Data Display - Element 10 (default)
______________________________
______________________________
______________________________
The table above indicates that only Mtr 1 grs load is displayable if the DanLoad 6000 is in the default configuration. If two or more components are defined, the flow meter assignment for each component must be determined. Once the flow meter / component relationship is determined, the
Mtr m grs load parameter must be made displayable as a Dynamic Data Display element. This task is accomplished as follows.
Perform the following steps to activate display of the dynamic data codes required for meter proof monitoring.
# Enter Setup Mode, select the program codes listed above for each defined component and record the flow meter assignment.
# Decide which of the sixteen default dynamic data codes are not of interest for display at your installation. Record the current program code assignment of these data display locations
(program codes 680 to 695).
# Select program codes from 680 to 688 or 690 to 695 (do not change program code 689
Dynamic data element 10 (Mtr 1 grs load) which is used to monitor the component delivery through flow meter number 1).
# Enter the Dynamic Data Codes 104 Mtr 2 grs load, 105 Mtr 3 grs load, and 106 Mtr 4 grs
load as required for each defined flow meter / component combination. Only program codes for defined flow meter / component combinations are displayable.
# The Dynamic Data Display can now display the Mtr m grs load parameter for each defined flow meter / component combination. The value of the active Mtr m grs load parameter is obtained and entered in the meter proof form during a meter proof.
Note: See Section 6 for a complete list of Dynamic Data Codes and see Appendix A for the sixteen default assignments (program codes 680 through 695).
5 - 8 ______________________________________________________ Flow Meter Proving
__________________________________________________________ DanLoad 6000 (v6.00)
Meter Factor Calculation
The method described below for calculating a new meter factor for a DanLoad 6000 generally follows the published API method with the following modifications.
# The API standard uses the flow meter registration which is the indicated volume without the current meter factor applied. The DanLoad 6000 parameter Mtr m grs load xxxx.xx is the gross volume with the current meter factor for the active component / flow rate combination applied. The meter proof calculations described in this section provide an adjustment number which is multiplied by the current meter factor to determine the value of the new meter factor. (Note: The meter factor calculation must be performed properly or large errors in flow measurement accounting can occur.)
# The API standard uses compensation for the effect of pressure on the on the liquid (factor
C
PLx
) which is rarely used at a load rack installation. To ignore C
PLx
, enter 1.0000 in the equation. (Note: The handling of C
PLx
must be determined by local regulations and the policy of your organization and clients.)
# The API standard uses compensation for the effect of temperature on the liquid (factor C
TLx
) and compensation for the effect of pressure on the liquid (factor C ) for both the master
PLx meter and the rack meter. Many organizations consider that the master meter and the rack meter are operating at identical process conditions during meter proving batch deliveries.
Therefore, C
TLx
and C
PLx
are ignored and entered as 1.0000 in the equations for both the master meter and the rack meter. (Note: The handling of C and C must be determined
TLx PLx by local regulations and the policy of your organization and clients.)
Flow Meter Proving ______________________________________________________ 5 - 9
DanLoad 6000 (v6.00) __________________________________________________________
The relation between the API volume designations and prover tank, master meter, and rack meter volumes are indicated in the following table.
API Volume Prover Tank indicated volume equal to: indicated volume gross volume gross volume at standard temperature gross standard volume which is equal to: gross volume equal to: gross volume which is equal to: indicated volume gross volume x C
TSP x C
TLP gross volume x C x C
TLP
TSP
Master Meter equal to: indicated volume which is equal to: registered volume indicated volume x meter factor gross volume x
C
TLP
Rack Meter equal to: indicated volume which is equal to: registered volume indicated volume x meter factor which is obtained from:
(Mtr m grs load xxxx.xx) gross volume x
C
TLM gross volume at standard temperature x
C
PLP gross volume at standard temperature x C
PLM
Prover / Meter Volume Relationship
Figure 5 - 1
5 - 10 ______________________________________________________ Flow Meter Proving
__________________________________________________________ DanLoad 6000 (v6.00)
The table Prover / Meter Volume Relationship, Figure 5 - 1, shows relation of meter volumes to the prover tank for information only. Note the following points.
# The prover tank is a fixed volume tank in which the volume is measured at the nominal atmospheric pressure. Therefore, the following factors, which do not apply to the prover tank, are ignored and considered to be equal to 1.0000.
# meter factor
#
#
C
PSP
(Effect of pressure on the steel of the vessel.)
C
PLP
(Effect of pressure on the volume of the liquid.)
This means that the volume delivered to the prover tank can be considered to be indicated
volume which is also equal to gross volume because a meter factor is not required to adjust the prover tank volume. Only temperature correction factors can be applied to the liquid volume delivered to the prover tank.
# The pressure correction factor for the effect of pressure on the liquid in the flow meter (C is usually ignored and considered to be equal to 1.0000 for rack operations.
PLx
)
# The Dynamic Data Display element Mtr m grs load xxxx.xx in the DanLoad 6000 is an accumulator for gross volume with a resolution of hundreds of a volume unit, such as gallons.
The meter proof methods described using a rack meter connected to a DanLoad 6000 use values obtained from the Mtr m grs load xxxx.xx accumulator. The basic calculation sequence, without temperature correction factors, is described below.
Meter proving calculation 1:
Calculate the volume error between the prover volume (prover tank or master meter) and the rack meter measured volume.
rack meter volume error = corrected delivery volume - rack meter
corrected
gross volume
Flow Meter Proving ______________________________________________________ 5 - 11
DanLoad 6000 (v6.00) __________________________________________________________ where: rack meter volume error The difference in the volume delivered to or measured by the prover and the rack meter corrected gross volume.
corrected delivery volume #
#
prover tank: The volume, corrected for the effect of temperature on the tank steel and the liquid, delivered to the prover tank.
master meter: The volume measured by the master meter, corrected by the master meter meter-factor, the effect of temperature on the liquid measured, and optionally the effect of pressure on the liquid measured.
rack meter corrected gross volume
The volume obtained from the Dynamic Data Display element Mtr
m grs load, corrected for the effect of temperature on the liquid measured and optionally the effect of pressure on the liquid measured.
Meter proving calculation 2:
Calculate the percentage error between the prover volume (prover tank or master meter) and the rack meter measured volume.
rack meter volume error rack meter percent error = ---------------------------------
rack meter corrected gross volume where: rack meter percent error rack meter volume error
The percentage of error in the corrected volume delivery.
The difference in the volume delivered to or measured by the prover and the rack meter corrected gross volume (obtained from calculation
1).
rack meter corrected gross volume
The volume obtained from the Dynamic Data Display element Mtr
m grs load, corrected for the effect of temperature on the liquid measured and optionally the effect of pressure on the liquid measured.
5 - 12 ______________________________________________________ Flow Meter Proving
__________________________________________________________ DanLoad 6000 (v6.00)
If this calculation produces a percentage error that is within the tolerances of the regulating organizations and your organization, the current meter factor is considered to be acceptable and no further action is required. The exact value must be determined by the governing regulations.
Example: A typical calculation might produce a result of 0.01 which is equal to one percent error.
Meter proving calculation 3:
Calculate the adjustment to be applied to the current meter factor, if it has been determined that the percentage of error (calculation 2) is not acceptable.
prover corrected gross volume adjustment = ---------------------------------
rack meter corrected gross volume where: adjustment A mathematical factor that is multiplied by the current rack meter factor to obtain the new meter factor, this factor is the error in the current meter factor (THIS NUMBER IS NOT THE NEW
METER FACTOR).
prover corrected gross volume
#
#
prover tank: The volume, corrected for the effect of temperature on the tank steel and the liquid, delivered to the prover tank.
master meter: The volume measured by the master meter, corrected by the master meter factor, the effect of temperature on the liquid measured, and optionally the effect of pressure on the liquid measured.
rack meter corrected gross volume
The volume obtained from the Dynamic Data Display element Mtr
m grs load, corrected for the effect of temperature on the liquid measured and optionally the effect of pressure on the liquid measured.
(Note: This volume is the gross volume with the current meter factor applied. The use of the gross volume in the calculation is the reason that the new meter factor cannot be calculated by this step.)
Flow Meter Proving ______________________________________________________ 5 - 13
DanLoad 6000 (v6.00) __________________________________________________________
Meter proving calculation 4:
Calculate the new meter factor which will be manually entered in program code ccc Comp p meter
factor f corresponding to the active program code ccc Comp p flow rate r.
new meter factor = adjustment x rack meter current meter-factor where: new meter factor adjustment
The calculated meter factor that must be manually entered for program code ccc Comp p meter factor f to correct the measurement error in future flow measurement.
The mathematical adjustment factor obtained from calculation 3 above.
rack meter current meter-factor
The current meter factor for the rack meter, obtained from program code ccc Comp p meter factor f before the meter proof sequence is started.
Three examples of meter factor calculations are provided below. The calculations show the relation between the measured volumes and the meter factor adjustments required. To simplify the examples, the temperature and pressure corrections are disregarded.
Assume that the volume accumulated Mtr m grs load is 1000.00 gallons and that the rack meter current active meter factor is 1.0123 for the component / flow rate combination. Then the indicated
volume is equal to 987.85 gallons.
Equation:
1000.00
987.85 = -------------
1.0123
Example 1: Correct delivery - assume after completion of a meter proof run:
5 - 14 ______________________________________________________ Flow Meter Proving
__________________________________________________________ DanLoad 6000 (v6.00)
Parameter corrected delivery volume
Mtr m grs load
RACK METER VOLUME ERROR
RACK METER PERCENT ERROR
Value
1000.00 gallons
1000.00 gallons
0 gallons
(1000.00 - 1000.00)
0 percent
(0 / 1000.00)
ADJUSTMENT 1
(1000.00 / 1000.00)
RACK METER CURRENT METER-FACTOR 1.0123
NEW METER FACTOR 1.0123 (no change)
(1 x 1.0123)
In the example above, the accumulated Mtr m grs load for the rack meter exactly equals the volume delivered to the prover tank or measured through the master meter. Since the delivered corrected gross volume is exactly equal to the rack meter corrected gross volume, the current_meter_factor is correct. The new_meter_factor value is exactly equal to the current_meter_factor value.
Therefore, the current meter factor, 1.0123, should not be changed.
Example 2: One percent over delivery - assume after completion of a meter proof run:
Parameter corrected delivery volume
Value
1010.00 gallons
Mtr m grs load
RACK METER VOLUME ERROR
RACK METER PERCENT ERROR
1000.00 gallons
10 gallons
(1010.00 - 1000.00)
0.01 (1 percent over delivery)
(10 / 1000.00)
Flow Meter Proving ______________________________________________________ 5 - 15
DanLoad 6000 (v6.00) __________________________________________________________
Parameter
ADJUSTMENT
Value
1.01
(1010.00 / 1000.00)
RACK METER CURRENT METER-FACTOR 1.0123
NEW METER FACTOR 1.0224
(1.01 x 1.0123)
In the example above, the accumulated Mtr m grs load for the rack meter is less than the volume delivered to the prover tank or measured through the master meter. Since the delivered corrected gross volume is greater than the rack meter corrected gross volume, the value of the
current_meter_factor is less than it should be. Therefore, the new_meter_factor (1.0224) should be manually entered for the value of the active program code ccc Comp p meter factor f.
Example 3: One percent under delivery - assume after completion of a meter proof run:
Parameter corrected delivery volume
Mtr m grs load
RACK METER VOLUME ERROR
RACK METER PERCENT ERROR
Value
990.00 gallons
1000.00 gallons
-10 gallons
(990.00 - 1000.00)
-0.01 (1 percent under delivery)
(-10 / 1000.00)
ADJUSTMENT 0.99
(990.00 / 1000.00)
RACK METER CURRENT METER-FACTOR 1.0123
NEW METER FACTOR 1.0022
(0.99 x 1.0123)
5 - 16 ______________________________________________________ Flow Meter Proving
__________________________________________________________ DanLoad 6000 (v6.00)
In the example above, the accumulated Mtr m grs load for the rack meter is greater than the volume delivered to the prover tank or measured through the master meter. Since the delivered corrected gross volume is less than the rack meter corrected gross volume, the value of the
current_meter_factor is greater than it should be. Therefore, the new_meter_factor (1.0022) should be manually entered for the value of the active program code ccc Comp p meter factor f.
5.1.1
Initial Setup
The examples above do not include temperature compensation calculations. However, during actual meter proving, these calculations must be performed. Before starting meter proving, obtain a copy of Table A-1 - Temperature Correction Factors for Mild Steel or Table A-2 - Temperature
Correction Factors for Stainless Steel from API MPMS Chapter 12 - Section 2 - Instructions for
Calculating Liquid Petroleum Quantities Measured by Turbine or Displacement Meters for use in calculating C
TSP
. And obtain a copy of Table 6A, 6B, 6C, 24A, or 24B from API MPMS Chapter
11.1 - Volume Correction Factors for use in calculating C
TLP
and C
TLM
.
Perform the following preliminary steps:
#
#
#
#
#
OPEN the Weights & Measures switch (release to extended position)
Enter Program Mode (press Program (ALT + ENTER) key)
Enter Passcode in response to prompt message
Enter Setup Mode (with box cursor on Setup selection, press ENTER key)
Access and change program codes as described below (refer to the tables located at the end of this section for program code information)
# If the DanLoad 6000 is a multi-component blender, specify a meter proof recipe as described above to select the desired component for proof. If the DanLoad 6000 delivers only one component, recipe number 1, which specifies a one component to one flow meter relationship, is selected automatically.
Flow Meter Proving ______________________________________________________ 5 - 17
DanLoad 6000 (v6.00) __________________________________________________________
#
#
#
#
#
#
169 Number of factors/component
Set to 1 to force continuous low flow rate for first meter proof (see additional information below).
170 Meter factor method
Set to fixed so that meter factor interpolation based on flow rate is disabled.
171 / 182 / 193 / 204 Nominal K-factor
Obtain actual meter K-factor from flow meter nameplate and round to nearest tenth, enter result (example: nameplate K-factor is 23.403, enter 23.4).
172 / 183 / 194 / 205 Master meter factor
Divide program code ccc Nominal K-factor by actual K-factor from nameplate and round to four decimal places. [Example: 23.4 divided by 23.403 = 0.9999, enter result (0.9999)].
(Note: The ccc Master meter factor is used to establish a plus / minus two percent limit for entries in the four program codes ccc Comp p flow rate r of the related component, this parameter is not used in volume calculations.)
173 / 184 / 195 / 206 Stop rate
Set the flow rate at which this component is delivered during the component’s configured low flow stop volume at the end of an inline batch. The overall flow rate of the blend at the end of a batch is the sum of the stop rates of any flowing components.
If an existing preset system that uses an effective K-factor for each flow rate is replaced by a DanLoad 6000, the DanLoad 6000 requires a nominal K-factor and meter factor for each flow rate. Set program code 171 / 182 / 193 / 294 Nominal K-factor as indicated above, enter program code ccc Comp p meter factor f as program code ccc Nominal K-factor divided by the effective K-factor for the flow rate and rounded to four decimal places.
5 - 18 ______________________________________________________ Flow Meter Proving
__________________________________________________________ DanLoad 6000 (v6.00)
The following two parameter group entries are required for all defined components:
# 174 / 185 / 196 / 207 Comp p flow rate 1
This parameter should be set to the desired low flow start / low flow stop flow rate that will be used in actual loading of the indicated component p. The first flow meter proof will always be at this flow rate.
# 175 / 186 / 197 / 208 Comp p meter factor 1
This parameter is the actual meter factor that is used to calibrate the flow meter registration when the flow is at the flow rate set in the corresponding program code ccc Comp p flow rate
1. This number should have been recorded in an operational installation as the current meter factor. Do not change an existing current meter factor.
The following two parameter group entries are required for all defined components in a two stage (low flow / normal flow) loading system:
# 176 / 187 / 198 / 209 Comp p flow rate 2
This parameter should be set to the desired maximum flow or first fall back flow rate that will be used in actual loading of the indicated component p.
# 177 / 188 / 199 / 210 Comp p meter factor 2
This parameter is the actual meter factor that is used to calibrate the flow meter registration when the flow is at the flow rate set in the corresponding ccc Comp p flow rate 2 parameter.
This number should have been recorded in an operational installation as the current meter factor. Do not change an existing current meter factor. If this is a new installation or the rack meter has never been proved in this installation, enter the value of program code 172
/ 183 / 194 / 205 Master meter factor corresponding to the component number.
The following four parameter group entries are required for all defined components only in loading systems that define three or four flow rates for loading:
# 178 / 189 / 200 / 211 Comp p flow rate 3
This parameter should be set to the desired maximum flow or second fall back flow rate that will be used in actual loading of the indicated component p.
Flow Meter Proving ______________________________________________________ 5 - 19
DanLoad 6000 (v6.00) __________________________________________________________
#
#
#
#
179 / 190 / 201 / 212 Comp p meter factor 3
This parameter is the actual meter factor that is used to calibrate the flow meter registration when the flow is at the flow rate set in the corresponding program code ccc Comp p flow rate
3. This number should have been recorded in an operational installation as the current meter factor. Do not change an existing current meter factor. If this is a new installation or the rack meter has never been proved in this installation, enter the value of program code 172
/ 183 / 194 / 205 Master meter factor corresponding to the component number.
180 / 191 / 202 / 213 Comp p flow rate 4
This parameter should be set to the desired maximum flow rate that will be used in actual loading of the indicated component p.
181 / 192 / 203 / 214 Comp p meter factor 4
This parameter is the actual meter factor that is used to calibrate the flow meter registration when the flow is at the flow rate set in the corresponding program code ccc Comp p flow rate
4. This number should have been recorded in an operational installation as the current meter factor. Do not change an existing current meter factor.
As mentioned above, the meter factor for program code ccc Comp p factor 1 will always be determined first. To assure continued flow at program code ccc Comp p flow rate 1 rate, set program code 169 Number of factors/component to 1.
5 - 20 ______________________________________________________ Flow Meter Proving
__________________________________________________________ DanLoad 6000 (v6.00)
5.2
Tank Prover Method
Rack meters, or a master meter, are proved with a tank prover by loading a batch of one product at one flow rate to the prover tank. The frequency of meter proofs of rack meters must be determined by company policy or regional regulations. Rack meters should be proved on each product and at the normal delivery flow rate for each product. The set of proofs of the rack meters provide a list of meter factors related to each product / flow rate combination. The corresponding meter factor is then entered into the DanLoad 6000 and is automatically active when the related product / flow rate combination is active.
A meter proof is performed by the tank prover method in the following manner.
# A meter proof wetting run should be performed first to wet the prover tank and help stabilize the temperature in the rack meter / prover tank circuit. The wetting run is a proof run without recording data.
# A liquid batch that will fill the tank prover to a liquid level visible in the graduated section is defined and delivered to a prover tank.
# Proof data is gathered and manual calculations are performed to determine the error between the prover tank volume (corrected for temperature) and the and the flow meter registration
(corrected for temperature).
# The volume and percentage error are calculated. If necessary, a new meter factor is calculated.
# The new meter factor, which should always be near 1.0000, is manually entered into the
DanLoad 6000 for the active program code ccc Comp p meter factor f, where ccc is one of the following program codes: 175 / 177 / 179 / 181 / 186 / 188 / 190 / 192 / 197 / 199 / 201
/ 203 / 208 / 210 / 212 / 214 dependent on the component number p (1 to 4) and the meter factor number f (1 to 4).
# The prover tank can be drained and the steps listed above are repeated and the results averaged, if desired.
Flow Meter Proving ______________________________________________________ 5 - 21
DanLoad 6000 (v6.00) __________________________________________________________
5.2.1
Tank Prover Meter-Proof RUN 1
#
#
#
#
#
For this example, assume that the loading system is a two component blender and that each component is loaded at one of three flow rates [low flow start / stop, fall back, and normal (high) flow]. Any other configuration, from a one component - one flow rate system to a four component four flow rate system is proved in a similar manner by proving each component (flow meter) at each flow rate, in flow rate ascending order. The component order of proving is not important.
# Make the system mechanically and electrically ready for delivery of a liquid batch to the prover tank.
# Select the previously defined recipe for proving component 1 (recipe definitions are in the program codes 480 to 661).
# Set program code 169 Number of factors/component, to 1 to assure that only the low flow rate is used.
Verify or set the low flow rate with program code 174.
Exit the Setup Menu
At the Loading Display, enter the preset volume as the volume of the prover tank.
Initiate the batch delivery to the prover tank.
Monitor the volume delivered in the dynamic data display. Press SELECT - 9 - 9 keys to display item 10 (Mtr 1 grs load n.nn). This volume is the gross uncompensated volume units delivered, adjusted by the current active meter factor, to hundredths of a volume unit.
# After the delivery is terminated, determine the new meter factor by entering the data in a copy of the METER PROVING REPORT FOR TANK PROVER METHOD form RUN 1 column.
5 - 22 ______________________________________________________ Flow Meter Proving
__________________________________________________________ DanLoad 6000 (v6.00)
5.2.2
Tank Prover Meter-Proof RUN 2
At this point the new meter factor, program code 175 Comp 1 meter factor 1, is within tolerance and accepted. The next higher flow rate, program code 176 Comp 1 flow rate 2, is used to determine the meter factor for that flow rate. Assume that flow rate 2 is 400 GPM, an fall back flow rate that is used as a fall-back flow rate if the maximum flow rate cannot be maintained. Set 176
Comp 1 flow rate 2 to 400.
During the meter proof at the low flow rate, the low flow rate was forced active by setting program code 169 Number of factors/component to 1 so that the DanLoad 6000 activates the low flow rate only. Set program code 169 Number of factors/component to 2 at this time to enable flow at the next higher flow rate.
The meter proof for component 1 flow rate 2 is performed similar to the meter proof for component
1 flow rate 1 except that the DanLoad 6000 is permitted to ramp up and ramp down the flow rate with the flow control valve. The flow rate during start and stop times is determined by the value of program code 174 Comp 1 flow rate 1.
Example:
If the flow rate is 200 GPM and the start / stop volumes are 50 gallons, the time at low flow is approximately 15 seconds during startup and 15 seconds during shutdown. All of the program codes that in any way affect the flow rates, volumes, or meter factors at lower flow rates must be set to their normal operational values before conducting meter proofs at higher flow rates. After the rack meter is proved at the highest flow rate for a component. The values of any of the program codes that affect meter proofs for that component should not be changed. If it is necessary to re-Prove a rack meter at a flow rate less than the highest flow rate, re-Prove at all lower flow rates in flow rate ascending order.
5.2.3
Tank Prover Meter-Proof RUN 3
At this point the new meter factor, program code 177 Comp 1 meter factor 2, is within tolerance and accepted. The next higher flow rate, program code 178 Comp 1 flow rate 3 is used to determine the meter factor for that flow rate. Assume that flow rate 3 is 600 GPM, the maximum (normal) loading flow rate for component 1. Set program code 178 Comp 1 flow rate 3 to 600.
The meter proof for component 1 flow rate 3 is performed similar to the meter proof for component
1 flow rate 2.
Flow Meter Proving ______________________________________________________ 5 - 23
DanLoad 6000 (v6.00) __________________________________________________________
5.2.4
Tank Prover Meter-Proof RUN 4 (if Required)
If the fourth flow rate for component 1 were defined, the meter proof at this flow rate would be conducted in a similar manner as described above.
5.2.5
Meter Proofs for Component 2
Assume at this point that the meter factors for component 1 at flow rates 1, 2, 3, and 4 (as required) have been determined and entered into program codes 175 / 177 / 179 / 181 (as required).
In order to perform the meter proof or proofs for component 2, component 1 must be disabled and component 2 enabled. This is accomplished by selecting the previously defined recipe for proving component 2 (recipe definitions are in the program code group 480 to 661).
The set of from one to four meter proofs, corresponding to flow rates, for component 2 can now be conducted. Follow the steps described above for meter proof sequences.
The fields contained in the METER PROVING REPORT FOR TANK PROVER METHOD, Figure
5 - 2, are described below.
Field
Station
Date / Time
Meter Tag
Meter S/N
Meter Mfg
Meter Model
Meter Size
Product
From Tank No.
To Prover Tank No.
Initial Totalizer Reading
Description
Name of station or terminal.
Date and time of meter proof.
Process tag number of flow meter.
Serial number of flow meter.
Manufacturer of flow meter.
Model number of flow meter.
Diameter of flow meter.
Product (component) used for meter proof.
The API gravity of the product.
Source tank identification.
Destination tank identification (prover tank identification).
Non-resetable totalizer reading before meter proof.
5 - 24 ______________________________________________________ Flow Meter Proving
__________________________________________________________ DanLoad 6000 (v6.00)
Prover Tank Volume Data
1 Flow rate The flow rate that is set in the program code ccc Comp p flow rate r corresponding to the meter proof run. Actual flow rate can be verified by accurately timing the period of delivery to the prover tank then dividing the volume delivered by the time to deliver. Example:
2010.36 gallons delivered in 3 minutes 56 seconds equals 564.7
gallons per minute.
2 Delivery to Prover Tank The gross volume delivered to the prover tank, obtained from prover tank data and neck sight gauge graduation reading.
The average temperature of the product in the prover tank, API recommends average of temperature at top, middle, and bottom.
4 C
5 C
TSP
TLP
Correction factor for the effect of temperature on the prover tank steel, obtained from API MPMS Chapter 12 - Section 2 - Table A-1
or Table A-2.
Correction factor for the effect of temperature on the liquid in the prover tank, obtained from API MPMS Chapter 11.1 - Table 6 or
Table 24.
6 CCF
P
Combined correction factor for the prover tank, obtained by multiplying C
TSP
times C
TLP
.
7 Corrected Delivery Volume
The volume, corrected for temperature effects, of liquid in the prover tank, obtained by multiplying Delivery to Tank (line 2) times
Load Rack Meter Data
8 Mtr m grs load (Final) The accumulated gross volume units at the end of the rack meter proof run, obtained from the Dynamic data display - Mtr 1 grs load,
Mtr 2 grs load, Mtr 3 grs load, or Mtr 4 grs load as applicable.
(Note: This value is uncompensated gross volume with the current active meter factor applied.)
9 Mtr m grs load (Initial) The meter registration for gross volume before the meter proof run is started, equal to 0 at start of delivery.
Flow Meter Proving ______________________________________________________ 5 - 25
DanLoad 6000 (v6.00) __________________________________________________________
10 Rack Meter Measured Gross Volume
The gross volume accumulated during the meter proof run, obtained by subtracting Mtr m grs load (Final) from Mtr m grs load (Initial).
11 Rack Meter Temperature
The temperature of the product close to the upstream or downstream side of the flow meter (usually upstream).
12 C
TLM
13 Rack Meter Pressure
14 C
PLM
Correction factor for the effect of temperature on the liquid in the flow meter, obtained from API MPMS Chapter 11.1 - Table 6 or
Table 24. (Note: C is set to 1.0000 if the pulse input from the
TLM flow meter is temperature compensated in the field, before input to the DanLoad 6000.)
The pressure of the product close to the upstream or downstream side of the flow meter (usually upstream).
Correction factor for the effect of pressure on the liquid in the flow meter, usually set to 1.000 and not considered, refer to the API
MPMS for additional information.
15 CCF
M
Combined correction factor for the flow meter, obtained from multiplying C
TLM
times C
PLM
.
16 Rack Meter Corrected Gross Volume
The temperature (and optionally, pressure) compensated volume accumulated by the rack meter during the meter proving, obtained by
multiplying Rack Meter Measured Gross Volume times CCF .
M
17 Rack Meter Volume Error
The difference between the corrected delivery volume to the prover tank and the rack meter corrected gross volume.
18 Rack Meter Percent Error
The percent of error in the rack meter accumulated volume.
19 Adjustment A calculated number that is used to adjust the current active meter factor.
5 - 26 ______________________________________________________ Flow Meter Proving
__________________________________________________________ DanLoad 6000 (v6.00)
20 Current Meter Factor
21 New Meter Factor
Test personnel block
The current active meter factor obtained from program code ccc
Comp p meter factor f corresponding to the component / flow rate combination being proved. (Obtained from: program code 175 / 177
/ 179 / 181 / 186 / 188 / 190 / 192 / 197 / 199 / 201 / 203 / 208 / 210
/ 212 / 214.)
The new_meter_factor is derived from the meter proof run, obtained by multiplying the current meter factor by the adjustment.
Lines to document the personnel conducting and witnessing the meter proof runs, form should be altered as required by your company.
Flow Meter Proving ______________________________________________________ 5 - 27
DanLoad 6000 (v6.00) __________________________________________________________
5.3
Master Meter Method
A master meter is a flow meter that is used as a reference standard for volume measurement comparison with rack meters. The volume measured by the master meter is determined by proving the master meter with a tank prover. The frequency of meter proofs of the master meter must be determined by company policy or regional regulations. As a minimum, the master meter should be proved twice a year. If the master meter is proved in mid spring and mid fall, the measurement accuracy of the master meter will be approximately adjusted for seasonal temperature changes that affect the temperature of the products handled. The master meter must be proved on each product and at the normal delivery flow rate for each product. The set of proofs of the master meter provide a list of meter factors related to each product / flow rate combination. The corresponding meter factor is then used in the calculation when proving a rack meter with the same product / flow rate combination.
#
#
A meter proof is performed by the master meter method in the following manner.
# Set the loading system valves to the proper positions so that all flow through the rack meter to be proved is routed in series with the master meter. Assure that no leakage or bypass paths are present at either flow meter or interconnecting pipe.
Connect an electronic prover counter to the raw pulse output of the master meter.
A meter proof stabilizing run should be performed first to help stabilize the temperature in the proof meter / master meter circuit. The stabilizing run is a proof run without data recorded.
# A liquid batch that satisfies the minimum proof batch requirements stated in the definition of Master Meter Proof at the beginning of this section is defined and delivered to a tank.
# Proof data is gathered and manual calculations are performed to determine the error between the master meter volume [corrected for temperature (and optionally pressure)] and the and the proof flow meter registration [corrected for temperature (and optionally pressure)].
# A new meter factor is calculated by dividing the volume measured through the master meter by the volume registered by the proof flow meter. The measured through the master meter and the volume registered by the proof flow meter are compensated for the effect of temperature on the liquid, and optionally compensated for the effect of pressure on the liquid. If compensation calculation is performed for either the master meter or the proof flow meter, a similar compensation calculation must be performed for the other flow meter.
5 - 28 ______________________________________________________ Flow Meter Proving
__________________________________________________________ DanLoad 6000 (v6.00)
#
#
#
#
Under delivery: If the flow meter registered delivery volume (Mtr m grs load) during the proof run is greater than the volume measured by the master meter, the meter factor value will be decreased to correct the flow meter measurement error.
Over delivery: If the flow meter registered delivery volume (Mtr m grs load) during the proof run is less than the volume measured by the master meter, the meter factor value will be increased to correct the flow meter measurement error.
The new meter factor, which should always be near 1.0000, is manually entered into the
DanLoad 6000 for the active program code ccc Comp p meter factor f, where ccc is one of the following program codes: 175 / 177 / 179 / 181 / 186 / 188 / 190 / 192 / 197 / 199 / 201
/ 203 / 208 / 210 / 212 / 214 dependent on the component number p (1 to 4) and the meter factor number f (1 to 4).
The prover counter is manually reset to zero and the steps listed above are repeated until the corrected meter registration is within 0.02 percent of the corrected prover volume.
5.3.1
Master Meter Meter-Proof RUN 1
For this example, assume that the loading system is a two component blender and that each component is loaded at one of three flow rates [low flow start / stop, fall back, and normal (high) flow]. Any other configuration, from a one component - one flow rate system to a four component four flow rate system is proved in a similar manner by proving each component (flow meter) at each flow rate, in flow rate ascending order. The component order of proving is not important.
# Make the system mechanically and electrically ready for delivery of a liquid batch through the master meter by connecting the master meter in series with the rack meter by high integrity block valves. All flow must pass through both the master meter and the rack meter no bypass leakage is allowed.
# Connect the master meter to a flow totalizer capable of measuring and displaying indicated volume units (without internal meter factor or temperature / pressure compensation) to a resolution of one one-hundredth of a volume unit (such as gallons).
# Select the previously defined recipe for proving component 1 (recipe definitions are in the program codes 480 to 661).
Flow Meter Proving ______________________________________________________ 5 - 29
#
#
#
#
#
DanLoad 6000 (v6.00) __________________________________________________________
#
#
Set program code 169 Number of factors/component to 1 to assure that one the low flow rate is used.
Verify or set the low flow rate with program code 174.
Exit the Setup Menu
At the Loading Display, enter the preset volume as the minimum proving volume required.
Initiate the batch delivery.
Monitor the volume delivered in the dynamic data display. Press SELECT - 9 - 9 keys to display item 10 (Mtr 1 grs load n.nn). This volume is the gross uncompensated volume units delivered, adjusted by the current active meter factor, to hundredths of a volume unit.
After the delivery is terminated, determine the new meter factor by entering the data in a copy of the METER PROVING REPORT FOR TANK PROVER METHOD form RUN 1 column.
5.3.2
Master Meter Meter-Proof RUN 2
At this point the new meter factor, program code 175 Comp 1 meter factor 1, is within tolerance and accepted. The next higher flow rate, program code 176 Comp 1 flow rate 2, is used to determine the meter factor for that flow rate. Assume that flow rate 2 is 400 GPM, an fall back flow rate that is used as a fall-back flow rate if the maximum flow rate cannot be maintained. Set program code 176 Comp 1 flow rate 2 to 400.
Set program code 169 Number of factors/component to 2 at this time to enable flow at the next higher flow rate. The meter proof for component 1 flow rate 2 is performed similar to the meter proof for component 1 flow rate 1 except that the DanLoad 6000 is permitted to ramp up and ramp down the flow rate with the flow control valve. The flow rate during start and stop times is determined by the value of program code 174 Comp 1 flow rate 1.
5 - 30 ______________________________________________________ Flow Meter Proving
__________________________________________________________ DanLoad 6000 (v6.00)
Example:
If the flow rate is 200 GPM and the start / stop volumes are 50 gallons, the time at low flow is approximately 15 seconds during startup and 15 seconds during shutdown. All of the program codes that in any way affect the flow rates, volumes, or meter factors at lower flow rates must be set to their normal operational values before conducting meter proofs at higher flow rates. After the rack meter is proved at the highest flow rate for a component. The values of any of the program codes that affect meter proofs for that component should not be changed. If it is necessary to re-Prove a rack meter at a flow rate less than the highest flow rate, re-Prove at all lower flow rates in flow rate ascending order.
5.3.3
Master Meter Meter-Proof RUN 3
At this point the new meter factor, program code 177 Comp 1 meter factor 2, is within tolerance and accepted. The next higher flow rate, program code 178 Comp 1 flow rate 3, is used to determine the meter factor for that flow rate. Assume that flow rate 3 is 600 GPM, the maximum
(normal) loading flow rate for component 1. Set program code 178 Comp 1 flow rate 3, to 600.
The meter proof for component 1 flow rate 3 is performed similar to the meter proof for component
1 flow rate 2.
5.3.4
Master Meter Meter-Proof RUN 4 (if Required)
If the fourth flow rate for component 1 were defined, the meter proof at this flow rate would be conducted in a similar manner as described above.
5.3.5
Meter Proofs for Component 2
Assume at this point that the meter factors for component 1 at flow rates 1, 2 , 3, and 4 (as required) have been determined and entered into program code 175 / 177 / 179 / 181 (as required).
In order to perform the meter proof or proofs for component 2, component 1 must be disabled and component 2 enabled. This is accomplished by selecting the previously defined recipe for proving component 2 (recipe definitions are in program code 480 to 661).
Flow Meter Proving ______________________________________________________ 5 - 31
DanLoad 6000 (v6.00) __________________________________________________________
The set of from one to four meter proofs, corresponding to flow rates, for component 2 can now be conducted. Follow the steps described above for meter proof sequences.
The fields contained in the METER PROVING REPORT FOR MASTER METER METHOD, Figure
5 - 3, are described below.
Field
Station
Date / Time
Product
From Tank No.
To Tank No.
Initial Totalizer Reading
Description
Name of station or terminal.
Date and time of meter proof.
Product (component) used for meter proof.
The API gravity of the product.
Source tank identification.
Destination tank / vehicle identification.
Non-resetable totalizer reading before meter proof.
5 - 32 ______________________________________________________ Flow Meter Proving
__________________________________________________________ DanLoad 6000 (v6.00)
Master Meter Volume Data
1 Flow rate The flow rate that is set in the program code ccc Comp p flow rate r corresponding to the meter proof run. Actual flow rate can be verified by accurately timing the period of delivery then dividing the volume delivered by the time to deliver. Example: 2010.36 gallons delivered in 3 minutes 56 seconds equals 564.7 gallons per minute.
2 Master Meter Final Reading
The indicated volume at the end of a rack meter proving run, obtained from a totalizer connected to the master meter.
3 Master Meter Initial Reading
The indicated volume at the start of a rack meter proving run, obtained from a totalizer connected to the master meter.
4 Master Meter Indicated Volume
The indicated volume measured by the master meter during the meter proving run. Master Meter Final Reading minus Master Meter Initial
Reading.
5 Master Meter Temperature, degrees F
The temperature of the product in the master meter during the meter proving run, used to derive C .
TLP
6 C
TLP
Correction factor for the effect of temperature on the liquid in the master meter, obtained from API MPMS Chapter 11.1 - Table 6 or
Table 24.
7 Master Meter Pressure, PSIG
The pressure of the product in the master meter during the meter proving run, used to derive C .
PLP
8 C
PLP
Correction factor for the effect of pressure on the liquid in the master meter, obtained from API MPMS Chapter 11.2.
9 Master Meter Meter-Factor
The current active meter factor for the master meter obtained from a tank prover meter proving of the master meter. The current master meter factor should for the same product and flow rate that is used in proving the rack meter. A table is provided at the end of this section for recording master meter factors.
Flow Meter Proving ______________________________________________________ 5 - 33
DanLoad 6000 (v6.00) __________________________________________________________
Field Description
10 CCF
P
Combined correction factor for the master meter, obtained by multiplying C
TLP
times C
PLP
times the master meter meter-factor.
11 Master Meter Corrected Gross Volume
The volume, corrected for temperature effect (and optionally pressure effect), of liquid in measured by the master meter, obtained by multiplying Master Meter Indicated Volume (line 4 times CCF
P
(line 10).
Rack meter Data
12 Mtr m grs load (Final) The accumulated gross volume units at the end of the rack meter proof run, obtained from the Dynamic data display - Mtr 1 grs load,
Mtr 2 grs load, Mtr 3 grs load, or Mtr 4 grs load as applicable.
(Note: This value is uncompensated gross volume with the current active meter factor applied.)
13 Mtr m grs load (Initial)
The meter registration for gross volume before the meter proof run is started. Equal to 0 at start of delivery.
14 Rack Meter Measured Gross Volume
The gross volume accumulated during the meter proof run, obtained by subtracting Mtr m grs load (Final) from Mtr m grs load (Initial).
15 Rack Meter Temperature
The temperature of the product close to the upstream or downstream side of the flow meter (usually upstream).
16 C
TLM
Correction factor for the effect of temperature on the liquid in the flow meter, obtained from API MPMS Chapter 11.1 - Table 6 or
Table 24. (Note: C
TLM
is set to 1.0000 if the pulse input from the flow meter is temperature compensated in the field, before input to the DanLoad 6000.)
17 Rack Meter Pressure
18 C
PLM
The pressure of the product close to the upstream or downstream side of the flow meter (usually upstream).
Correction factor for the effect of pressure on the liquid in the rack meter, usually set to 1.000 and not considered, refer to the API
MPMS for additional information.
5 - 34 ______________________________________________________ Flow Meter Proving
__________________________________________________________ DanLoad 6000 (v6.00)
19 CCF
M
Combined correction factor for the rack meter, obtained from multiplying C
TLM
times C
PLM
.
20 Rack Meter Corrected Gross Volume
The temperature (and optionally, pressure) compensated volume accumulated by the rack meter during the meter proving, obtained by
multiplying Rack Meter Measured Gross Volume times CCF .
M
21 Rack Meter Volume Error
The difference between the Master Meter Corrected Volume and the
Rack Meter Corrected Gross Volume.
22 Rack Meter Percent Error
The percent of error in the rack meter accumulated volume.
23 Adjustment A calculated number that is used to adjust the current active meter factor.
24 Rack Meter Current Meter-Factor
The current active meter factor obtained from program code ccc
Comp p meter factor f corresponding to the component / flow rate combination being proved. (Obtained from: program code 175 / 177
/ 179 / 181 / 186 / 188 / 190 / 192 / 197 / 199 / 201 / 203 / 208 / 210
/ 212 / 214)
25 New Rack Meter Factor
The new_meter_factor is derived from the meter proof run, obtained by multiplying the current meter factor by the adjustment.
Test personnel block Lines to document the personnel conducting and witnessing the meter proof runs, form should be altered as required by your company.
Flow Meter Proving ______________________________________________________ 5 - 35
DanLoad 6000 (v6.00) __________________________________________________________
Program codes 169 to 214 are used to calibrate the DanLoad 6000 for each flow meter, component, flow rate combination.
Code Parameter
169
170
Number of factors/component
Meter factor method
Default
Attribute
Options /
Values
METER FACTORS
W&M 1 to 4
W&M Fixed
Linear
COMPONENT 1 FACTORS
W&M 0.5 to 2000.0
Default
Value
2
Fixed
Value to Use During
Meter Proof temporarily set to 1
171
172
Nominal K-factor
Master meter factor W&M 0.5000 to 2.0000
23.0
round meter nameplate K-factor to nearest tenth program code 171 / nameplate
K-factor set to inline batch end volume 173
174
175
Stop rate
Comp 1 flow rate 1
Comp 1 meter factor 1
W&M 0 to 99999
COMPONENT 1 FACTOR 1
W&M 0 to 99999
W&M
COMPONENT 1 FACTOR 2
W&M 0 to 99999
120
200 set to desired low flow rate see text
176 Comp 1 flow rate 2 600 set to desired fall back or high flow rate see text 177 Comp 1 meter factor 2 W&M
COMPONENT 1 FACTOR 3
W&M 0 to 99999 178 Comp 1 flow rate 3 set to desired fall back or high flow rate see text 179 Comp 1 meter factor 3 W&M
COMPONENT 1 FACTOR 4
W&M 0 to 99999 180 Comp 1 flow rate 4 set to desired fall back or high flow rate see text 181 Comp 1 meter factor 4 W&M
COMPONENT 2 FACTORS
W&M 0.5 to 200.0
182
183
Nominal K-factor
Master meter factor W&M 0.5000 to 2.0000
round meter nameplate K-factor to nearest tenth program code 182 / nameplate
K-factor set to inline batch end volume 184 Stop rate
186
Code
Comp 2 meter factor 1
Parameter
W&M 0 to 99999
Yes
COMPONENT 2 FACTOR 1
W&M 0 to 99999
120
185 Comp 2 flow rate 1
W&M
Attribute Options
COMPONENT 2 FACTOR 2
Default set to desired fall back or high flow rate see text
Meter Proof
5 - 36 ______________________________________________________ Flow Meter Proving
Code
187
Parameter
Comp 2 flow rate 2
188 Comp 2 meter factor 2
189
190
Comp 2 flow rate 3
Comp 2 meter factor 3
191
192
Comp 2 flow rate 4
Comp 2 meter factor 4
193
194
195
Nominal K-factor
Master meter factor
Stop rate
196
197
Comp 3 flow rate 1
Comp 3 meter factor 1
198
199
Comp 3 flow rate 2
Comp 3 meter factor 2
200
201
Comp 3 flow rate 3
Comp 3 meter factor 3
202
203
Comp 3 flow rate 4
Comp 3 meter factor 4
__________________________________________________________ DanLoad 6000 (v6.00)
Attribute
W&M
Options
0 to 99999
W&M
COMPONENT 2 FACTOR 3
W&M 0 to 99999
W&M
COMPONENT 2 FACTOR 4
W&M 0 to 99999
W&M
COMPONENT 3 FACTORS
W&M 0.5 to 200.0
Default
W&M 0.5000 to 2.0000
W&M 0 to 99999
COMPONENT 3 FACTOR 1
W&M 0 to 99999
120
W&M
COMPONENT 3 FACTOR 2
W&M 0 to 99999
W&M
COMPONENT 3 FACTOR 3
W&M 0 to 99999
W&M
COMPONENT 3 FACTOR 4
W&M 0 to 99999
W&M
Meter Proof set to desired fall back or high flow rate see text set to desired fall back or high flow rate see text set to desired fall back or high flow rate see text round meter nameplate K-factor to nearest tenth program code 193 / nameplate
K-factor set to inline batch end volume set to desired fall back or high flow rate see text set to desired fall back or high flow rate see text set to desired fall back or high flow rate see text set to desired fall back or high flow rate see text
Flow Meter Proving ______________________________________________________ 5 - 37
DanLoad 6000 (v6.00) __________________________________________________________
Code Parameter
204
205
Nominal K-factor
Master meter factor
206 Stop rate
207
208
Comp 4 flow rate 1
Comp 4 meter factor 1
209
210
Comp 4 flow rate 2
Comp 4 meter factor 2
211
212
Comp 4 flow rate 3
Comp 4 meter factor 3
213
214
Comp 4 flow rate 4
Comp 4 meter factor 4
Attribute Options
COMPONENT 4 FACTORS
W&M 0.5 to 200.0
W&M 0.5000 to 2.0000
Default
W&M 0 to 99999
COMPONENT 4 FACTOR 1
W&M 0 to 99999
W&M
COMPONENT 4 FACTOR 2
W&M 0 to 99999
W&M
COMPONENT 4 FACTOR 3
W&M 0 to 99999
W&M
COMPONENT 4 FACTOR 4
W&M 0 to 99999
W&M
120
Meter Proof round meter nameplate K-factor to nearest tenth program code 204 / nameplate
K-factor set to desired high flow rate see text set to desired high flow rate see text set to desired high flow rate see text set to desired high flow rate see text
5 - 38 ______________________________________________________ Flow Meter Proving
METER PROVING REPORT FOR TANK PROVER METHOD
M E T E R S
/
N S T A T IO N M E T E R T A G D AT E
P R O D U C T M E T E R M F G
F R O M T A N K N O
.
M E T E R M O D E L
T O P R O V E R T A N K N O
.
M E T E R S IZ E
IN IT IA L T O T A L IZ E R R E A D IN G
Report:
T IM E
A P I G R A V IT Y
@ 60 F
R U N
1
R U N
2
R U N
3
P R O V E R T A N K V O L U M E D AT A
3
4
1
2
5
6
7
F L O W R A TE
D E L IV E R Y T O P R O V E R T A N K
P R O V E R T AN K T E M P E R A T U R E
(
A V G
),
D E G R E E S
F
C (
T A B L E
A-1 / A-2)
T S P
C
T L P
(
T A B L E
6)
C O M B IN E D C O R R E C T IO N F A C T O R
CCF
P
(
L IN E
4
X L IN E
5)
C O R R E C TE D D E L IV E R Y V O L U M E
(
L IN E
2
X L IN E
6)
19
20
21
11
12
13
R A C K M E T E R D A T A
[D
A N
L
O AD
6000]
8 M
T R M G R S L O AD
(
F IN A L
)
9
10
M
T R M G R S L O AD
(
IN IT IA L
)
R AC K M E T E R M E A S U R E D G R O S S V O L U M E
(
L IN E
8 -
L IN E
9)
R AC K M E T E R T E M P E R A T U R E
,
D E G R E E S
F
14
15
C
T L M
(
T A B L E
6)
R AC K M E T E R P R E S S U R E
, PSIG
C (
C H A P
11.2)
P L M
C O M B IN E D C O R R E C T IO N F A C T O R
CCF
M
(
L IN E
12
X L IN E
14)
16
17
18
R AC K M E T E R C O R R E C TE D G R O S S V O L U M E
(
L IN E
10
X L IN E
15)
R AC K M E T E R V O L U M E E R R O R
(
L IN E
7 -
L IN E
16)
R AC K M E T E R P E R C E N T E R R O R
(
L IN E
17 /
L IN E
16)
A D J U S T M E N T
(
L IN E
7 /
L IN E
16)
R A C K M E T E R C U R R E N T M E T E R
-
F A C T O R
N E W M E T E R F A C T O R
(
L IN E
19
X L IN E
20)
S IG N AT U R E
E N G IN E E R
W IT N E S S
R E M A R K S
R U N
1
D AT E
R U N
2
R U N
3
R E P R E S E N T IN G
R U N
4
R U N
4
Figure 5 - 2 (Typical)
METER PROVING REPORT FOR MASTER METER METHOD
Report:
T O T A N K N O
:
S T A T IO N
:
P R O D U C T
:
F R O M T A N K N O
:
A P I G R A V IT Y
@ 60 F:
IN IT IA L T O T A L IZ E R R E A D IN G
:
M A S T E R M E T E R D A TA M F G
:
M O D E L
:
S E R IA L N O
:
S IZ E
: K-
F A C T O R
:
R U N
1
R U N
2
5
8
9
6
7
10
M A S T E R M E T E R V O L U M E D AT A
1
2
3
4
F L O W R A TE
M A S T E R M E T E R F IN AL R E A D IN G
M A S T E R M E T E R IN IT IA L R E A D IN G
11
M AS T E R M E T E R IN D IC AT E D V O L U M E
(
L IN E
2 -
L IN E
3)
M A S T E R M E T E R T E M P E R A T U R E
,
D E G R E E S
F
C
T L P
(
T A B L E
6)
M A S T E R M E T E R P R E S S U R E
, PSIG
C
P L P
(
C H A P
11.2)
M A S T E R M E T E R M E T E R
-
F A C T O R
C O M B IN E D C O R R E C T IO N F A C T O R
CCF
P
(
L IN E
6
X L IN E
8
X L IN E
9)
M AS T E R M E T E R C O R R E C TE D G R O S S V O L U M E
(
L IN E
4
X L IN E
10)
23
24
25
15
16
17
R A C K M E T E R V O L U M E D A T A
[D
A N
L
O AD
6000]
M
T R M G R S L O AD
(
F IN A L
) 12
13 M
T R M G R S L O AD
(
IN IT IA L
)
14
R AC K M E T E R M E A S U R E D G R O S S V O L U M E
(
L IN E
12 -
L IN E
13)
R AC K M E T E R T E M P E R A T U R E
,
D E G R E E S
F
C
T L M
(
T A B L E
6)
R AC K M E T E R P R E S S U R E
, PSIG
18
19
C
P L M
(
C H A P
11.2)
C O M B IN E D C O R R E C T IO N F A C T O R
CCF
M
(
L IN E
16
X L IN E
18)
20
21
22
R AC K M E T E R C O R R E C TE D G R O S S V O L U M E
(
L IN E
14
X L IN E
19)
R AC K M E T E R V O L U M E E R R O R
(
L IN E
11 -
L IN E
20)
R AC K M E T E R P E R C E N T E R R O R
(
L IN E
21 /
L IN E
20)
A D J U S T M E N T
(
L IN E
11 /
L IN E
20)
R A C K M E T E R C U R R E N T M E T E R
-
F A C T O R
N E W R AC K M E T E R F A C T O R
(
L IN E
23
X L IN E
24)
R U N
1
R U N
2
R U N
3
R U N
3
R U N
4
R U N
4
D A TE
:
R U N
5
R U N
5
S IG N AT U R E D AT E R E P R E S E N T IN G
E N G IN E E R
W IT N E S S
R E M AR K S
T IM E
:
A V E R AG E
A V E R AG E
Figure 5 - 3 (Typical)
__________________________________________________________ DanLoad 6000 (v6.00)
This table contains meter factors for the master meter derived from tank prover proving of the master meter on up to four different products at up to four different flow rates for each product. The master meter meterfactors are related to component / flow rate assignments within the DanLoad 6000 for reference during proving of rack meters.
MASTER METER:
Manufacturer / model: ___________________________________________________
Size: _________________________________________________________________
Serial number: _________________________________________________________
Nominal K-factor: ______________________________________________________
Product
(component)
Meter Factor
Date Master Meter Flow Rate
174 Comp 1 flow rate 1
176 Comp 1 flow rate 2
178 Comp 1 flow rate 3
180 Comp 1 flow rate 4
182 Comp 2 flow rate 1
184 Comp 2 flow rate 2
186 Comp 2 flow rate 3
188 Comp 2 flow rate 4
190 Comp 3 flow rate 1
192 Comp 3 flow rate 2
194 Comp 3 flow rate 3
196 Comp 3 flow rate 4
198 Comp 4 flow rate 1
200 Comp 4 flow rate 2
202 Comp 4 flow rate 3
204 Comp 4 flow rate 4
Master Meter Meter-Factor
175 Comp 1 meter factor 1
177 Comp 1 meter factor 2
179 Comp 1 meter factor 3
181 Comp 1 meter factor 4
183 Comp 2 meter factor 1
185 Comp 2 meter factor 2
187 Comp 2 meter factor 3
189 Comp 2 meter factor 4
191 Comp 3 meter factor 1
193 Comp 3 meter factor 2
195 Comp 3 meter factor 3
197 Comp 3 meter factor 4
199 Comp 4 meter factor 1
201 Comp 4 meter factor 2
203 Comp 4 meter factor 3
205 Comp 4 meter factor 4
Flow Meter Proving ______________________________________________________ 5 - 41
DanLoad 6000 (v6.00) __________________________________________________________
This page intentionally left blank.
5 - 42 ______________________________________________________ Flow Meter Proving
________________________________________________________________________________________ DanLoad 6000 (v6.00)
This section contains descriptions of all program codes. Each program code consists of a three-digit number, an identifying name, a variable that conveys control or numeric configuration data to the Danload 6000, and four attributes. The variable part of each program code defines a setup, configuration, or database value. Each program code number / name combination identifies a unique parameter that is either a setpoint, or limit value, or an option that defines some method or mode of operation. Data entry in a value / option field is accomplished by prompting the user to enter a numeric value, enter an alpha-numeric string, or select an option from a short list of options (pick list).
Each program code has four program code attributes associated with it that can be toggled ON or OFF to provide specific security restrictions and status information for selected program codes.
Program codes are displayed in the following format when the
DanLoad 6000 is operating in the setup option of Program Mode. ccc aaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaa vvv where: ccc
A three-digit identifier, this number is unique for each program code. Program codes numbers are from 001 to 991. (Note:
Several numbers in the series are not used.) aaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaa
An alpha-numeric name of up to thirty-four characters that specifies the function of the program code. Some names are repeated several times when the parameter type is repeated for similar functions, such as different meters, components, or additives. However, the three digit program code is always unique.
Program Code Definitions ________________________________________________________________________ Section 6 - 1
________________________________________________________________________________________ DanLoad 6000 (v6.00)
# vvv ...
A value assigned to the program code at setup time or modified in the field. Note that the data type displayed and acceptable entry in this field is dependent on the program code variable type.
These data types are:
# integer
Whole number without a fractional part or decimal separator. Example:
078 Maximum preset volume 3000
# alpha-numeric string
A message consisting of letter and number characters.
Example:
066 Component ID Component #1 selection
A predefined option selected from a scrollable short list of options. Example:
028 Language English
# real number
A number consisting of a whole part, decimal separator, and fractional part. Example:
130 Factor 1.0
Section 3 - Setup Contains information on the procedures used to enter data in the various types of data fields mentioned above.
Program Code Definitions ________________________________________________________________________ Section 6 - 2
Program code attributes are characteristics that are associated with each program code. There are four program code attributes for any program code.
Access to program code attributes is by selection of the Program
Code Attributes option under the Program Mode Menu. It is assumed that the DanLoad 6000 is in the loading mode with the
Loading Display active at this time.
Access program code attributes:
#
#
#
#
#
________________________________________________________________________________________ DanLoad 6000 (v6.00)
6.1
Program Code Attributes
#
#
#
Enter the three digit program code in response to the
Enter program code prompt message. (Note: One or two preceding zeros must be entered if the program code is less than 100.)
Press the 9 (down arrow) key or the 8 (up arrow) key to select (move the box outline cursor over the item) the desired program code attribute.
Press the SELECT key to toggle the Yes or No status of the program code.
Select different program code:
#
#
Press the EXIT (ALT+CLEAR) key.
Perform steps listed above under Access program code
attributes as desired.
#
Press the PROGRAM (ALT+ENTER) key.
Enter 1 to 9 digit supervisor passcode in response to
Enter passcode _________ prompt.
Press the ENTER key.
The first display page of the Program Mode Menu is displayed.
Press the 9 (down arrow) key repeatedly to select (move the box cursor over the item) Program code attributes
(item five in the list).
Press the ENTER key.
Program Code Definitions ________________________________________________________________________ Section 6 - 3
________________________________________________________________________________________ DanLoad 6000 (v6.00)
6.1
Program Code Attributes (continued)
Exit program code attribute modification mode:
#
#
#
Press the EXIT (ALT+CLEAR) key (returns to
program code attributes).
Press the EXIT (ALT+CLEAR) key (returns to
Program Mode Menu).
Press the EXIT (ALT+CLEAR) key (returns to
Loading Mode).
The options for program code attributes are described below.
Read only
Prevent modification, in Setup, of the value of the program code variable. The message, Read only, is displayed on the message line of the display if this attribute is set to Yes for the corresponding selected program code. (Note: Some program codes can only be modified by internal logic or calculations and are always Read only.)
# No
Disable this attribute for this program code.
# Yes
Enable this attribute for this program code.
Weights and measures
Prevent modification, in Setup and through communications with a terminal automation system, of the value of the program code value, unless the Weights and Measures switch located on the operator control panel is open (out position). The message,
Weights and measures, is displayed on the message line of the display if this attribute is set to Yes for the corresponding selected program code.
# No
Disable this attribute for this program code.
# Yes
Enable this attribute for this program code.
Program Code Definitions ________________________________________________________________________ Section 6 - 4
________________________________________________________________________________________ DanLoad 6000 (v6.00)
6.1
Program Code Attributes (continued)
Data logging
Automatically log new values of program codes if modified in
Setup. The changes are only logged if program code 702
Program code value change log is set to any logging printer and data logging is enabled by program code 668 Ch. B mode.
# No
Disable this attribute for this program code.
# Yes
Enable this attribute for this program code. This is the default value for all program codes at initial startup time.
Value changed
The value of the program code variable was changed in Setup or via communications. This program code attribute cannot be changed manually. The program code attribute is set (Yes) internally if the value was changed and can only be reset (No) by a command from a Terminal Automation System. (Refer to
DanLoad 6000 Communications Specification, Part Number 3-
9000-674)
# No
Program code has not been changed in Program Mode or via communications.
# Yes
Program code has been changed in Program Mode or via communications.
Program Code Definitions ________________________________________________________________________ Section 6 - 5
________________________________________________________________________________________ DanLoad 6000 (v6.00)
6.2
Program Code Groups
Program codes are grouped according to their logical functions.
Program codes are accessed by the Setup Menu. Figure 6 - 1 is a diagram of the complete menu tree. Figure 6 - 2 contains an overview of the program code groups. Access to the program codes is allowed while in the Program Mode. Access to the
Program Mode from the Loading Mode is described below. It is assumed at this time that the DanLoad 6000 is in the Loading
Mode with either the Recipe Selection Menu, the Additive
Selection Menu, or the Loading Display active at this time.
#
#
#
Enter Setup Mode:
#
#
#
#
Press the PROGRAM (ALT+ENTER) key.
Enter 1 to 9 digit supervisor passcode in response to:
Enter passcode _________ prompt.
Press the ENTER key.
The first display page of the Program Mode Menu is displayed.
The box cursor is at the first selection Alarm Reset.
Press the 9 (down arrow) to move the cursor to the Setup selection.
Press the ENTER key.
#
#
#
#
#
#
The first display page of the Setup Menu is displayed.
The box cursor is at the first selection Security
Parameters.
Press the 9 (down arrow) key or the 8 (up arrow) key to select (move the box cursor over the item) the desired program code group from the list of twenty-four groups, divided into four display pages.
Press the ENTER key.
The first page of the selected program code group is displayed.
Note: Each program code group is divided into pages of one to six program codes.
Press the 9 (down arrow) key or the 8 (up arrow) key to select (move the box cursor over the item) the desired program code. Program codes are not displayed for undefined meters, valves, components, additives, etc.
For example, if two meters are configured, then program codes for meters 3 and 4 are not displayed.
Program Code Definitions ________________________________________________________________________ Section 6 - 6
________________________________________________________________________________________ DanLoad 6000 (v6.00)
6.2
#
Program Code Groups (continued)
Note: The displayed data for each program code is entered for the program code value when the EXIT
(ALT+CLEAR) key is pressed to exit the program code group. Verify that data is correct before exiting a program code group.
Exit Setup Mode:
#
#
#
Press the EXIT (ALT+CLEAR) key (returns to Setup
Menu).
Press the EXIT (ALT+CLEAR) key (displays Setup
Complete).
Press the EXIT (ALT+CLEAR) key (resets the
DanLoad 6000 and returns to the Loading Mode).
Program Code Definitions ________________________________________________________________________ Section 6 - 7
________________________________________________________________________________________ DanLoad 6000 (v6.00)
Program Mode Menu
Alarm reset 6 Alarm reset display
Reprint transaction 6 Reprint transaction display
Setup - Setup menu
|
Program code attributes 6 Program code attributes display |
|
Set date and time 6 Set date and time display |
|
Set contrast/backlighting 6 Set contrast/backlighting display |
|
Diagnostics - Diagnostics menu |
| |
Reprint cutoff - Reprint end-of-day processing data | |
CALMON status - Calibration monitoring Diagnostics Menu Setup Menu
Firmware versions Security parameters
Additive calibration - Additive meter calibration screen RAM tests Unit parameters
Keypad Valve parameters
EXIT (ALT+CLEAR) Display Meter parameters
Inputs/Outputs Component parameters
DUART Delivery parameters
ARCNET Digital valve parameters
Crash analysis Pulse per unit outputs
Show memory Additive delivery parameters
Print configuration Factors
Exit (ALT+CLEAR) Alarms
I/O parameters
Additive I/O parameters
Component I/O parameters
Temperature/pressure/density
Recipes
Data communications
Dynamic data display
Data logging
Blending
Additive pumps/block valves
LPG/pressure
Transaction storage
Transaction ticket
Analog inputs
Exit (ALT+CLEAR)
Menu Tree - Figure 6 - 1
Program Code Definitions ________________________________________________________________________ Section 6 - 8
________________________________________________________________________________________ DanLoad 6000 (v6.00)
6.2
Program Code Groups (continued)
Group Name Used For
001 to 018
023 to 047
048, 049 V
050 to 061
065 to 077
078 to 111
112 to 127
128 to 134
135 to 168
169 to 219
220 to 279
280 to 379
380 to 399
400 to 425
426 to 479
480 to 661
Security parameters
Unit parameters
Valve parameters
Meter parameters
Component parameters
Delivery parameters
Digital valve parameters
Pulse per unit outputs Volume pulses to external equipment
Additive delivery parameters Additive injection
Factors
Alarms
I/O parameters
Additive I/O parameters
Component I/O parameters
Temperature / pressure / density
Recipes
Operation security
Global parameters
Flow control valves
Flow meters
Liquid components
Batch deliveries
Digital flow control valves
Flow meter factors and flow rates
Actions and limits
Input / output signal assignments
Additive injection signal assignments
Component block valve signal assignments
Standard quantity calculation
Product / batch deliveries
Parameters List Overview - Figure 6 - 2a
Program Code Definitions ________________________________________________________________________ Section 6 - 9
________________________________________________________________________________________ DanLoad 6000 (v6.00)
6.2
Program Code Groups (continued)
Group Name Used For
662 to 672
679 to 695
696 to 710
711 to 799
Data communications
Dynamic data display
Data logging
Blending
Logging / terminal automation system
Operator data view (programmable)
Reports to printer
Product blending control
800 to 817
818 to 833
834 to 902
920 to 982
983 to 991
Additive pumps/block valves
LPG/pressure
Transaction storage
Transaction ticket
Analog inputs
Additive pump and block valve control
LPG pressure control
Allocate storage for transaction and batch loading data
Format control for user defined transaction tickets v2 CPU board calibration for 4-20 mA and RTD
Parameters List Overview (continued) - Figure 6 - 2b
Program Code Definitions ________________________________________________________________________ Section 6 - 10
________________________________________________________________________________________ DanLoad 6000 (v6.00)
6.2
Program Code Groups (continued)
How to Use the Program Code List
The list of program codes on the remaining pages in this section is divided into groups as they appear in the Setup Menu.
# The tables in each section summarize each group of program codes in the left-hand column and show the possible Range/Option and Default settings in the righthand column.
# Some program code groups are sub-divided into several tables for ease of reading.
# A detailed description of each program code is located below the corresponding table.
# If a program code number is unique, that number is used.
If several program code numbers are used to identify different devices, components, or additives, each number is separated by a ‘/’ (slash).
#
#
When the list of program code numbers is too long to list, the actual first number and the actual last number are shown with ellipsis to indicate the missing numbers.
(Example: nnn / ... / nnn.)
The vertical columns in the tables indicate the different sub-groups of parameters and the actual program code number that can be obtained from the corresponding table.
Example: If only one flow meter is specified by program code 050 Number of meters, the program codes related to flow meter 1 (051 to 052) are displayable and program codes 054 to 062 for flow meters 2, 3, and 4 are not displayable.
Program Code Definitions ________________________________________________________________________ Section 6 - 11
________________________________________________________________________________________ DanLoad 6000 (v6.00)
6.3
Security Parameters
PC# / Function
(Six Users)
001 / 004 / 007 / 010 / 013 / 016 Passcode
002 / 005 / 008 / 011 / 014 / 017 User ID
003 / 006 / 009 / 012 / 015 / 018 Supervisor privilege
Range <Default> OR Option (* = Default)
0 to 999999999
<6000> (001 only)
1 to 16 characters
<DanLoad 6000> (002 only)
0 Yes * (003 only)
1 No
Program Code Definitions (001 to 024 Security Parameters) __________________________________________ Section 6 - 12
________________________________________________________________________________________ DanLoad 6000 (v6.00)
6.3
Security Parameters (continued)
Security parameters contain data which defines access passcodes and access privileges for selecting menu options and changing parameter values. Security parameters do not affect operation in the Loading Mode which is active during batch deliveries. Up to eight users / operators, each with unique access privileges, can be defined. Passcodes should be maintained and recorded by a
“supervisor-privileged” user. If all supervisor-privileged passcodes are lost of forgotten, it will not be possible to access the DanLoad 6000. A “randomly-generated” emergency passcode is available from Daniel Customer Service. The
DanLoad 6000 is shipped from the factory with the security parameters for User 1 set to the following default values / selections.
001 Passcode
002 User ID
003 Supervisor privilege
6000
DanLoad 6000
Yes
001 / ... / 016 Passcode
This program code assigns a numeric value (one to nine digits) that is used as a unique passcode for the user. Duplicate passcodes, except for zero (which is not a valid passcode), are not permitted. A minimum of one passcode must be non-zero.
002 / ... / 017 User ID
This program code assigns an alpha-numeric entry (Up to sixteen characters) that is used to identify the user / operator with a meaningful name. (Example: Operator # 1, John Jones, or similar)
Program Code Definitions (001 to 024 Security Parameters) __________________________________________ Section 6 - 13
________________________________________________________________________________________ DanLoad 6000 (v6.00)
6.3
Security Parameters (continued)
003 / ... / 018 Supervisor privilege
This program code enables or disables supervisor privilege for the corresponding user.
# Yes
The corresponding user has supervisor privileges and thus has access to all program mode menu options including
Setup/Security parameters in order to perform passcode maintenance.
# No
The corresponding user has supervisor privilege disabled and can access only the following menu options:
#
#
#
Alarm reset
Reprint transaction
Reprint cutoff
Program Code Definitions (001 to 024 Security Parameters) __________________________________________ Section 6 - 14
________________________________________________________________________________________ DanLoad 6000 (v6.00)
CONTINUE
Program Code Definitions (001 to 024 Security Parameters) __________________________________________ Section 6 - 15
________________________________________________________________________________________ DanLoad 6000 (v6.00)
6.4
Unit Parameters
Function
023 Side stream Blending
024 Sequential proportional
025 Operating mode
026 Unit type
027 Valve type
028 Language
Range <Default> OR Option (* = Default)
Yes "Side" stream blending enabled
No "Side" Stream blending disabled *
Yes - “Side” stream sequential blending performed using in-line proportional blending logic
No - "Side" Stream sequential blending performed using in-line non-proportional logic *
0 Auto (* for automation systems)
1 Manual (* for local control systems)
0 Seq. (auto) (* for sequential unit types)
1 Seq. (manual)
2 In-line (* for in-line unit types)
3 Off-rack (not used)
4 Dispenser
0 Std digital *
1 Std 2-stage
2 Stem sw.
0 English *
1 English 2
2 Spanish
3 German
4 Portuguese
5 Dutch
6 French
7 Norwegian
8 Slovak
9 Polish
10 Macedonian
11 Italian
12 Greek
13 Malay
14 Russian
15 Croatian
16 Vietnamese
Program Code Definitions (023 to 047 Unit Parameters) ______________________________________________ Section 6 - 16
________________________________________________________________________________________ DanLoad 6000 (v6.00)
Function
029 Product units
Range <Default> OR Option (* = Default)
0 Off
1 Bbl
2 Dek
3 L
4 Gal *
5 lbs
6 kgs
Program Code Definitions (023 to 047 Unit Parameters) ______________________________________________ Section 6 - 17
________________________________________________________________________________________ DanLoad 6000 (v6.00)
6.4
Unit Parameters (continued)
Note: The default for Unit Type is dependent on options specified during initial setup.
Unit Parameters contain data which defines various general operating characteristics of the DanLoad 6000.
023 Side stream blending
This program code enables or disables the side stream blending.
024 Sequential proportional
This program code specifies whether the blend of side stream component and primary component is performed as an in-line proportional blend or an in-line non-proportional blend. This program code is applicable only when the DanLoad is configured for sequential blending for primary components.
025 Operating mode
This program code selects the operating mode of the DanLoad
6000 for interaction with a terminal automation system. The data logging feature operates in the Manual mode, only. Data logging
is not available in the Auto mode. The operating modes are:
#
#
Auto
A terminal automation system maintains bi-directional communications with the DanLoad 6000 and performs monitoring and control of the batch delivery operations.
If used, program code 343 Auto/manual changeover should be CLOSED to select this option.
Manual
A terminal automation system can maintain bi-directional communications with the DanLoad 6000 and performs monitoring of the batch delivery operations. Control functions issued from the terminal automation system are not accepted by the DanLoad 6000. If used, program code 343 Auto/manual changeover should be OPEN to select this option.
Program Code Definitions (023 to 047 Unit Parameters) ______________________________________________ Section 6 - 18
________________________________________________________________________________________ DanLoad 6000 (v6.00)
6.4
Unit Parameters (continued)
026 Unit type
This program code selects the method of controlling batch deliveries. The options are:
# Seq. (auto)
Sequential blending is performed. One to four components are loaded sequentially, one at a time. The block valves are controlled automatically.
# Seq. (manual)
Sequential blending is performed. One to four components are loaded sequentially, one at a time. The operator is prompted to open and close block valves.
# In-line
In-line proportional or in-line non-proportional blending
(depending on recipe configuration) is performed. One or more components are loaded simultaneously with each component flow measured by a separate flow meter and controlled by a separate digital flow control valve.
#
#
Off-rack
Not used.
Dispenser
A dispenser inherits most of the characteristics of an inline blender. However, the following differences from an in-line blender should be noted:
- The STOP key stops and ends a batch.
- A primary or secondary alarm stops and ends a batch.
Note: A single component DanLoad 6000 can be either a sequential or in-line unit type depending on which other characteristics of these unit types are of interest.
Program Code Definitions (023 to 047 Unit Parameters) ______________________________________________ Section 6 - 19
________________________________________________________________________________________ DanLoad 6000 (v6.00)
6.4
Unit Parameters (continued)
027 Valve type
This program code selects the flow control valve (FCV) type used in the system. All flow control valves in the system must be the same type.
# Std digital
The flow control valve is a standard digital type. The flow rate is automatically adjusted to match a setpoint value. The DanLoad 6000 can “lock” the flow rate at configured values for the best possible accuracy.
# Std 2-stage
The flow control valve is a standard 2-stage type. This valve type can also be used to control simple on-off valves. The flow rates achieved are a function of line pressure.
# Stem sw.
The flow control valve is a 2-stage type with stem switches providing inputs to the DanLoad 6000 to control low flow start and stop (program codes 294 and 295 for valve 1, etc.). The flow rates achieved are a function of switch adjustment and line pressure. The unit type
(program code 026) should be set to “Seq. (Auto)” or
“Seq. (Manual)” and initial flow time (program code 049) should be 0.
Program Code Definitions (023 to 047 Unit Parameters) ______________________________________________ Section 6 - 20
________________________________________________________________________________________ DanLoad 6000 (v6.00)
028 Language
This program code selects the language used for the Loading
Display and data logging.
#
#
#
#
#
#
#
#
#
#
#
#
#
#
#
#
#
#
English
English 2 (See notes following list on message codes.)
Spanish
German
Portuguese
Dutch
French
Norwegian
Slovak
Polish
Macedonian
Italian
Greek
Malay
(Data logging in English)
(Data logging in English)
Russian
Croatian
(Data logging in English)
(Data logging in English)
Vietnamese (Data logging in English)
Slovenian (Data logging - no accented characters)
Program Code Definitions (023 to 047 Unit Parameters) ______________________________________________ Section 6 - 21
________________________________________________________________________________________ DanLoad 6000 (v6.00)
6.4
Unit Parameters (continued)
English2 in the list above has message numbers appended to permit the use of printed code translation card for other languages. In v5.70, the message number for the “Flow rate too high” message was changed from 15 to 6. All available message codes are shown below:
01 Enter passcode
02 Invalid passcode
03 Enter preset volume _STR
04 Press START when ready or STOP cancel
05 Load in progress
06 Flow rate too high meter X
07 Batch started - testing display
08 Line pack delay
09 Memory check failure
10 Valve closed early meter X
11 Invalid entry - more than maximum
12 Invalid entry - less than minimum
13 Side not authorized
14 Please wait
15 Safety Circuit 1 message
16 Safety Circuit 2 message
17 Flow rate too low meter X
18 Unable to close valve meter X
19 Timed-out - no flow detected meter X
20 Unauth. flow exceeds limit meter X
21 Safety circuit 3 message
22 Additive X failure
23 Pulse security error meter X
24 Temperature failure meter X
25 Safety circuit 4 message
26 Density failure component X
27 Component X block valve not closed
28 Data logging memory full
29 Pressure failure meter X
30 Comms failure channel X
31 Unable to maintain blend
32 Ramping up to high flow rate
33 Ramping down to low flow rate
34 Shutting valve
35 Use arrow keys and SELECT
36 Additive #
37 Not available
38 Opening block valve
39 Invalid recipe (percentages)
40 Open block valve - press ENTER
41 Close block valve - press ENTER
42 Primary or secondary display failure
43 Supervisor passcode required
44 Original passcode required
Program Code Definitions (023 to 047 Unit Parameters) ______________________________________________ Section 6 - 22
________________________________________________________________________________________ DanLoad 6000 (v6.00)
6.4
Unit Parameters (continued)
45 Power failure
46 Storage memory full
47 Maximum batches on transaction
48 Unable to ramp down
49 MPMC X failure
50 Calibration failure meter X
51 Intermediate level input
029 Product units
This identifies the product (component) units so that conversions can be made when necessary. In particular, converting additive volumes to cubic centimeters (during additive calibration) and external additive units (during loading). The nominal K-factor in the Factors setup group specifies the number of pulses per unit of product. The product units should typically be set to the units in which the K-factor is specified. For example, if the K-factor is in pulses per U.S. gallon, then the product units should be “Gal”.
The default value is “Gal”.
# Off
Undetermined units. (Not recommended)
#
#
Bbl
The product units are barrels.
Dek
The product units are dekaliters.
#
#
L
The product units are liters.
Gal
The product units are U.S. gallons.
#
# lbs
The product units are pounds.
kgs
The product units are kilograms.
See also: Gross and standard product unit mnemonics (program code 217 and 218).
Program Code Definitions (023 to 047 Unit Parameters) ______________________________________________ Section 6 - 23
________________________________________________________________________________________ DanLoad 6000 (v6.00)
6.4
Unit Parameters (continued)
Function
030 Number of data items
031 #1 Prompt for data item #1
032 #2 Prompt for data item #2
033 #3 Prompt for data item #3
034 #4 Prompt for data item #4
035 #5 Prompt for data item #5
036 Prompt time-out (s)
037 Check display
Range <Default> OR Option (* = Default)
0 to 5 <0>
32 characters <Enter data item #1>
32 characters <Enter data item #2>
32 characters <Enter data item #3>
32 characters <Enter data item #4>
32 characters <Enter data item #5>
0 to 9999 <60>
0 Off *
1 Start
2 Start/Restart
Program Code Definitions (023 to 047 Unit Parameters) ______________________________________________ Section 6 - 24
________________________________________________________________________________________ DanLoad 6000 (v6.00)
6.4
Unit Parameters (continued)
030 Number of data items
This program code sets the number of data prompts in the general format Enter data item #1__________, displayed in the message line of the display panel. These prompts allow the operator to enter up to five numbers of up to eight digits each number, before the first preset quantity is entered in the Loading Display, i.e. prior to authorization of the transaction. The data items can be printed on the Batch Summary, Transaction Summary and
Transaction Ticket data logs. If the DanLoad 6000 is in a terminal automation system network, the data items can be transmitted to the DanLoad 6000 from the terminal automation system in the Authorize Transaction command (refer to Comms
Spec, part number ___________) for accounting purposes. Data item entries are not validated and do not affect the operation of the DanLoad 6000.
032 #2 Prompt for data item #2
This program code contains the message to be displayed for data item prompt # 2. The default message is Enter data item #2 which can be modified to a more descriptive prompt.
Example: Enter invoice number:
033 #3 Prompt for data item #3
This program code contains the message to be displayed for data item prompt # 3. The default message is Enter data item #3 which can be modified to a more descriptive prompt.
Example: Enter driver number:
031 #1 Prompt for data item #1
This program code contains the message to be displayed for data item prompt # 1. The default message is Enter data item #1 which can be modified to a more descriptive prompt.
Example: Enter order number:
034 #4 Prompt for data item #4
This program code contains the message to be displayed for data item prompt # 4. The default message is Enter data item #4 which can be modified to a more descriptive prompt.
Example: Enter trailer number:
Program Code Definitions (023 to 047 Unit Parameters) ______________________________________________ Section 6 - 25
________________________________________________________________________________________ DanLoad 6000 (v6.00)
6.4
Unit Parameters (continued)
035 #5 Prompt for data item #5
This program code contains the message to be displayed for data item prompt # 5. The default message is Enter data item #5 which can be modified to a more descriptive prompt.
Example: Enter permit number:
036 Prompt time-out (s) (0 to 9999)
The time allowed for various operations in loading mode in the manual operating mode, i.e.
- Prompting for a data item.
- Prompting for a preset quantity. (“Enter preset quantity”.)
- Prompting to start or restart a batch. (“Press START when ready or STOP to cancel”.)
- Prompting for an additive selection, i.e. the additive selection screen. (See program code 136.)
- Ending a transaction with no batch in progress. (See program code 839.) The time-out is not used in program mode.
Typically, the automation system controls the time-out in the automatic operating mode. (Refer to the DanLoad 6000
Communications Specification for details.) Zero disables the time-out. The default value is 60 seconds.
037 Check display
This program code selects the method of verifying the operation of the display panel. The area of the display that is used to display the large digits of the batch-loaded quantity is momentarily darkened then lightened to verify that all pixels that form the digits are displayable. The current batch-loaded quantity is automatically re-displayed after completion of the test.
# Off
#
Disable display panel check function.
Start
When a batch delivery is initially started, perform the display check after displaying Press START when ready
or STOP to cancel on the message line while in the
Loading Mode.
Program Code Definitions (023 to 047 Unit Parameters) ______________________________________________ Section 6 - 26
________________________________________________________________________________________ DanLoad 6000 (v6.00)
6.4
Unit Parameters (continued)
# Start/Restart
When batch delivery is initially started or subsequently restarted, perform the display check after displaying Press
START when ready or STOP to cancel on the message line while in the Loading Mode.
Program Code Definitions (023 to 047 Unit Parameters) ______________________________________________ Section 6 - 27
________________________________________________________________________________________ DanLoad 6000 (v6.00)
6.4
Unit Parameters (continued)
Function
038 Date format
039 Date separator
040 Decimal separator
041 Display data rate
Range <Default> OR Option (* = Default)
0 mm/dd/yy *
1 dd/mm/yy
2 yy/mm/dd
0 / (slash) *
1 . (dot)
2 - (stroke)
0 . (dot) *
1 , (comma)
0 1200 bps
1 2400 bps
2 4800 bps
3 9600 bps
4 19200 bps
5 28800 bps *
Program Code Definitions (023 to 047 Unit Parameters) ______________________________________________ Section 6 - 28
________________________________________________________________________________________ DanLoad 6000 (v6.00)
6.4
Unit Parameters (continued)
038 Date format
#
#
#
This program code selects the format of the date for display, date entry, and logging purposes. Selections are indicated in the table. Displayed / printed ranges are: month - 01 to 12, day - 01 to 31, year - 00 to 99.
mm/dd/yy dd/mm/yy yy/mm/dd
040 Decimal separator
This program code selects the character used to separate the whole part and fractional part of a real number.
#
# ,
.
<dot>
<comma>
039 Date separator
This program code selects the character used to separate the month, day, and year components of the date.
#
#
# -
.
/ <slash>
<dot>
<hyphen>
041 Display data rate
This program code selects the rate that data is transferred from the processor to the local and remote display panels. Data to / from the display panel is on a dedicated RS-422 serial link. This link is normally operated at 28800 bps. If data errors are observed, the data speed may be reduced. Operation at reduced data speed should only be necessary in cases where a display panel is located a long distance from the CPU board.
Program Code Definitions (023 to 047 Unit Parameters) ______________________________________________ Section 6 - 29
________________________________________________________________________________________ DanLoad 6000 (v6.00)
6.4
Unit Parameters (continued)
Function Range <Default> OR Option (* = Default)
042 Transaction #
043 Batch #
044 Additive units
045 Round method
0 to 9999 <9999>
0 to 9999 <9999>
0 cc *
1 in3
2 Gal
3 L
0 Trunc
1 Up *
2 Up/odd
046 Density/gravity scale 1 to 4 <4>
047 Batches/transaction 0 to 10000 <0>
Program Code Definitions (023 to 047 Unit Parameters) ______________________________________________ Section 6 - 30
________________________________________________________________________________________ DanLoad 6000 (v6.00)
6.4
Unit Parameters (continued)
042 Transaction #
This program code indicates the sequence number of the current active transaction if one is in progress. If a transaction is not currently in progress, this parameter indicates the sequence number of the last completed transaction.
043 Batch #
This program code indicates the sequence number of the current batch loading operation if one is in progress. If a batch loading operation is not currently in progress, this parameter indicates the sequence number of the last completed batch loading operation.
044 Additive units
#
#
This program code selects the engineering units for display and printout of additive injection volumes. (Internal engineering units depend on the configured additive injection method.) cc 0.0 to 9999999.99 cubic centimeters in3 0.0 to 9999999.99 cubic inches
Internal calculation:
Vol(in3) = Vol(cc) / 16.387064
# Gal 0.0 to 99999.9999 US gallons
Internal calculation:
Vol(Gal) = Vol(cc) / 3785.412
# L 0.0 to 99999.9999 liters
Internal calculation:
Vol(L) = Vol(cc) / 1000
Program Code Definitions (023 to 047 Unit Parameters) ______________________________________________ Section 6 - 31
________________________________________________________________________________________ DanLoad 6000 (v6.00)
6.4
Unit Parameters (continued)
045 Round method
This program code selects the method for rounding the displayed and printed meter and component quantities to whole numbers.
# Trunc, i.e. truncate
Discard accumulated fractions (tenths) of a quantity.
# Up
IF fractional accumulation is GREATER THAN OR
EQUAL TO xxxxx.5, add 1 to the whole units accumulation and discard the fractional accumulation.
# Up/odd
IF whole units accumulation is even AND IF fractional
(tenths) accumulation is GREATER THAN xxxxx.5, add 1 to the whole units accumulation. IF whole units accumulation is odd AND IF fractional (tenths) accumulation is GREATER THAN OR EQUAL TO xxxxx.5, add 1 to the whole units accumulation.
046 Density/gravity scale
This program code defines the number of decimal places to use when displaying and printing density or gravity.
3
4
1
2
Value Format Typical Use xxxx.x density in kg/m 3 xxx.xx API gravity xx.xxx
gravity
Warning
The density /gravity (program code 46) scale must be entered appropriately for the density/gravity units and CTL/SPL options being used.
This must be set carefully since the density/gravity scale is also used for mass computation. See Mass adjustment (program codes
068 / 071 / 074 / 077).
Program Code Definitions (023 to 047 Unit Parameters) ______________________________________________ Section 6 - 32
________________________________________________________________________________________ DanLoad 6000 (v6.00)
6.4
Unit Parameters (continued)
047 Batches/transaction
This program code defines the maximum number of batches that can be grouped into each transaction. The message “Maximum
batches on transaction” is displayed when an attempt is made to enter the preset quantity for a further batch. The default value 0 indicates that the number batches per transaction is unlimited.
Program Code Definitions (023 to 047 Unit Parameters) ______________________________________________ Section 6 - 33
________________________________________________________________________________________ DanLoad 6000 (v6.00)
6.5
Valve Parameters
Function
048 Number of valves
049 Initial flow time (s)
Range <Default> OR Option (* = Default)
1 to 4 <1>
0 to 9.999 < 0.200>
Valve Parameters select the configuration of the flow control valves.
048 Number of valves
This program code sets the number of flow control valves in the system. A minimum of one flow control valve must be defined.
049 Initial flow time (s)
This program code defines the time (in seconds) during which each flow control valve remains in its initial state as defined by its Open method (program codes 115 / 119 / 123 / 127).
Program Code Definitions (048, 049 Valve Parameters) _______________________________________________ Section 6 - 34
________________________________________________________________________________________ DanLoad 6000 (v6.00)
CONTINUE
Program Code Definitions (048, 049 Valve Parameters) _______________________________________________ Section 6 - 35
________________________________________________________________________________________ DanLoad 6000 (v6.00)
6.6
Meter Parameters
PC# / Function
(Four Meters)
050 Number of meters
051 / 054 / 057 / 060 Meter ID
052 / 055 / 058 / 061 Valve
053/056/059/062 Side Stream Meter (Ethanol
Meter)
063 Midgrade Primary blend stream meter
(Midgrade Gasoline Meter)
Range <Default> OR Option (* = Default)
1 to 4 <1>
5 characters <M1>
1 to “number of valves”
<depends on initial setup choices>
0 to 4 < 0 >
0 No Side Stream meter
0 to 4 < 0 >
0 No Side Stream meter
Program Code Definitions (050 to 063 Meter Parameters) _____________________________________________ Section 6 - 36
________________________________________________________________________________________ DanLoad 6000 (v6.00)
6.6
Meter Parameters (continued)
Meter Parameters contain data which defines from one to four flow meters. The first parameter in the group, program code 050
Number of meters, sets the total number of component flow meters in the system. Additive meters are configured separately.
The remaining parameters are organized in groups related to each flow meter.
050 Number of meters
This program code sets the total number of flow meters used in the system. A minimum of one flow meter must be defined.
051 / 054 / 057 / 060 Meter ID
This program code identifies the flow meter for display and logging purposes.
052 / 055 / 058 / 061 Valve
This program code identifies the flow control valve that controls flow through this meter. Note that two meters can use the same flow control valve.
053 / 056 / 059 / 062 "Side" Stream Meter (Ethanol Meter)
These program codes specify the meter number used as a Side
Stream Meter.
For example, assume meter 1 as the primary premium blend stream meter used for loading Premium and measures the blend of Premium and Ethanol. Meter 2 as the primary regular blend stream meter used for loading Regular and measures the blend of
Regular and Ethanol. Meter 3 as the side stream meter for measuring the Ethanol component volume.
Program Code Definitions (050 to 063 Meter Parameters) _____________________________________________ Section 6 - 37
________________________________________________________________________________________ DanLoad 6000 (v6.00)
6.6
Meter Parameters (continued)
Program code 053, 056, 059, and 062 correspond respectively to preset meters 1, 2, 3, and 4 set in PC 051, 054, 057, and 060. In the above example meter 1 (PC 051) measures the combined blend volume of both the Premium component and the Ethanol component, and meter 2 (PC 054) measures the combined blend volume of both the Regular component and the Ethanol component, Meter 3 (PC 057) measures only the Ethanol volume.
As an example, the user sets program code 053 = 3, 056 = 3, and
059=0. This configuration indicates that the Ethanol measured by
Meter 3 is passing through the Premium meter 1 (053) and through the Regular meter 2 (056). Meter 3 (059) is not being used to measure a final delivered flow, however the volume being measured by meter 3 flows though meter 1 or meter 2.
063 Midgrade Primary blend stream meter (Midgrade
Gasoline Meter)
This program code defines the meter number where the side stream (Ethanol stream) passes through in case of more than two product blending.
Note: This program code is applicable only when DanLoad 6000 is configured for inline blending.
For example, meter 1 is for Premium, meter 2 is for Regular and meter 3 is for Ethanol. Set program code value to 1 if the
Premium meter (meter 1) is used to pass the Ethanol for
Midgrade product (Blending of Premium, Regular and Ethanol)
Program Code Definitions (050 to 063 Meter Parameters) _____________________________________________ Section 6 - 38
________________________________________________________________________________________ DanLoad 6000 (v6.00)
6.7
Component Parameters
PC # / Function
(Four Components)
Range <Default> OR Option (* = Default)
065 Number of components
066 / 069 / 072 / 075 Component ID
1 to 4 <1>
16 characters <Component #1>
067 / 070 / 073 / 076 Meter 0 to number of meters <depends on choices made during initial setup>
068 / 071 / 074 / 077 Mass adjustment 0.000000 to 999.999999 <0.000000>
Program Code Definitions (065 to 077 Component Parameters) ________________________________________ Section 6 - 39
________________________________________________________________________________________ DanLoad 6000 (v6.00)
6.7
Component Parameters (continued)
Component Parameters contain data which defines from one to four liquid components. The first parameter in the group, program code program code 065 Number of components, sets the total number of components for the system. The remaining parameters are organized in groups of three parameters related to each component.
065 Number of components
This program code sets the number of liquid components used in the system. A minimum of one component must be defined.
066 / 069 / 072 / 075 Component ID
This program code identifies the component for display and logging purposes. For example, during delivery of a sequential blend, the component currently being loaded is displayed.
067 / 070 / 073 / 076 Meter
This program code identifies the flow meter (1 to 4) used to measure this component. The entry of a zero (0) disables the component, making it unavailable for loading. In a sequential blending application, all components flow through the same meter, one at a time.
068 / 071 / 074 / 077 Mass adjustment
This program code sets the component’s “mass computation adjustment” factor (1) such that:
Mass = Std volume x (Density - Buoyancy) x 1
Warning
Whereas the standard volume is typically similar in magnitude to the gross volume, i.e. a similar number of units, the mass may be substantially different from either. Thus, when preset/delivery is by mass (program code 80), it is recommended that several
"small" batches be loaded to ensure that the DanLoad 6000's configuration is correct before attempting to preset a full compartment.
Program Code Definitions (065 to 077 Component Parameters) ________________________________________ Section 6 - 40
________________________________________________________________________________________ DanLoad 6000 (v6.00)
6.7
Component Parameters (continued)
Zero disables mass computation. A non-zero value causes the "standard quantity", i.e. the meter, component, batch and running totalizer standard quantities, to be computed as mass (using the formula above) rather than standard (temperature and/or pressure corrected) volume.
Note: The "meter X std load quantity to 2 decimal places" (data codes 147, 148, etc. per meter) is "std volume" even if the DanLoad 6000 is configured to compute mass. If the preset/delivery type (program code 80) is "Std" and there is more than one standard product unit per gross product unit, i.e. if mass is larger than volume in magnitude, then the low flow stop quantity (program code 86, etc. per component) may need to be increased (because the low flow stop quantity is gross or standard quantity depending on the preset/delivery type). The default mass computation adjustment factor is 0.000000. (Buoyancy is configured via program code 426.)
Some example mass computation adjustment factors are:
Required
Mass
Units
Vol
Units per K-Factor
Dens
Units
1 kg kg kg kg kg
L @T
L @T
L @15°C
L @60°F
L @60°F r.d. 15°C/4°C r.d. 60°F/60°F
°API
0.001000
1.000000
1.000000
0.999012
(141.5 x 0.999012) / ((°API - Buoyancy) x (°API - Buoyancy + 131.5)), i.e. a function of the API gravity, e.g. 0.013817 (rounded) for
55.00°API
8.337161 (rounded) lb ton
U.S. Gal @60°F
L @T r.d. 60°F/60°F
0.001000 ** WARNING: DL6000 6000 WILL ROUND TO WHOLE TONS! **, e.g. 5000
L
/
4 tons
0.000001 ** WARNING: DL6000 6000 WILL ROUND TO WHOLE TONS! ** ton L @T
For example, if your K-Factor is for U.S gallons, your density is in relative density 60°F/60°F and you wish to compute mass in lbs, configure the component’s s
to 8.337161.
Program Code Definitions (065 to 077 Component Parameters) ________________________________________ Section 6 - 41
________________________________________________________________________________________ DanLoad 6000 (v6.00)
6.8
Delivery Parameters
PC # / Function
(Four Components)
078 Maximum preset qty
079 Minimum preset qty
080 Preset/delivery type
081 Delivery display type
082 Stop key action
083 Fall back qty
084 / 090 / 096 / 102 Low flow start qty
085 / 091 / 097 / 103 Low flow restart qty
086 / 092 / 098 / 104 Low flow stop qty
087 / 093 / 099 / 105 Line pack delay (s)
088 / 094 / 100 / 106 Pump stop delay (s)
089 / 095 / 101 / 107 Block valve delay (s)
Range <Default> OR Option (* = Default)
5 to 999999 <3000>
0 to 999999 <50>
0 Gross *
1 Std
0 Gross *
1 Std
0 Low flow *
1 Immediate
0 to 99999 <1000>
0 to 99999 <50>
0 to 99999 <20>
0 to 99999 <50>
0 to 99999 <2>
0 to 999 <30>
0 to 99 <0>
Program Code Definitions (188 to 111 Delivery Parameters) ___________________________________________ Section 6 - 42
________________________________________________________________________________________ DanLoad 6000 (v6.00)
6.8
Delivery Parameters (continued)
Delivery Parameters contain data which define the batch delivery characteristics. The first six parameters in the group, program code 078 to 083 are global parameters that are applicable to all batch deliveries. The remaining parameters are organized in groups of six parameters related to each component. Delivery
Parameters provide a unique profile for fine tuning the delivery of each component.
078 Maximum preset qty
This program code sets the maximum quantity (gross or standard, depending on the preset/delivery type), that can be preset in a single batch. This must be greater than or equal to the minimum preset quantity, program code 079.
079 Minimum preset qty
This program code sets the minimum quantity (gross or standard, depending on the preset/delivery type), that can be delivered in a single batch. A batch cannot be started or restarted if the remaining quantity is less than the minimum preset quantity.
This must be less than or equal to the maximum preset quantity, program code 078 Maximum preset qty. The default value is 50.
The special value zero (0) bypasses preset quantity entry, i.e. the maximum preset quantity is entered automatically when a batch is authorized, and the operator need only press "START" to start the batch; the operator should press "STOP" followed by
"ALT"+"ENTER" (within one second) in order to enter program mode. The special value one (1) suggests, i.e. automatically pretypes in large digits, the maximum preset quantity as the preset quantity, and the operator can press "ENTER" to preset the maximum preset quantity or "CLEAR" to enter a smaller preset quantity.
Program Code Definitions (188 to 111 Delivery Parameters) ___________________________________________ Section 6 - 43
________________________________________________________________________________________ DanLoad 6000 (v6.00)
6.8
Delivery Parameters (continued)
It is possible to preset and deliver by gross quantity, but to display "Loaded" by gross or standard quantity. Similarly, it is possible to preset and deliver by standard quantity, but to display
"Loaded" by gross or standard quantity. However, the
"Remaining" quantity is always the preset quantity minus the loaded quantity (gross or standard). This is controlled by the following two program codes.
080 Preset/delivery type
This program code selects the quantity used for preset, loaded, and remaining quantities. Ramp up to high flow rate is always based on gross quantity. Ramp down to low flow rate and flow control valve closure is based on the quantity specified by this parameter.
# Gross
Delivered quantity based on gross quantity calculation.
# Std
Delivered quantity based on standard quantity calculation, i.e. net volume or mass.
081 Delivery display type
This program code selects the quantity used for display purposes.
# Gross
Display quantity based on gross quantity calculation.
# Std
Display quantity based on standard quantity calculation.
Program Code Definitions (188 to 111 Delivery Parameters) ___________________________________________ Section 6 - 44
________________________________________________________________________________________ DanLoad 6000 (v6.00)
6.8
Delivery Parameters (continued)
082 Stop key action
This program code selects the method used to suspend a batch delivery operation after the STOP key is pressed. (Note: The
STOP key function should not be used for an emergency shutdown because the power to the permissive circuits is not removed by this function.)
# Low flow
Ramp to low flow rate before finally closing the flow control valve to stop all flow while keeping the pump running. This method of shutdown prevents hydraulic shock in the piping system. (Note: The 086 / 092 / 098
/ 104 Low flow stop qty is not delivered during this method of shutdown.)
# Immediate
Close the flow control valve and stop the pump immediately. This method of shutdown may cause hydraulic shock in the piping system.
083 Fall back qty
This program code sets the quantity (gross or standard, depending on the unit type and preset/delivery type), to deliver at a fall back flow rate before the DanLoad 6000 attempts to ramp up flow rate to the next higher flow rate, i.e. recovery from fall back. A fall back quantity greater than or equal to the maximum preset quantity (largest batch) disables this feature.
Preset/delivery type:
Gross
Preset/delivery type:
Standard
Sequential
Unit type
In-line
Unit type
Recovery from fall back is by gross quantity
Recovery from fall back is by gross quantity
Recovery from fall back is by standard quantity
Recovery from fall back is by gross quantity
084 / 090 / 096 / 102 Low flow start qty
This program code sets the quantity to deliver before controlling the flow control valve to increase the flow rate to the high flow rate.
Program Code Definitions (188 to 111 Delivery Parameters) ___________________________________________ Section 6 - 45
________________________________________________________________________________________ DanLoad 6000 (v6.00)
6.8
Delivery Parameters (continued)
085 / 091 / 097 / 103 Low flow restart qty
This program code sets the quantity to deliver before controlling the flow control valve to increase the flow rate to the high flow rate after restarting a suspended batch delivery and after the initial program code 084 / 090 / 096 / 102 Low flow start volume has been delivered. The default value is 20 units. Can also be used for multiple component sequential blending applications; see program code 219.
087 / 093 / 099 / 105 Line pack delay (s)
This program code sets the time between starting the pump for this component and opening the flow control valve when a batch is started or restarted. The default value is 2 seconds.
088 / 094 / 100 / 106 Pump stop delay (s)
This program code sets the time between terminating flow through the meter and de-energizing the pump for this component.
086 / 092 / 098 / 104 Low flow stop qty
This program code sets the quantity (gross or standard depending on the preset/delivery type) to deliver at the low flow rate or stop rate before all flow is stopped. The default value is 50 units.
(Note: If this quantity is set to a very low value, the DanLoad
6000 may not be able to stabilize the flow rate during delivery of the Low flow stop quantity. If this happens, the control value closure quantity cannot be accurately computed and the preset
target volume will be missed.) It should be remembered that flow control valves that operate using line pressure typically close more slowly when line pressure is low.
089 / 095 / 101 / 107 Block valve delay (s)
This program code sets the time between opening the component block valve and opening the component flow control valve during startup. The component block valve is closed after flow has been terminated by the flow control valve, or when a primary alarm is raised.
Program Code Definitions (188 to 111 Delivery Parameters) ___________________________________________ Section 6 - 46
________________________________________________________________________________________ DanLoad 6000 (v6.00)
CONTINUE
Program Code Definitions (188 to 111 Delivery Parameters) ___________________________________________ Section 6 - 47
________________________________________________________________________________________ DanLoad 6000 (v6.00)
6.8
Delivery Parameters (continued)
PC # / Function
108 Ramp clicks
109 Maintenance clicks
110 Additive pump stop (s)
111 Primary component
Range <Default> OR Option (* = Default)
0 to 999 <30>
0 to 999 <30>
0 to 9999 <10>
1 to 4 <1>
Program Code Definitions (188 to 111 Delivery Parameters) ___________________________________________ Section 6 - 48
________________________________________________________________________________________ DanLoad 6000 (v6.00)
6.8
Delivery Parameters (continued)
108 Ramp clicks
This program code selects the maximum number of attempts
(flow control valve solenoid clicks) to increase flow rate to a higher flow rate before halting attempts and maintaining current or fall back flow rate.
111 Primary component
This program code defines (by component number) the primary component of a blend which is used to determine a blend error if the Blend error method (program code 722) is Grsqtydiff or
Stdqtydiff. In this case there must be a non-zero percentage of the primary component in every recipe. This program code is also used for line flushing at the end of a delivery, in which case the highest octane component is usually defined to be the primary component.
109 Maintenance clicks
This program code selects the maximum number of attempts
(flow control valve solenoid clicks) to maintain flow rate before halting attempts and going to a lower “fall back” flow rate.
110 Additive pump stop (s)
This program code selects the time delay between the load stop and deenergizing the additive pump outputs (program code 800
/ 802 / 804 / 806 / 808 / 810 Pump output).
Program Code Definitions (188 to 111 Delivery Parameters) ___________________________________________ Section 6 - 49
________________________________________________________________________________________ DanLoad 6000 (v6.00)
6.9
Digital Valve Parameters
PC # / Function
(Four Digital Valves)
112 / 116 / 120 / 124 Low flow % error
113 / 117 / 121 / 125 High flow % error
114 / 118 / 122 / 126 Maint click adjustment
115 / 119 / 123 / 127 Open method
Range <Default> OR Option (* = Default)
2 to 10 <5>
2 to 10 <2>
0.000 to 0.500 <0.040>
0 Normal *
1 Opened
2 Closed
Program Code Definitions (112 to 127 Digital Valve Parameters) ______________________________________ Section 6 - 50
________________________________________________________________________________________ DanLoad 6000 (v6.00)
6.9
Digital Valve Parameters (continued)
Digital Valve Parameters contain data which defines the method for controlling the operation of digitally operated flow control valves. The parameters are organized in groups of four parameters related to each digital flow control valve.
Digital Valve Parameters are not applicable to other types of flow control valves selected by program code 027 Valve type.
112 / 116 / 120 / 124 Low flow % error
This program code sets the percentage of difference in the actual low flow rate and the programmed low flow rate (setpoint) allowed before a flow rate adjustment command is sent to the flow control valve. This program code defines the deadband and is only in effect when the low flow rate is established and not in effect when the flow rate is changing to the low flow rate during startup or shutdown. The suggested value is 5 percent. Higher values may affect measurement accuracy since the flow rate will be allowed to vary over a wider range without being controlled.
113 / 117 / 121 / 125 High flow % error
This program code sets the percentage of difference in the actual high flow rate and the programmed high flow rate (setpoint) allowed before a flow rate adjustment command is sent to the flow control valve. A “high flow rate” is any flow rate greater than the low flow start rate or the stop rate. This program code defines the deadband and is only in effect when the high flow rate is established and not in effect when the flow rate is increasing to the high flow rate setpoint during startup. The suggested value is 2 percent. Higher values may affect measurement accuracy since the flow rate will be allowed to vary over a wider range without being controlled.
WARNING
Increasing the low or high flow deadbands may reduce measurement accuracy since product may not flow out at the same flow rate each time a batch is loaded.
Program Code Definitions (112 to 127 Digital Valve Parameters) ______________________________________ Section 6 - 51
________________________________________________________________________________________ DanLoad 6000 (v6.00)
6.9
Digital Valve Parameters (continued)
114 / 118 / 122 / 126 Maint click adjustment (s)
This program code sets the time that is added to the “base” times that the valve control solenoids are “toggled on” (to increase the flow rate) and “toggled off” (to decrease the flow rate) during flow rate maintenance. The base times are 20 milliseconds to increase the flow rate and 40 milliseconds to decrease the flow rate. The default value is 0.040 seconds, i.e. 60 milliseconds to increase the flow rate and 80 milliseconds to decrease the flow rate. Decrease this value if flow-rate maintenance adjustments cause the flow rate to oscillate above and below the required flow rate. Increase this value if flow-rate maintenance adjustments do not significantly change the flow rate. Use increments of 0.01
seconds, i.e. 10 milliseconds.
115 / 119 / 123 / 127 Open method
This program code sets the method for controlling the flow control valve during the time specified by program code 049
Initial flow time. (Note: This feature is intended for use in multi- component blending systems. The purpose is to allow a component with low pumping pressure to start flowing before other components with higher pumping pressure.)
# Normal
Flow control valve solenoid 2 is energized during program code
049 Initial flow time. (Note: The flow control valve may or may not “crack open” during the initial flow time depending on the orifice sizes exposed by solenoids 1 and 2, and the upstream pressure provided by the pump.)
# Opened
Flow control valve solenoid 1 and solenoid 2 are energized during program code 049 Initial flow time. (Note: The component flows during the initial flow time as the valve tries to become fully open.)
Program Code Definitions (112 to 127 Digital Valve Parameters) ______________________________________ Section 6 - 52
________________________________________________________________________________________ DanLoad 6000 (v6.00)
6.9
Digital Valve Parameters (continued)
# Closed
Flow control valve solenoid 1 and solenoid 2 are deenergized during program code 049 Initial flow time. (Note: The component does not flow during initial flow time. This effectively increases the line-pack delay. See program codes 087 / 093 / 099
/ 105.)
Program Code Definitions (112 to 127 Digital Valve Parameters) ______________________________________ Section 6 - 53
________________________________________________________________________________________ DanLoad 6000 (v6.00)
6.10
Pulse Per Unit Outputs
PC # / Function Range <Default> OR Option (* = Default)
128 Number of pulse per unit outputs 0 to 2 <2> for sequential unit type
<0> for in-line unit type
129 / 132 Control meters 4 characters <GXXX>
(Only G, S and X are valid)
130 / 133 Factor
131 / 134 Pulse width (ms)
0.1 to 10.0 <1.0>
10 to 87 <20>
Program Code Definitions (128 to 134 Pulse per Unit Outputs) _________________________________________ Section 6 - 54
________________________________________________________________________________________ DanLoad 6000 (v6.00)
6.10
Pulse Per Unit Outputs (continued)
Pulse Per Unit Outputs contains data which define the method of processing pulsed outputs for each measured product. The first parameter in the group, program code 128 Number of pulse per
unit outputs, sets the number of pulse per unit outputs that are assigned to discrete outputs (program codes 313 and 314). The remaining parameters are organized in groups of three parameters related to each pulse per unit output. Each output can be setup to provide different outputs derived from the flow measured through different flow meters and with different scaling.
128 Number of pulse per unit outputs
This program code sets the total number of pulse per unit outputs.
(Note: If more than 2 pulse per unit outputs are needed, the additive ratio outputs: program code 380 / 383 / 386 / 389 / 392
/ 395 Ratio output with the corresponding program code 140 /
145 / 150 / 155 / 160 / 165 Ratio qty set to 1.0 can be used for this purpose.)
129 / 132 Control meters
This program code selects the flow meter or combination of flow meters and either the gross or standard quantities to drive this output. Access to internal accumulators for flow meters is assigned by a one to four character string, one character position for each flow meter, i.e. the first character specifies the accumulator for meter 1, the second character specifies the accumulator for meter 2, etc. The selections for each position in the string are X, G or S using alphanumeric string-type entry.
# X Flow through this meter is not used for determining the control quantity.
# G Use the gross quantity through this meter for determining the control quantity.
# S Use the standard quantity through this meter for determining the control quantity.
Program Code Definitions (128 to 134 Pulse per Unit Outputs) _________________________________________ Section 6 - 55
________________________________________________________________________________________ DanLoad 6000 (v6.00)
6.10
Pulse Per Unit Outputs (continued)
# Example: SXGS
The example shows four character positions which indicates that four flow meters are defined. The number of character positions in the string is automatically set to the number of defined flow meters (program code 050
Number of meters). The 'SXGS' selections specify the following quantity sum (combination) is used to drive the assigned discrete output.
meter 1 standard + meter 3 gross + meter 4 standard, do not sum quantity from meter 2
131 / 134 Pulse width (ms)
This program code sets the duration of output ON pulse in ten millisecond increments. The OFF time is equal to or greater than the ON time. The default pulse width is 20 milliseconds (20 milliseconds ON / at least 20 milliseconds OFF, a 40 millisecond minimum period which allows a maximum of 25 pulses per second).
20 ms 20 ms
130 / 133 Factor
This program code sets the scale factor for the corresponding output. A factor of 1.0 causes the output to be pulsed for each accumulated unit of product. A factor of 0.1 causes the output to pulse for each one-tenth of an accumulated unit of product. A factor of 10.0 causes the output to pulse one time for each ten accumulated units of product.
=20 ms =20 ms =20ms
Program Code Definitions (128 to 134 Pulse per Unit Outputs) _________________________________________ Section 6 - 56
________________________________________________________________________________________ DanLoad 6000 (v6.00)
CONTINUE
Program Code Definitions (128 to 134 Pulse per Unit Outputs) _________________________________________ Section 6 - 57
________________________________________________________________________________________ DanLoad 6000 (v6.00)
6.11
Additive Delivery Parameters
PC # / Function
(Six Additives)
135 Number of additives
136 Selection method
137 Inject Percentage
138 Clean line qty
Range <Default> OR Option (* = Default)
0 to 6 <0>
0 External *
1 Prompt
2 Inputs
3 Recipe
4 Multi Rate
0 to 100 <50>
0 to 9999 <0>
Program Code Definitions (135 to 168 Additive Delivery Parameters) ___________________________________ Section 6 - 58
________________________________________________________________________________________ DanLoad 6000 (v6.00)
6.11
Additive Delivery Parameters (continued)
PC # / Function
(Six Additives)
Range <Default> OR Option (* = Default)
139 / 144 / 149 / 154 / 159 / 164 Additive control meters
140 / 145 / 150 / 155 / 160 / 165 Ratio qty
141 / 146 / 151 / 156 / 161 / 166 Injection Method
4 characters <GGGG>
(only G, S and X are valid)
1 to 9999 <40>
0 Mech *
1 Handshake
2 Meter
3 Control
142 / 147 / 152 / 157 / 162 / 167 Volume/pulse or K-factor 0.00 to 9999.99
<0.00>
143 / 148 / 153 / 158 / 163 168 Additive per 1000 0.0000 to 999999.9999
<0.0000>
Program Code Definitions (135 to 168 Additive Delivery Parameters) ___________________________________ Section 6 - 59
________________________________________________________________________________________ DanLoad 6000 (v6.00)
6.11
Additive Delivery Parameters (continued)
Additive Delivery Parameters contains data which define automatic control injection of up to six additives into the delivered product stream. The first four parameters in the group, program code 135, 136, 137, and 138, define values and selections that are applicable to all additive deliveries. The remaining parameters are organized in groups of five parameters related to each additive.
135 Number of additives
This program code sets the number of logical additives to be controlled and/or measured. There may be one or more logical additives for each physical additive or additive injector. Each logical additive has its own batch and running totalizers that can be displayed in the dynamic data display or printed on various data logs.
136 Selection method
This program code selects the method for selecting additives while in the manual mode or if not overridden in the automatic mode. (Note: Additives can be selected by the Terminal
Automation System via the Authorize Transaction command while in the automatic mode. Refer to the Danload 6000
Communications Specification)
# External
All configured (“Number of additives”) additive ratio outputs are cycled. An additive can be selected by an external contact, e.g. an automation system relay or a key switch can close the circuit from the additive ratio output to the injector.
# Prompt
The local operator is prompted, via the Additive selection
display prior to the start of each transaction, to select the additives to be injected.
Program Code Definitions (135 to 168 Additive Delivery Parameters) ___________________________________ Section 6 - 60
________________________________________________________________________________________ DanLoad 6000 (v6.00)
6.11
Additive Delivery Parameters (continued)
# Inputs
Configured (“Number of additives”) additive ratio outputs are cycled only if their corresponding additive selection inputs are closed during a batch.
The default value is “External”. The decimal equivalent of the additive “bit map” for the “Recipe” and “Multi Rate” selection methods is computed by adding together the appropriate values from the right-hand column of the following table:
#
#
Recipe
The additives specified by the last two characters of the recipe name, entered as the 2-digit decimal equivalent of an additive “bit map” (see below), are selected automatically. Multiple additives can be selected per recipe. The ratio quantity defined in the additive delivery parameters is used.
Multi Rate
Additive #
1
2
3
4
5
6
Value
1
2
4
8
16
32
The additives specified by the last two characters of the recipe name, entered as the 2-digit decimal equivalent of an additive “bit map” (see below), are selected automatically. Multiple additives can be selected per recipe. The ratio quantity defined in the recipe parameters (component 4 percentage) is used. For multiple rates per injector, see Section 3.10.5 for further explanation.
For example, if additive 3 is to be injected in recipe 1, then 04 should be entered as the last two characters of recipe 1's name
(program code 481). For additives 2 and 4, 10 would be entered as the last two characters.
Program Code Definitions (135 to 168 Additive Delivery Parameters) ___________________________________ Section 6 - 61
________________________________________________________________________________________ DanLoad 6000 (v6.00)
6.11
Additive Delivery Parameters (continued)
137 Inject Percentage
This program code selects the percentage of the adjusted additive ratio cycle at which injection begins, i.e. the ratio output is switched on. For the “Mech”, “Handshake” and “Meter” injection methods, injection ends, i.e. the ratio output is switched off, after 50% of the adjusted additive ratio quantity has been delivered. For the “Control” injection method, injection ends, i.e.
the ratio output is switched off, when the appropriate quantity of additive for the ratio cycle has been metered. The default value is 50.
Setting the inject percent to 100 and the injection method
(program code 141, etc.) to “Handshake” implements the “inject after ratio quantity” control sometimes required for mercaptan injection.
138 Clean line qty
This program code sets the additive clean line quantity, i.e. the gross or standard quantity (depending on the configured preset/delivery type) of product delivered prior to the end of a batch during which no additive injection takes place, so that the next batch is not contaminated with the previous batch’s additive.
This value should be at least as large as the volume of the pipe and loading arm between the point where additive is injected and the connection to the vehicle.
For example, if the additive ratio quantity is 40 and the clean line quantity is 50, then for a preset quantity of 1000 the additive ratio quantity is adjusted to 38 so that the required 25 injection cycles are completed with 50 units of product remaining to be delivered.
Program Code Definitions (135 to 168 Additive Delivery Parameters) ___________________________________ Section 6 - 62
________________________________________________________________________________________ DanLoad 6000 (v6.00)
6.11
Additive Delivery Parameters (continued)
139 / 144 / 149 / 154 / 159 / 164 Additive control meters
This program code identifies the product flow meters whose measured quantities are used to control additive injection cycles based on the additive’s ratio quantity. Flow meters are designated by relative character positions in a one to four-character alpha string (one character position for each configured flow meter).
# X Flow through this meter is not used for determining the control quantity.
# G Use the gross quantity through this meter for determining the control quantity.
# S Use the standard quantity through this meter for determining the control quantity.
Example: SXGS
The example shows four character positions which indicates that four flow meters are defined. The number of character positions in the string is automatically set to the number of defined flow meters (program code 050
Number of meters). The 'SXGS' selections specify the following quantity sum (combination) is used to drive the assigned additive injection output.
meter 1 std + meter 3 gross + meter 4 std, do not sum quantity from meter 2
Program Code Definitions (135 to 168 Additive Delivery Parameters) ___________________________________ Section 6 - 63
________________________________________________________________________________________ DanLoad 6000 (v6.00)
6.11
Additive Delivery Parameters (continued)
140 / 145 / 150 / 155 / 160 / 165 Ratio qty
The quantity (possibly a combination of gross and/or standard quantities through multiple component meters) in product units
(program code 29) which controls one additive injection cycle.
The default value is 40 which is suitable when the product units are gallons. A value of 100 or 150 is suitable when the product units are liters.
141 / 146 / 151 / 156 / 161 / 166 Injection Method
The first two injection methods ("Mech" and "Handshake") totalize additive based on a volume per pulse, and their internal and "Control") totalize additive using an additive meter K-factor, and their internal additive units are the configured product units
(program code 29). For all four injection methods, the DanLoad
6000 converts additive volumes from internal units to external units (program code 44) for display and printing. Since the injection method is configured per additive (program codes 141,
146, etc.), one additive can be injected via a simple mechanical injector ("Mech") while another can be injected and measured via an additive panel ("Control"). The default value is “Mech”.
Select one of the following:
#
#
Mech
Additive injection via a mechanical injector (fixed dose per ratio cycle) with feedback. The DanLoad 6000 controls the ratio output (if configured) and totalizes additive using the volume per pulse on input (if a feedback input is configured) or on output (if not).
Additive verification is based on the configured required number of feedback pulses per ratio cycle (program code
247) and the configured additive error limit (program code 246).
Handshake
Additive injection via a handshake cycle for (mercaptan).
The DanLoad 6000 controls the ratio output (if configured) based on the ratio cycle and the feedback input, and totalizes additive using the volume per pulse on input. Additive verification is based on one feedback pulse per ratio cycle, the configured additive error limit
(program code 246) and the configured additive feedback count (program code 247) which is interpreted as a number of seconds.
Program Code Definitions (135 to 168 Additive Delivery Parameters) ___________________________________ Section 6 - 64
________________________________________________________________________________________ DanLoad 6000 (v6.00)
6.11
Additive Delivery Parameters (continued)
# Meter
Additive injection via a mechanical injector (fixed dose per ratio cycle) with additive meter. The additive meter should be upstream of the injector cylinder. The
DanLoad 6000 controls the ratio output (if configured) and totalizes additive using the additive K-factor on input
(if a feedback input is configured). Additive verification is based on the volume of additive per 1000 of product (if configured) and the additive per 1000 error limit (program code 278).
# Control
Additive control via an on/off valve (variable dose per ratio cycle) with additive meter. The DanLoad 6000 controls (by manipulating the on/off valve) the volume of additive per ratio cycle (unlike the other injection methods) and totalizes additive using the additive Kfactor on input (if a feedback input is configured).
Additive dose per ratio cycle and verification is based on the volume of additive per 1000 of product and the additive per 1000 error limit (program code 278). The volume of additive per 1000 of product must be configured for the "Control" injection method.
Program Code Definitions (135 to 168 Additive Delivery Parameters) ___________________________________ Section 6 - 65
________________________________________________________________________________________ DanLoad 6000 (v6.00)
6.11
Additive Delivery Parameters (continued)
142 / 147 / 152 / 157 / 162 / 167 Volume/pulse or K-factor
This program code is used for totalizing additive (both authorized and unauthorized additive flow). This is in “internal additive units”. For the “Mech” and “Handshake” injection methods it is injection methods, it is the additive meter’s K-factor, i.e. pulses per product unit (Product units per program code 29). An additive meter’s nominal K-factor is usually marked on the meter, and provides a good starting value. The additive meter’s actual
K-factor can be determined using the additive meter calibration screen (accessible from the Program Mode menu). Internal additive units are converted to external additive units for display, printing and communications via the configured Additive units
(program code 044).
The default value is 0.00.
143 / 148 / 153 / 158 / 163 /168 Additive per 1000
The required volume of additive (in product units specified by program code 029) per 1000 units of product. When a non-zero value is configured, the DanLoad 6000 verifies that the volume of additive is within limits (program codes 272, 273 and 278) during a batch and calculates the actual percentage of the required additive per 1000 continuously throughout a batch (data code 239 for additive 1, etc.). Thus, “additive volume verification” can be enabled independently of the additive injection method (program codes 141, 146, etc.). An additive failure alarm is raised if the measured volume of additive is not within limits during a batch.
This is a primary alarm which stops the batch. It is usually necessary to correct the problem, end the batch and start a new batch for the remaining quantity of product.
The default value is 0.0000.
Conversions:
1) Additive PPM = Additive per 1000 x 1000
2) Additive per 1000 = Additive PPM / 1000
Program Code Definitions (135 to 168 Additive Delivery Parameters) ___________________________________ Section 6 - 66
________________________________________________________________________________________ DanLoad 6000 (v6.00)
CONTINUE
Program Code Definitions (135 to 168 Additive Delivery Parameters) ___________________________________ Section 6 - 67
________________________________________________________________________________________ DanLoad 6000 (v6.00)
6.12
Factors
PC # / Function
(Four Components)
169 Number of factors/component
170 Meter factor method
171 / 182 / 193 / 204 Nominal K-factor
172 / 183 / 194 / 205 Master meter factor
173 / 284 / 195 / 206 Stop rate
Range <Default> OR Option (* = Default)
1 to 4 <2>
0 Fixed *
1 Linear
0.5 to 2000.0 <23.0>
0.5000 to 2.0000 <1.0000>
0 to 99999 <120>
Program Code Definitions (169 to 219 Meter Factor Parameters) _______________________________________ Section 6 - 68
________________________________________________________________________________________ DanLoad 6000 (v6.00)
6.12
Factors (continued)
Factors contains data which define the flow meter calibration characteristics for up to four components at up to four different flow rates for each component. The first two parameters in the group, program code 169 and program code 170, apply to the calculation of all factors; the remaining parameters are organized in groups of three parameters related to each defined component and groups of two parameters related to each defined flow rate for that component, thus allowing different components that flow through the same flow meter. e.g. in a sequential blending application, to have different meter factors for that meter.
This program code sets the number of meter factors, determined at different flow rates, available for each flow meter and component combination. The lowest flow rate, for low flow startup and shutdown, must be entered first
(Component # factor 1), the highest flow rate must be entered last (Component # factor 1, 2, 3, or 4).
Each configured flow rate lower than the highest flow rate can be considered to be a “fall back flow rate” if the highest flow rate cannot be achieved or maintained.
169 Number of factors/component
[Sequential unit] Number of flow rates at which to control the flow rate and to calibrate each component’s meter.
[In-line units] Number of flow rates at which to calibrate each component’s meter.
170 Meter factor method
This program code selects the method used to determine the meter factor used in the flow calculation.
Note: The Meter factor method MUST be set to “Fixed” during meter proving.
Program Code Definitions (169 to 219 Meter Factor Parameters) _______________________________________ Section 6 - 69
________________________________________________________________________________________ DanLoad 6000 (v6.00)
6.12
Factors (continued)
# Fixed
The meter factor that was determined at a flow rate that is closest to the current flow rate is used. Fixed is normally selected for digital flow control valves in single component or sequential blending loading operations.
# Linear
The meter factor is calculated by an interpolation process that uses the meter factors determined at the next highest flow rate and the next lowest flow rate from the current flow rate. A ratio between the two flow rates and the corresponding two meter factors is determined. The current meter factor is calculated assuming that the meter factor value increments are linear between the two proved meter factors and based on the current flow rate and the ratio. Linear is sometimes selected for 2-stage flow control valves or in-line blending when the meter cannot be calibrated at every possible flow rate that will be seen. However, the meter factor method must be set to “Fixed” during meter proving.
171 / 182 / 193 / 204 Nominal K-factor
This program code sets the nominal pulses per product unit received from the flow meter. The K-factor is sometimes referred to as the system factor and is usually printed on the flow meter nameplate. The default value is 23.0 which is the nominal pulses per gallon for a Daniel 4-inch diameter LR turbine meter. This entry should always be set to match the K-factor of the actual flow meter and should not be changed during meter proving. A
K-factor of at least 10 is recommended, and the meter-pulse input frequency at low flow should not be less than 40 Hz, particularly if a digital flow control valve is used.
Program Code Definitions (169 to 219 Meter Factor Parameters) _______________________________________ Section 6 - 70
________________________________________________________________________________________ DanLoad 6000 (v6.00)
6.12
Factors (continued)
172 / 183 / 194 / 205 Master meter factor
This program code sets the number used internally to verify the probability of a valid meter factor entry. All meter factors for this component must be within the ± percent (set by program code
215 Master MF %) of this value or the meter factor entry is considered to be out of range. The master meter factor is not used in flow computations.
Example: Assume program code 215 equals 2.00 (2 %). If this entry is 1.0000, acceptable meter factors for any of the corresponding program codes 175 / ... / 214 Component # meter
factor # entries are 0.9800 to 1.0200.
173 / 184 / 195 / 206 Stop rate
This program code defines the flow rate at which this component is delivered during the component’s configured low-flow stop quantity at the end of an in-line batch. Thus, the final closure of the flow control valve is always from the same flow rate so that
“valve closure averaging” will work correctly, independent of the individual component blend percentages in the recipes. This also means that the overall flow rate at the end of a batch is the sum of the stop rates of any flowing components. The default value is
120.
Program Code Definitions (169 to 219 Meter Factor Parameters) _______________________________________ Section 6 - 71
________________________________________________________________________________________ DanLoad 6000 (v6.00)
6.12
Factors (continued)
PC # /Function (Four Components)
174 / 185 / 196 / 207 Flow rate 1
175 / 186 / 197 / 208 Meter factor 1
176 / 187 / 198 / 209 Flow rate 2
177 / 188 / 199 / 210 Meter factor 2
178 / 189 / 200 / 211 Flow rate 3
179 / 190 / 201 / 212 Meter factor 3
180 / 191 / 202 / 213 Flow rate 4
181 / 192 / 203 / 214 Meter factor 4
215 Master MF %
216 Adjacent MF %
217 Gross units mnemonic
218 Std units mnemonic
219 Use restart qty
Range <Default> OR Option (* = Default)
0 to 99999 <200> per PC 215 / PC 216 <1.0000>
0 to 99999 <600> per PC 215 / PC 216 <1.0000>
0 to 99999 <0> per PC 215 / PC 216 <1.0000>
0 to 99999 <0> per PC 215 / PC 216 <1.0000>
0.00 to 99.99 <2.00>
0.00 to 99.99 <0.25>
6 characters <Gal>
6 characters <Gal>
0 No *
1 Yes
Program Code Definitions (169 to 219 Meter Factor Parameters) _______________________________________ Section 6 - 72
________________________________________________________________________________________ DanLoad 6000 (v6.00)
6.12
Factors (continued)
174 / 185 / 196 / 207 Flow rate 1
This program code sets the value in quantity per minute at which the meter factor for the low flow rate is established. Engineering units for flow rates are determined by the K-factor scaling
(program code 171 / 182 / 193 / 204 Nominal K-factor) for the component. The units entered for this parameter are GPM,
dLPM, LPM, etc.
175 / 186 / 197 / 208 Meter factor 1
This program code sets the meter factor that is used for the corresponding flow rate indicated in the previous parameter.
176 / 187 / 198 / 209 Flow rate 2
This program code sets the value in quantity per minute at which the meter factor for the high flow rate, or an intermediate flow rate, is established. Engineering units for flow rates are determined by the K-factor scaling (program code 171 / 182 /
193 / 204 Nominal K-factor) for the component. The units entered for this parameter are GPM, dLPM, LPM, etc.
177 / 188 / 199 / 210 Meter factor 2
This program code sets the meter factor that is used for the corresponding flow rate indicated in the previous parameter.
Program Code Definitions (169 to 219 Meter Factor Parameters) _______________________________________ Section 6 - 73
________________________________________________________________________________________ DanLoad 6000 (v6.00)
6.12
Factors (continued)
178 / 189 / 200 / 211 Flow rate 3
This program code sets the value in quantity per minute at which the meter factor for the high flow rate, or an intermediate flow rate, is established. Engineering units for flow rates are determined by the K-factor scaling (program code 171 / 182 /
193 / 204 Nominal K-factor) for the component. The units entered for this parameter are GPM, dLPM, LPM, etc.
179 / 190 / 201 / 212 Meter factor 3
This program code sets the meter factor that is used for the corresponding flow rate indicated in the previous parameter.
180 / 191 / 202 / 213 Flow rate 4
This parameter sets the value in quantity per minute at which the meter factor for the high flow rate is established. Engineering units for flow rates are determined by the K-factor scaling
(program code 171 / 182 / 193 / 204 Nominal K-factor) for the component. The units entered for this parameter are GPM,
dLPM, LPM, etc.
181 / 192 / 203 / 214 Meter factor 4
This parameter sets the meter factor that is used for the corresponding flow rate indicated in the previous parameter.
Program Code Definitions (169 to 219 Meter Factor Parameters) _______________________________________ Section 6 - 74
________________________________________________________________________________________ DanLoad 6000 (v6.00)
6.12
Factors (continued)
215 Master MF %
This program code sets the percentage bandwidth for limit checks of the individual Component p meter factor f referenced to the program code 172 / 183 / 194 / 205 Master meter factor. The default value is 2.00 which limits any program code 175 / ... / 214
Component p meter factor f entry to ± 2 percent of the corresponding program code 172 / 183 / 194 / 205 Master meter
factor for the component (meter).
216 Adjustment MF %
This program code sets the allowable percentage difference between any two adjacent meter factors. Adjacent meter factors are:
[program code 175 / 186 / 197 / 208 Component p meter factor
1 and program code 177 / 188 / 199 / 210 Component p meter factor 2]
[program code 177 / 188 / 199 / 210 Component p meter factor
2 and program code 175 / 186 / 197 / 208 Component p meter factor 1 and program code 179 / 190 / 201 / 212 Component p meter factor 3]
[program code 179 / 190 / 201 / 212 Component p meter factor
3 and program code 177 / 188 / 199 / 210 Component p meter factor 2 and program code 181 / 192 / 203 / 214 Component p meter factor 4]
[program code 181 / 192 / 203 / 214 Component p meter factor
4 and program code 179 / 190 / 201 / 212 Component p meter factor 3]
Entering 0.00 disables the validation.
The default value is 0.25 percent.
Program Code Definitions (169 to 219 Meter Factor Parameters) _______________________________________ Section 6 - 75
________________________________________________________________________________________ DanLoad 6000 (v6.00)
6.12
Factors (continued)
217 Gross units mnemonic
The gross product units mnemonic independent of the configured product units (program code 29) for display on the loading screen and printing on data logs. This allow the units mnemonic to be entered in any language of local abbreviation. Six character alphanumeric entry. The default value is “Gal”.
218 Std units mnemonic
The standard quantity units mnemonic independent of the configured product units (program code 29) for display on the loading screen and printing on the data logs. This allows the units mnemonic to be entered in any language or local abbreviation. Six character alphanumeric entry. The default value is “Gal”.
219 Use restart qty
For sequential unit type, this code indicates whether or not a component’s low flow restart quantity should be used for starting up components after loading the first component in the recipe’s
“sequence to load”. Select one of the following:
# No
Start up each component by loading its low flow start quantity at its low flow rate.
# Yes
Start up the first component by loading its low flow start quantity at its low flow rate. Start up further components by loading their low flow restart quantities at their low flow rates. This typically reduces the time required to load a sequential blend batch.
Program Code Definitions (169 to 219 Meter Factor Parameters) _______________________________________ Section 6 - 76
________________________________________________________________________________________ DanLoad 6000 (v6.00)
6.13
Alarms
The response to each alarm is controlled by the setting of the Alarm Action corresponding to that alarm. The four possible alarm actions are described below. The alarm actions for several alarms are limited to less than four selections. Alarm action for several alarms is fixed and not selectable. The allowable alarm action selections for each alarm are listed for each alarm parameter.
Alarm Action
Primary
Secondary
Description
If a delivery is in progress, the flow control valve is shut and the delivery is suspended.
A message is displayed on the message line of the display panel.
Delivery cannot resume until the alarm is cleared.
Red LED indicators on primary and secondary operator displays are ON.
Alarm discrete output, program code 287 Alarm output 1 is maintained closed (if defined and enabled by program code 269 Alarm o/p 1 mask). Alarm discrete output program code 379 Alarm
output 2 is maintained closed (if defined and enabled by 270 Alarm o/p 2 mask).
If a delivery is in progress, the flow control valve is shut and the delivery is suspended. A message is displayed on the message line of the display panel.
Delivery cannot resume until the alarm is cleared or the Secondary alarm reset time has elapsed.
Red LED indicators on primary and secondary operator displays are flashing.
Alarm discrete output, program code 287 Alarm output 1 is pulsed (if defined and enabled by program code 269 Alarm o/p 1 mask). Alarm discrete output program code 379 Alarm output 2 is pulsed (if defined and enabled by 270 Alarm o/p 2 mask).
Info
Off
A message is displayed on the message line of the display panel for ten seconds.
Disable monitoring of this alarm.
Reset
Keypad in program Mode.
Alarm reset discrete input, program code
344 Primary alarm reset (if defined).
Terminal automation system.
Correct cause of alarm
Automatically reset after time value in program code 220 Secondary alarm reset
(s) has elapsed. The batch can be restarted
(“Press START when ready or STOP to cancel”) if the remaining quantity is not less than the min. preset.
Automatically reset after ten seconds have elapsed.
N/A
Program Code Definitions (220 to 279 Alarm Parameters) ___________________________________________ Section 6 - 77
________________________________________________________________________________________ DanLoad 6000 (v6.00)
6.13
Alarms (continued)
PC # /Function
220 Secondary alarm reset (s)
221 Low flow alarm action
222 Minimum flow rate
223 Low flow time (s)
224 High flow alarm action
225 Maximum flow rate
226 High flow time (s)
Range <Default> OR Option (* = Default)
0 to 9999 <300>
0 Off
1 Info
2 Secondary
3 Primary *
0 to 99999 <100>
5 to 999 <10>
0 Off
1 Info
3 Primary *
0 to 99999 <660>
5 to 999 <10>
Program Code Definitions (220 to 279 Alarm Parameters) ___________________________________________ Section 6 - 78
________________________________________________________________________________________ DanLoad 6000 (v6.00)
6.13
Alarms (continued)
Alarms Parameters contain data which defines the conditions that generate alarms and the method that the DanLoad 6000 responds to alarms. Multiple alarms can be processed simultaneously.
Alarms are processed in the chronological order that they are detected. The first parameter, program code 220 Secondary
alarm reset (s), is applicable to all alarms that have the alarm action set to Secondary. All other alarm parameters are related to specific alarm actions or limits.
The response to any alarm is handled by a specific alarm action.
There are up to four possible alarm actions for any alarm. In some cases, the alarm action is permanently set at one option and cannot be modified. Alarm action selections are located in relation to associated alarm parameters in the following alarm tables.
220 Secondary alarm reset (s)
This program code sets the elapsed time to allow a secondary alarm to be active before it is cleared automatically. The default value is 300 seconds.
221 Low flow alarm action
This program code selects the response to a low flow condition.
If Secondary is chosen the batch is stopped without an alarm being raised if the flow rate falls below the configured minimum flow rate (program code 222) for the configured low flow time
(program code 223). The default selection is Primary.
222 Minimum flow rate
This program code sets the value of the minimum flow rate permitted for the time period set in program code 223 Low flow
time (s) before the low flow alarm is set. The default entry is 100 product units per minute.
Program Code Definitions (220 to 279 Alarm Parameters) ___________________________________________ Section 6 - 79
________________________________________________________________________________________ DanLoad 6000 (v6.00)
6.13
Alarms (continued)
223 Low flow time (s)
This program code sets the maximum time allowed to elapse at or less than the flow rate specified by program code 222 Minimum
flow rate before the low flow alarm is set.
226 High flow time (s)
This program code sets the maximum time allowed to elapse at or greater than the flow rate specified by program code 225
Maximum flow rate before the high flow alarm is set.
224 High flow alarm action
This program code selects the response action to a high flow condition. The default selection is Primary.
225 Maximum flow rate
This program code sets the value of the maximum flow rate permitted for the time period set in program code 226 High flow
time (s) before the high flow alarm is set. The default entry is 660 product units per minute. (Note: Set this value slightly greater than the highest expected flow rate through any single meter.
This setting enables the DanLoad 6000 to detect loss of control of a flow control valve and alarm the condition.)
Program Code Definitions (220 to 279 Alarm Parameters) ___________________________________________ Section 6 - 80
________________________________________________________________________________________ DanLoad 6000 (v6.00)
CONTINUE
Program Code Definitions (220 to 279 Alarm Parameters) ___________________________________________ Section 6 - 81
________________________________________________________________________________________ DanLoad 6000 (v6.00)
6.13
Alarms (continued)
PC # / Function
227 Overrun limit qty
228 Underflow alarm action
229 Underflow limit qty
230 No flow t-o alarm action
231 No flow t-o time (s)
232 Unauthorized flow limit qty
Range <Default> OR Option (* = Default)
0.0 to 99.9 <2.0>
0 Off *
3 Primary
0.0 to 99.9 <5.0>
0 Off
1 Info
2 Secondary
3 Primary *
1 to 99 <5>
0.0 to 99.9 <10>
Program Code Definitions (220 to 279 Alarm Parameters) ___________________________________________ Section 6 - 82
________________________________________________________________________________________ DanLoad 6000 (v6.00)
6.13
Alarms (continued)
227 Overrun limit qty
This program code sets the allowable quantity in excess of the preset quantity to be delivered before the Unable to close valve
meter # alarm is set.
228 Underflow alarm action
This program code selects the response to an underflow condition. The default selection is Off.
229 Underflow limit qty
This program code sets the allowable quantity by which the loaded quantity can be less than the preset quantity before the
Valve closed early meter # alarm is issued.
230 No flow t-o (time out) alarm action
This program code selects the response to a no flow condition. If there is no flow through a meter when there should be flow, i.e.
the appropriate flow control valve has been opened, for the configured no flow time-out time (program code 231). If
Secondary is chosen, the batch is simply stopped without an alarm being raised The default selection is Primary.
WARNING
The no flow alarm is important for detecting meter pulse stream failures, and should not be disabled without careful consideration.
It may be necessary to disable the no flow alarm in applications where the DanLoad 6000 does not operate the flow control valve.
Program Code Definitions (220 to 279 Alarm Parameters) ___________________________________________ Section 6 - 83
________________________________________________________________________________________ DanLoad 6000 (v6.00)
6.13
Alarms (continued)
231 No flow t-o time (s)
This program code sets the elapsed time to allow for no flow pulse input to be detected after opening the flow control valve.
The default value is 5 seconds. (Note: This delay can be set to
1 or 2 seconds if detection of a meter pulse input failure or other cause of the no flow condition must be detected immediately.)
232 Unauthorized flow limit quantity
This program code sets the allowable quantity to be recorded as unauthorized flow before the Unauthorized flow exceeds limit
meter # primary alarm is issued. The default value is 10 product units.
If the unauthorized flow quantity is set to “something point 1", e.g. 0.1, 1.1 or 2.1, then a meter’s unauthorized flow counter (the internal one that causes the alarm to be raised, not the running totalizer seen in the dynamic data display or by the automation system) is cleared whenever the meter is authorized for a batch; this prevents the “unauthorized flow alarm will eventually happen” problem.
With the dual pulse stream pulse security option, the DanLoad
6000 has the ability to eliminate “spurious” unauthorized flow pulses that can occur with turbine or PD meters due to vibrational effects.
The default value is 10.0.
Program Code Definitions (220 to 279 Alarm Parameters) ___________________________________________ Section 6 - 84
________________________________________________________________________________________ DanLoad 6000 (v6.00)
CONTINUE
Program Code Definitions (220 to 279 Alarm Parameters) ___________________________________________ Section 6 - 85
________________________________________________________________________________________ DanLoad 6000 (v6.00)
6.13
Alarms (continued)
PC # / Function
233 Error limit (pulses)
234 Reset count (pulses)
The pulse security function provides verification of meter pulse inputs per API Manual of Petroleum Measurement Standards,
Chapter 5 - Metering, Section 5 - Fidelity and Security of Flow
Measurement Pulsed-Data Transmission Systems and IP 252,
Part XIII - Fidelity and Security of Measurement-Data
Transmission Systems. This function can only be implemented if there are two meter pulse train inputs from a single flow meter.
The dual meter pulse inputs must be 90 degrees electrically out of phase. Turbine meters capable of implementing this function must have two pick-up coils, 90 degrees electrically out of phase, and two preamplifiers. Positive displacement meters must have dual pulse transmitters.
Pulse stream “A” is used for measuring flow. Pulse stream “B” is used for verification and should trail pulse stream “A” by around 90 degrees electrically.
Range <Default> OR Option (* = Default)
0 to 255 <0>
0 to 65535 <10000>
A
B jk _ jk _ jk _ jk _ jk _ jk _ jk _ jk _ jk _ jk _
))))))))) 6 time
DanLoad 6000 dual pulse security is available per the IP252 level-B standard. This is accomplished by monitoring the two meter pulse inputs that are electrically 90° ± 89° out of phase.
The algorithm is in the firmware of a Program Logic Device
Integrated Circuit (PLD).
The PLD performs a level B security check while a load is in progress. The Channel A input stream is sent directly to the CPU for totalizing the product flow.
Program Code Definitions (220 to 279 Alarm Parameters) ___________________________________________ Section 6 - 86
________________________________________________________________________________________ DanLoad 6000 (v6.00)
6.13
Alarms (continued)
Channel B is used as a comparison input stream to determine flow direction and errors. The PLD samples the two input streams at 6 MHZ and watches for a state transition in either channel. As soon as one of the channels changes states, the PLD determines if it was a forward transition. If the change was not a forward transition, the PLD decrements the error counter by one.
As soon as the error counter reaches zero, the meter board triggers an interrupt to the CPU which will halt the load.
While in a no load condition, the PLD will set a REV flag if any reverse state transitions are seen. This will inhibit channel A output to the CPU. A forward transition will clear the REV flag and enable channel A output to the CPU on the next forward transition. This will eliminate any pulses sent by a blade rocking across a pick-up.
The level-B security-checking PLD is U9 on the 2-Channel Meter
Pulse board or U9 and U10 on the 4-Channel Meter Pulse board.
Possible Pulse Security Inputs
Meter Pulse Boards
Installed one 2-channel two 2-channel one 2-channel and one 4-channel 3 two 4-channel 4
233 Error limit (pulses)
MAX # of Meters with Pulse Security
1
2
This program code sets the error count at which a pulse security alarm occurs. Pulse security checks are performed only when a
load is in progress. This value is used to reload an 8-bit hardware counter, which generates an interrupt when it counts down to zero, i.e. error limit exceeded. Zero disables pulse security. The default value is 0, i.e. no pulse security.
Program Code Definitions (220 to 279 Alarm Parameters) ___________________________________________ Section 6 - 87
________________________________________________________________________________________ DanLoad 6000 (v6.00)
6.13
Alarms (continued)
234 Reset count (pulses)
This program code sets the value of raw pulses accumulated during pulse error checking before resetting the accumulator to zero. This value defines a window of accumulated raw pulses that is used to determine if program code 233 Error limit value is exceeded. A zero entry resets the error count only at the start of each batch delivery. A value greater than zero indicates that the accumulated error count will be cleared each time the accumulated raw pulses equal the entry. This field is not used if the value of program code 233 Error limit is set to zero.
PC # / Function Range <Default> OR Option (* = Default)
235 Data logging alarm action 0 Info *
3 Primary
236 Time-out ch. A (s)
237 Time-out ch. B (s)
0 to 300 <10>
0 to 300 <10>
Program Code Definitions (220 to 279 Alarm Parameters) ___________________________________________ Section 6 - 88
________________________________________________________________________________________ DanLoad 6000 (v6.00)
6.13
Alarms (continued)
235 Data logging alarm action
This program code selects the response to a data logging memory full condition. This condition is caused by failure to print data logs due to the logging printer being off-line, out of paper, or some other disabling condition. Around 10 pages of data logs are
“spooled” to battery-backed memory before the alarm is raised, and are printed automatically as soon as the problem with the logging printer is rectified. The default selection is Info.
237 Time-out ch. B (s)
This program code sets the time-out (in seconds) for the “Comms failure channel B” alarm, which is a primary alarm. The alarm is raised when the DanLoad 6000 is in “Auto” (program code 25) and the channel’s communications mode (program code 668) is configured for “Modbus RTU”, i.e. automation system communications, and the DanLoad 6000 does not receive a query
(with its communications address) on the channel for the configured number of seconds. The “Comms failure channel B” alarm can also be raised in the manual operating mode. See program code 673. Zero disables the alarm. The default value is
10.
236 Time-out ch. A (s)
This program code sets the time-out (in seconds) for the “Comms failure channel A” alarm, which is a primary alarm. The alarm is raised when the DanLoad 6000 is in “Auto” (program code 25) and the channel’s communications mode (program code 663) is configured for “Modbus RTU”, i.e. automation system communications, and the DanLoad 6000 does not receive a query
(with its communications address) on the channel for the configured number of seconds. Zero disables the alarm. The default value is 10.
Program Code Definitions (220 to 279 Alarm Parameters) ___________________________________________ Section 6 - 89
________________________________________________________________________________________ DanLoad 6000 (v6.00)
6.13
Alarms (continued)
PC # / Function
238 Temp fail alarm action
239 Minimum temperature
240 Maximum temperature
241 Density fail alarm action
242 Minimum density/gravity
243 Maximum density/gravity
244 Minimum pressure
245 Maximum pressure
246 Additive error limit
247 Additive Feedback count
248 Block valve time (s)
Range <Default> OR Option (* = Default)
0 Off
1 Info
3 Primary *
-999.9 to 999.9 <-40.0>
-999.9 to 999.9 <110.0>
1 Info
3 Primary *
-9.9999 to 9.9999 <0.0000>
-9.9999 to 9.9999 <0.0000>
0.0 to 9999.99 <0.00>
0.0 to 9999.99 <0.00>
1 to 99 <3>
0 to 9999 <0>
0 to 99 <10>
Program Code Definitions (220 to 279 Alarm Parameters) ___________________________________________ Section 6 - 90
________________________________________________________________________________________ DanLoad 6000 (v6.00)
6.13
Alarms (continued)
238 Temp fail alarm action
This program code sets the temperature to use (live or backup) and selects the response to a temperature out-of-range condition.
“Live temperature” refers to temperature read from an RTD input.
“Backup temperature” refers to a value in Setup.
# Off
Use backup temperature from program code 434 / 437 /
440 / 443 backup temperature entry.
# Info
Use live temperature if in limits of program code 239
Minimum temperature and program code 240 Maximum
temperature else use program code 434 / 437 / 440 / 443
Backup temperature.
# Primary
Use live temperature only and halt loading if it is out of limits set by program code 239 Minimum temperature and program code 240 Maximum temperature.
239 Minimum temperature
This program code sets the minimum allowable process temperature input from an RTD before the Temperature failure
meter # alarm is issued. The temperature units are specified by program code 427 Temperature units (either degrees Fahrenheit or degrees Celsius). The default value is -40.0 degrees.
240 Maximum temperature
This program code sets the maximum allowable process temperature input from an RTD before the Temperature failure
meter # alarm is issued. The temperature units are specified by program code 427 Temperature units (either degrees Fahrenheit or degrees Celsius). The default value is +110.0 degrees.
Program Code Definitions (220 to 279 Alarm Parameters) ___________________________________________ Section 6 - 91
________________________________________________________________________________________ DanLoad 6000 (v6.00)
6.13
Alarms (continued)
241 Density fail alarm action
This program code selects the response to a process density input out of range condition. The default selection is Primary.
location in this field is dependent on the setting in program code
046 Density/gravity scale.
242 Minimum density/gravity
This program code sets the minimum allowable process density input from a densitometer before the Density failure component
# alarm is issued. The density units are dependent on the selection of program code 432 / 435 / 438 / 441 Temperature
option corresponding to the component. The decimal point location in this field is dependent on the setting in program code
046 Density/gravity scale.
244 Minimum pressure
This program code sets the minimum allowable process pressure input from a pressure transmitter before the Pressure failure
meter # alarm is issued. Refer to Section 4.5.1 Alarm Messages for possible minimum pressure failure causes.
245 Maximum pressure
This program code sets the maximum allowable process pressure input from a pressure transmitter before the Pressure failure
meter # alarm is issued. Refer to Section 4.5.1 Alarm Messages for possible maximum pressure failure causes.
243 Maximum density/gravity
This program code sets the maximum allowable process density input from a densitometer before the Density failure component
# alarm is issued. The density units are dependent on the selection in program code 432 / 435 / 438 / 441 Temperature
option corresponding to the component. The decimal point
Program Code Definitions (220 to 279 Alarm Parameters) ___________________________________________ Section 6 - 92
________________________________________________________________________________________ DanLoad 6000 (v6.00)
6.13
Alarms (continued)
246 Additive error limit
For the “Mech” and “Handshake” injection methods this is the maximum number of pulses by which the actual feedback pulse count can differ from the ideal feedback pulse count before an additive failure alarm is raised. The ideal feedback pulse count is based on the additive feedback count (program code 247), or is
1 for the “Handshake” injection method (independent of configuration). The default value is 3.
248 Block valve time (s)
This program code sets the time period allowed for any component block valve to close. The default value is 10 seconds.
247 Additive feedback count
This program code sets the expected number of feedback pulses per additive ratio cycle for the “Mech” additive injection method, e.g. 1 for Titan PAC-3 “confirmation pulse”, 2 for Hyrolec injector. The number of seconds within which the additive feedback input must go on and off again after the additive ratio output has been energized for the “Handshake” additive injection method, e.g. 5 (per Mapco). The default value is 0.
Program Code Definitions (220 to 279 Alarm Parameters) ___________________________________________ Section 6 - 93
________________________________________________________________________________________ DanLoad 6000 (v6.00)
6.13
Alarms (continued)
PC # / Function
249 Circuit 1 alarm action
250 #1 <message>
251 Circuit 2 alarm action
252 #2 <message>
253 Circuit 3 alarm action
254 #3 <message>
Range <Default> OR Option (* = Default)
0 Off
1 Info
2 Secondary *
3 Primary
Up to 32 characters
<Ground detector open>
0 Off
1 Info
2 Secondary
3 Primary *
Up to 32 characters
<Overspill detector open>
0 Off
1 Info
2 Secondary *
3 Primary
Up to 32 characters
<Permissive power failure>
Program Code Definitions (220 to 279 Alarm Parameters) ___________________________________________ Section 6 - 94
________________________________________________________________________________________ DanLoad 6000 (v6.00)
6.13
Alarms (continued)
Safety Circuit Alarm Action
Note: Refer to Section 4.5.1 for alarm message and alarm action configuration.
Alarm program codes 249 to 268 define the operation of eight configurable safety circuit inputs (permissive circuits). All eight safety circuits are configurable to be either side independent or dedicated to side 1 or dedicated to side 2. The safety circuit 3 and
4 alarms have alternate uses as the “end” and “recipe selection” alarms respectively. Safety Circuit #3 can also be used as the additive meter flush alarm in multi-stream injection mode, if so configured.
The physical discrete inputs for the safety circuits are assigned with program codes 345 to 352.
249 Circuit 1 alarm action
This program code selects the response (either primary or secondary alarm action) to an OPEN state for the discrete input assigned to this function by program code 344 Safety circuit 1.
#
#
Off
The associated input, if any, is read, and its current status is made available in the dynamic data display (if configured) and via the automation system Request Status and Enhanced Request Status commands. The DanLoad
6000 performs no other processing on the input. This allows an automation system to process discrete inputs independently of the DanLoad 6000 with no communications overhead.
Info
If the associated input (safety circuit input or “redirected” input) is open at any time in loading mode, i.e. in the recipe selection screen, the additive selection screen or the loading screen, and there is no “higher priority”
(secondary or primary) alarm active then the associated alarm message is displayed for the first 10 seconds of every 15 second period. If multiple informational safety circuit alarms are active, the associated alarm messages are displayed in rotation, i.e. a new message every 15 seconds.
Program Code Definitions (220 to 279 Alarm Parameters) ___________________________________________ Section 6 - 95
________________________________________________________________________________________ DanLoad 6000 (v6.00)
6.13
Alarms (continued)
See program code 249 for options and descriptions. The default value is “Primary”.
#
#
An informational safety circuit alarm neither prevents a batch from being started nor stops a batch in progress. There is no discrete output (alarm output) associated with an informational safety circuit alarm. Safety circuits may be side-dependent even if configured as informational.
Secondary
Primary
The default is “Secondary”.
250 #1 <Ground detector open>
This program code contains the alarm message assigned to this safety circuit. The default message is indicated above.
252 #2 <Overspill detector open>
This program code contains the alarm message assigned to this safety circuit. The default message is indicated above.
253 Circuit 3 alarm action
This program code selects the response to an OPEN state for the discrete input assigned to this function by program code 347
Safety circuit 3 and program code 424 End input. See program codes 249, 423 and 425 for multi-purpose options and descriptions. The default value is “Secondary”.
251 Circuit 2 alarm action
This program code selects the response to an OPEN state for the discrete input assigned to this function by program code 346
Safety circuit 2.
254 #3 <Permissive power failure>
This program code contains the alarm message assigned to this safety circuit, the default message is indicated above.
Program Code Definitions (220 to 279 Alarm Parameters) ___________________________________________ Section 6 - 96
________________________________________________________________________________________ DanLoad 6000 (v6.00)
CONTINUE
Program Code Definitions (220 to 279 Alarm Parameters) ___________________________________________ Section 6 - 97
________________________________________________________________________________________ DanLoad 6000 (v6.00)
6.13
Alarms (continued)
PC # / Function
255 Circuit 4 alarm action
256 #4 <message>
257 Circuit 5 alarm action
258 #5 <message>
259 Circuit 6 alarm action
260 #6 <message>
Range <Default> OR Option (* = Default)
0 Off
1 Info
2 Secondary *
3 Primary
Up to 32 characters <Additive injection failure>
0 Off
1 Info
2 Secondary *
3 Primary
Up to 32 characters <Arm down side 1>
0 Off
1 Info
2 Secondary *
3 Primary
Up to 32 characters <Arm down side 2>
Program Code Definitions (220 to 279 Alarm Parameters) ___________________________________________ Section 6 - 98
________________________________________________________________________________________ DanLoad 6000 (v6.00)
6.13
Alarms (continued)
255 Circuit 4 alarm action
This program code selects the response to an OPEN state for the discrete input assigned to this function by program code 348
Safety circuit 4. If program code 348 Safety circuit 4 is set to 0, then program codes 361 through 366 Recipe X input are enabled.
See program code 249 for options and descriptions. The default value is “Secondary”.
256 #4 <Additive injection failure>
This program code contains the alarm message assigned to this safety circuit. The default message is indicated above.
257 Circuit 5 alarm action
This program code selects the response to an OPEN state for the discrete input assigned to this function by program code 349
Safety circuit 5. See program code 249 for options and descriptions. The default value is “Secondary”.
258 #5 <Arm down side 1>
This program code contains the alarm message assigned to this safety circuit. The default message is indicated above.
259 Circuit 6 alarm action
This program code selects the response to an OPEN state for the discrete input assigned to this function by program code 350
Safety circuit 6. See program code 249 for options and descriptions. The default value is “Secondary”.
260 #6 <Arm down side 2>
This program code contains the alarm message assigned to this safety circuit. The default message is indicated above.
Program Code Definitions (220 to 279 Alarm Parameters) ___________________________________________ Section 6 - 99
________________________________________________________________________________________ DanLoad 6000 (v6.00)
6.13
Alarms (continued)
PC # / Function
261 Circuit 7 alarm action
262 #7 <message>
263 Circuit 8 alarm action
264 #8 <message>
Range <Default> OR Option (* = Default)
0 Off
1 Info
2 Secondary *
3 Primary
Up to 32 characters <Walkway down side 1>
0 Off
1 Info
2 Secondary *
3 Primary
Up to 32 characters <Walkway down side 2>
Program Code Definitions (220 to 279 Alarm Parameters) ___________________________________________ Section 6 - 100
________________________________________________________________________________________ DanLoad 6000 (v6.00)
6.13
Alarms (continued)
261 Circuit 7 alarm action
This program code selects the response to an OPEN state for the discrete input assigned to this function by program code 351
Safety circuit 7. See program code 249 for options and descriptions. The default value is “Secondary”.
263 Circuit 8 alarm action
This program code selects the response to an OPEN state for the discrete input assigned to this function by program code 352
Safety circuit 8. See program code 249 for options and descriptions. The default value is “Secondary”.
262 #7 <Walkway down side 1>
This program code contains the alarm message assigned to this safety circuit. The default message is indicated above.
264 #8 <Walkway down side 2>
This program code contains the alarm message assigned to this safety circuit. The default message is indicated above.
Program Code Definitions (220 to 279 Alarm Parameters) ___________________________________________ Section 6 - 101
________________________________________________________________________________________ DanLoad 6000 (v6.00)
6.13
Alarms (continued)
Safety Circuit
5
6
7
8
1
2
3
4
PC # Function
265 Circuit 5 type
266 Circuit 6 type
267 Circuit 7 type
268 Circuit 8 type
Program Code
265
266
267
268
830
831
832
833
Range <Default> OR Option (* = Default)
0 to 2 <1>
0 to 2 <2>
0 to 2 <1>
0 to 2 <2>
All safety circuits have an associated “safety circuit type” which controls special processing. Note that Safety Circuits 1 through
4 are defined by program codes 830 through 833.
Type 0 is standard processing, i.e. the safety circuit is checked for the purpose of alarming independently of the swing-arm side if the safety circuit’s alarm action is “Info”, “Secondary” or
“Primary”.
Type 1 means that the safety circuit is checked for the purpose of alarming only while the swing-arm side is 1 if the safety circuit’s alarm action is “Info”, “Secondary” or “Primary”.
Type 2 means that the safety circuit is checked for the purpose of alarming only while the swing-arm side is 2 if the safety circuit’s alarm action is “Info”, “Secondary” or “Primary”. Thus the safety-circuit type provides flexibility for double-sided (swingarm) applications.
Program Code Definitions (220 to 279 Alarm Parameters) ___________________________________________ Section 6 - 102
________________________________________________________________________________________ DanLoad 6000 (v6.00)
6.13
Alarms (continued)
265 Circuit 5 type
This program code sets the side assignment for safety circuit number 5.
#
#
#
0 = side independent
1 = enabled only if loading at side 1
2 = enabled only if loading at side 2
Side is determined by the swing arm position inputs.
266 Circuit 6 type
This program code sets the side assignment for safety circuit number 6.
#
#
#
0 = side independent
1 = enabled only if loading at side 1
2 = enabled only if loading at side 2
Side is determined by the swing arm position inputs.
267 Circuit 7 type
This program code sets the side assignment for safety circuit number 7.
#
#
#
0 = side independent
1 = enabled only if loading at side 1
2 = enabled only if loading at side 2
Side is determined by the swing arm position inputs.
268 Circuit 8 type
This program code sets the side assignment for safety circuit number 8.
#
#
#
0 = side independent
1 = enabled only if loading at side 1
2 = enabled only if loading at side 2
Side is determined by the swing arm position inputs.
Program Code Definitions (220 to 279 Alarm Parameters) ___________________________________________ Section 6 - 103
________________________________________________________________________________________ DanLoad 6000 (v6.00)
6.13
Alarms (continued)
PC # / Function
269 Alarm o/p 1 mask
270 Alarm o/p 2 mask
271 Unauth additive flow vol
272 Prod/add - %
273 Prod/add + %
274 Storage alarm action
275 Power fail alarm action
Range <Default> OR Option (* = Default)
0 to 16777215 <16777215>
0 to 16777215 <0>
0.0000 to 99999.9999 <0.0000>
0 to 99 <0>
0 to 99 <0>
0 Off *
3 Primary
0 Off *
3 Primary
Program Code Definitions (220 to 279 Alarm Parameters) ___________________________________________ Section 6 - 104
________________________________________________________________________________________ DanLoad 6000 (v6.00)
6.13
Alarms (continued)
269 Alarm o/p 1 mask
To enable the alarm output 1 and/or 2 capability, enter the decimal sum of the values corresponding to the alarm types from the Alarm Type Mask Values table.
Including an alarm type’s mask value in the sum configures the alarm output to respond per the alarm’s configured action, i.e.
primary or secondary.
270 Alarm o/p 2 mask
To enable the alarm output 1 and/or 2 capability, enter the decimal sum of the values corresponding to the alarm types from the Alarm Mask Bit-Map table found on the following page.
Note
In the Alarm Mask Bit-Map that follows, Alarm Type 15 (if enabled) will activate the alarm output if any of the configured safety circuits go into an alarm state during the loading process.
Program Code Definitions (220 to 279 Alarm Parameters) ___________________________________________ Section 6 - 105
________________________________________________________________________________________ DanLoad 6000 (v6.00)
6.13
3 =
4 =
5 =
6 =
7 =
0 =
1 =
2 =
8 =
9 =
10 =
11 =
Alarms (continued)
Alarm Type Mask Values
Alarm Type Mask Value
Display failure
Comms failure
Unable to maintain blend
Flow rate to low
Flow rate too high
Valve closed early
Timed out - not flow detected
Unauthorized flow exceeds limit
Pulse security error
Temperature failure
Pressure failure
Unable to shut valve
1
2
4
8
16
32
64
128
256
512
1024
2048
19 =
20 =
21 =
22 =
23 =
12 = Density failure
13 = Unable to close block valve
14 =
15 =
16 =
17 =
Additive failure
Safety circuit
16384
32768
Data logging memory full 65536
Memory check failed
4096
8192
131072
18 =
Alarm Type Mask Values
Alarm Type Mask Value
Storage memory full
Power failure
262144
524288
Unable to ramp down
MPMC failure
Calibration failure
Intermediate level input
1048576
2097152
4194304
8388608
Program Code Definitions (220 to 279 Alarm Parameters) ___________________________________________ Section 6 - 106
________________________________________________________________________________________ DanLoad 6000 (v6.00)
6.13
Alarms (continued)
271 Unauthorized Additive flow volume
The volume (units determined by additive K-factor) of unauthorized additive flow at which an additive X failure alarm is raised for the "Meter" and "Control" injection methods
(program codes 141, 146, etc.). Unauthorized additive flow is detected as a feedback error for the "Mech" and "Handshake" injection methods. Zero disables the alarm. The default value is
0.0000, i.e. disabled.
Note:
Due to discrete (dosed) injection of additive, program codes
272 and 273 will be checked only after program code 278
Additive per 1000 error limit has been exceeded.
272 Prod/add -%
For the "Meter" and "Control" injection methods 143 / 148 / 153
/ 158 / 163 / 168 Additive per 1000, this is the percentage of the ideal quantity of additive at any point in a batch (determined from the actual number of injection cycles, the configured additive ratio quantity and the configured volume of additive per thousand of product) below which an additive failure alarm is raised. The default value is 0.
273 Prod/add + %
For the "Meter" and "Control" injection methods 143 / 148 / 153
/ 158 / 163 / 168 Additive per 1000, this is the percentage of the ideal quantity of additive at any point in a batch
(determined from the actual number of injection cycles, the configured additive ratio quantity and the configured quantity of additive per thousand of product) above which an additive failure alarm is raised. The default value is 0.
Program Code Definitions (220 to 279 Alarm Parameters) ___________________________________________ Section 6 - 107
________________________________________________________________________________________ DanLoad 6000 (v6.00)
6.13
Alarms (continued)
274 Storage alarm action
Enable triggering of a transaction storage memory full alarm.
This alarm is raised if starting a new transaction or batch in manual mode would cause an overwrite of previously archived transaction / batch records. The default is “Off”, i.e. the storage memory full alarm is disabled.
275 Power fail alarm action
Enable triggering of a power fail alarm. This alarm is raised during power-up if a power failure or processing crash occurred during the last batch delivery. Following a power failure during a batch, the batch preset quantity is available (Dynamic Data
Display) via data code 245, the batch gross and standard quantities via data codes 130 and 131, and the batch remaining quantity via data code 246. The default is “Off”, i.e. the power fail alarm is disabled.
Program Code Definitions (220 to 279 Alarm Parameters) ___________________________________________ Section 6 - 108
________________________________________________________________________________________ DanLoad 6000 (v6.00)
CONTINUE
Program Code Definitions (220 to 279 Alarm Parameters) ___________________________________________ Section 6 - 109
________________________________________________________________________________________ DanLoad 6000 (v6.00)
6.13
Alarms (continued)
PC # / Function
276 Ramp down alarm action
277 Ramp down time (s)
278 Additive per 1000 error limit
279 End time (s)
Range <Default> OR Option (* = Default)
0 Off
3 Primary *
0 to 9999 <4>
1 to 99 <1>
0 to 9999 <180>
276 Ramp down alarm action
This program code selects the response to an Unable to ramp
down alarm when the DanLoad 6000 cannot reduce the flow rate to a defined lower flow rate within the time period specified by program code 277 Ramp down time (s).
This alarm is intended to stop a batch of LPG when there is insufficient line pressure to “pinch back” using a line-pressure operated control valve.
For non-LPG applications, a good value for the ramp down time is the time that would be required to load 3/4 of the low flow stop quantity at the high flow rate.
# Off Disable function.
# Primary Enable function based on time period specified by program code 277 Ramp
down time (s).
277 Ramp down time (s)
[For program code 026 Unit type equal to sequential or in-line type.] Sets time limit for attempt to ramp down flow rate before triggering an Unable to ramp down alarm.
Program Code Definitions (220 to 279 Alarm Parameters) ___________________________________________ Section 6 - 110
________________________________________________________________________________________ DanLoad 6000 (v6.00)
6.13
Alarms (continued)
278 Additive per 1000 error limit
For the "Meter" and "Control" injection methods this is the number of injection cycles worth of additive, i.e. ideal doses of additive, by which the actual volume of additive can differ from the ideal volume of additive at any point in a batch before the
±percentages (program codes 272 and 273) are checked for the purpose of raising an alarm. For the “Control” injection method a value of 1 is recommended; larger values may be required for the “Meter” injection method depending on required tolerances and additive meter calibration accuracy. The default value is 1.
279 End time (s)
The end batch/transaction, depending on the configured end output method (program code 373), time in seconds. See "end output" program code 423 for more information. The default value is 180.
Program Code Definitions (220 to 279 Alarm Parameters) ___________________________________________ Section 6 - 111
________________________________________________________________________________________ DanLoad 6000 (v6.00)
6.14
I/O Parameters
PC # / Function
280 Slot 1 board
281 Slot 2 board
282 Slot 3 board
283 Slot 4 board
284 Slot 5 board
285 Slot 6 board
286 Slot 7 board
Range <Default> OR Option (* = Default)
0 Empty
1 DC I/O
2 AC I/O
3 8-Ch. Analog Input
4 2-Ch. Pulse Input
5 Enhanced I/O
6 2-Ch. Analog Input
7 4-Ch. Pulse Input
<same as above>
<same as above>
<same as above>
<same as above>
<same as above>
<same as above>
Program Code Definitions (280 to 379 I/O Parameters) ______________________________________________ Section 6 - 112
________________________________________________________________________________________ DanLoad 6000 (v6.00)
6.14
I/O Parameters (continued)
I/O Parameters contain data which defines the type of process input / output signal card that is inserted in each card cage slot.
Physical I/O points are assigned logical functions by logical I/O points.
uses, configurations and connections. Appropriate drawings are also referenced in Section 2.2.2 and can be found in
Appendix E.
NOTE
Refer to Section 2.2.2 Input/Output Board Descriptions and
Jumper Settings for detailed information about board types,
280 / 281 / 282 / 283 / 284 / 285 / 286 Slot # board
#
#
#
#
#
#
#
#
This program code indicates the type of board located in slot J#, and is automatically detected on power-up/reset. The J number for the input / output board connector is the same as the # in the parameter name.
Empty
DC I/O
AC I/O
Enhanced I/O
No card present.
DC Voltage discrete input / output board.
AC Voltage discrete input / output board.
8-Ch. Analog Input 8-channel analog input board.
2-Ch. Pulse Input
2-Ch. Analog Input 2-channel analog input board.
4-Ch. Pulse Input
2-channel meter pulse input board.
Enhanced input / output board.
4-channel meter pulse input board
Program Code Definitions (280 to 379 I/O Parameters) ______________________________________________ Section 6 - 113
________________________________________________________________________________________ DanLoad 6000 (v6.00)
6.14
I/O Parameters (continued)
Function
287 Alarm output 1
Range <Default> OR Option (* = Default)
0 to number of discrete outputs <4>
287 Alarm output 1
This program code assigns a physical discrete control output for the general alarm control output logical function. This output is pulsed ON (CLOSED) when a Secondary alarm is active and is steady ON (CLOSED) when a Primary alarm is active. The output is enabled per alarm type by program code 269 Alarm o/p
1 mask. (Note: See also program code 379 Alarm output 2.)
Program Code Definitions (280 to 379 I/O Parameters) ______________________________________________ Section 6 - 114
________________________________________________________________________________________ DanLoad 6000 (v6.00)
6.14
I/O Parameters (continued)
PC # / Function
(Four Product Pumps)
288 / 289 / 290 / 291 Pump control output
288 / 289 / 290 / 291 Pump control output
This program code assigns a physical discrete control output for the product pump control output logical function. This output is normally OFF and is maintained ON to run a product pump motor or to indicate “component in use”. See also component line pack delay (program code 87, etc. per component) and pump stop delay (program code 88, etc. per component).
Recommended discrete output assignments:
2
3
Component Program Code Discrete Output
1 288 3
289
290
7
11
4 291 15
Range <Default> OR Option (* = Default)
0 to number of discrete outputs <see table below>
Program Code Definitions (280 to 379 I/O Parameters) ______________________________________________ Section 6 - 115
________________________________________________________________________________________ DanLoad 6000 (v6.00)
6.14
I / O Parameters (continued)
PC # / Function
(Four Flow Control Valves)
292 / 297 / 302 / 307 Solenoid 1 (upstream)
293 / 298 / 303 / 308 Solenoid 2 (downstream)
294 / 299 / 304 / 309 Stem switch 1
295 / 300 / 305 / 310 Stem switch 2
296 / 301 / 306 / 311 Close input
Range <Default> OR Option (* = Default)
0 to number of discrete outputs <1>
0 to number of discrete outputs <2>
0 to number of discrete inputs,
51 to (50 + max. discrete input) <0>
0 to number of discrete inputs,
51 to (50 + max. discrete input) <0>
0 to number of discrete inputs,
51 to (50 + max. discrete input) <0>
Recommended discrete output assignments:
2
3
4
Flow Control
Valve
1
Solenoid 1
Program Code
292
297
302
307
5
9
13
Discrete
Output
1
Solenoid 2
Program Code
293
298
303
308
6
10
14
Discrete
Output
2
Program Code Definitions (280 to 379 I/O Parameters) ______________________________________________ Section 6 - 116
________________________________________________________________________________________ DanLoad 6000 (v6.00)
6.14
I/O Parameters (continued)
292 / 297 / 302 / 307 Solenoid 1 (upstream)
This program code assigns a physical discrete control output for the corresponding solenoid 1 logical function. This output is used to control the normally open pilot on a digital flow control valve or 2-stage flow control valve.
detecting leakage even if the meter pulse stream has failed, e.g.
preamp or pulse transmitter failure. The stem switch should be installed such that it provides a “closed” (1) input to the DanLoad
6000 when the flow control valve is closed, and an “open” (0) input otherwise. Input numbers 51 and above are “inverted”, i.e.
the actual input is the input number minus 50, but the state (open or closed) is inverted.
293 / 298 / 303 / 308 Solenoid 2 (downstream)
This program code assigns a physical discrete control output for the corresponding solenoid 2 logical function. This output is used to control the normally closed pilot on a digital flow control valve or 2-stage flow control valve.
294 / 299 / 304 / 309 Stem switch 1
The low flow start (normally closed) stem switch input. The
DanLoad 6000 “locks” the flow control valve when this input opens while ramping up to low flow.
An unauthorized flow alarm is raised for a meter if the associated flow control valve’s stem switch 1 input is open when the meter is not authorized. This provides a method of
295 / 300 / 305 / 310 Stem switch 2
The low flow stop (normally open) stem switch input. The
DanLoad 6000 “locks” the flow control valve when this input closes while ramping down to low flow.
An unauthorized flow alarm is raised for a meter if the associated flow control valve’s stem switch 2 input is closed when the meter is not authorized. This provides a method of detecting leakage even if the meter pulse stream has failed, e.g. preamp or pulse transmitter failure. The stem switch should be installed such that it provides an open (0) input to the DanLoad 6000 when the flow control valve is open, and a closed (1) input otherwise. Input numbers 51 and above are “inverted”, i.e. the actual input number is the input number minus 50, but the state (open or closed) is inverted.
Program Code Definitions (280 to 379 I/O Parameters) ______________________________________________ Section 6 - 117
________________________________________________________________________________________ DanLoad 6000 (v6.00)
Note: Stem switches 1 and/or 2 can be used to monitor the position of the flow control valve when the meter is not authorized independent of the flow control valve type (program code 027).
296 / 301 / 306 / 311 Close input
This program code assigns a physical discrete status input for the corresponding close input logical function. This input is used to sense some external condition or permissive circuit which controls the state of the flow control valve. If assigned, this input must be CLOSED during batch deliveries. An OPEN input on this circuit closes the flow control valve. Input numbers 51 and above are “inverted”, i.e. the actual input is the input number minus 50, but the state (open or closed) is inverted.
Program Code Definitions (280 to 379 I/O Parameters) ______________________________________________ Section 6 - 118
________________________________________________________________________________________ DanLoad 6000 (v6.00)
CONTINUE
Program Code Definitions (280 to 379 I/O Parameters) ______________________________________________ Section 6 - 119
________________________________________________________________________________________ DanLoad 6000 (v6.00)
6.14
I/O Parameters (continued)
PC # / Function
312 Side detect method
313 Pulse per unit output 1
314 Pulse per unit output 2
315 Trip 1 output
316 Trip 2 output
317 Trip 3 output
Range <Default> OR Option (* = Default)
0 Sgl w/o sw. *
1 Sgl 1 sw. (SW2)
2 Sgl 1 sw. (SW1)
3 Dbl 1 sw. (SW2)
4 Dbl 1 sw. (SW1)
5 Dbl 2 sw.
0 to number of discrete outputs <0>
0 to number of discrete outputs <0>
0 to number of discrete outputs <0>
0 to number of discrete outputs <0>
0 to number of discrete outputs <0>
Program Code Definitions (280 to 379 I/O Parameters) ______________________________________________ Section 6 - 120
________________________________________________________________________________________ DanLoad 6000 (v6.00)
6.14
I/O Parameters (continued)
312 Side detect method
This program code selects the method of detecting one of three possible positions of the product loading swing arm, based on inputs from one or two swing arm position switches. Swing arm switch input is connected to two physical discrete contact closure inputs, accessible at the three connector terminal board on the main processor board (v1 CPU board) [SWING1 is swing arm input 1 which is the rightward terminal on the main processor board] [SWING2 is swing arm input 2 which is the leftward terminal on the main processor board] [COMMON is the common connection for both inputs and in the center terminal on the main processor board]. (Note: The connections are labeled
on the aluminum board retainer plate.)
Discrete input swing-arm switches can also be used as per program codes 376 and 377. The v2 CPU board does not have dedicated swing-arm inputs.
Sgl = single-sided load spot; Dbl = double-sided load spot
SW1 = right terminal to center (common) terminal or discrete input per program code 376.
SW2 = left terminal to center (common) terminal or discrete input per program code 377.
Side Detect
M ethod
Sgl w/o sw
Sgl 1 sw (SW 2)
Sgl 1 sw (SW 1)
Dbl 1 sw (SW 2)
Dbl 1 sw (SW 1)
Dbl 2 sw
Swing Arm Switch Status
Side 1 Side 2
Enabled
SW 2
CLOSED
SW 1
CLOSED
N/A
N/A
N/A
SW 2
CLOSED
SW 2
OPEN
SW 1 must be OPEN
SW 1
CLOSED
SW 1
OPEN
SW 2 must be OPEN
SW 2
CLOSED
SW 2
OPEN
SW 1
OPEN
SW 1
CLOSED
Parked
N/A
SW 2
OPEN
SW 1
OPEN
N/A
N/A
SW 2
OPEN
SW 1
OPEN
Program Code Definitions (280 to 379 I/O Parameters) ______________________________________________ Section 6 - 121
________________________________________________________________________________________ DanLoad 6000 (v6.00)
6.14
I/O Parameters (continued)
#
#
#
#
Sgl w/o sw.
Single side without swing arm switch. Side 1 forced active at all times.
Sgl 1 sw. (SW2)
Single side with one swing arm switch.
SW2 CLOSED = side 1, SW2 OPEN = parked).
Sgl 1 sw. (SW1)
Single side with one swing arm switch.
SW1 CLOSED = side 1, SW1 OPEN = parked.
Dbl 1 sw. (SW2)
Double side with one swing arm switch.
SW2 CLOSED = side 1, SW2 OPEN = side 2;
(SW1 must be OPEN).
#
#
Dbl 1 sw. (SW1)
Double side with one swing arm switch.
SW1 CLOSED = side 1, SW1 OPEN = side 2;
(SW2 must be OPEN).
Dbl 2 sw.
Double side with two swing arm switches,
SW2 CLOSED and SW1 OPEN = side 1;
SW2 OPEN and SW1 CLOSED = side 2;
SW2 OPEN and SW1 OPEN = parked.
Note that the v2 CPU board does not have dedicated swing-arm inputs. Discrete input swing-arm switches per program codes 376 and 377 should be used. The v2 CPU board simulates “SW2 closed, SW1 open” so that side 1 will be detected for all values of program code 312 except
“Sgl 1 switch (SW1)” and “Dbl 1 switch (SW1)” if neither program code 367 nor 377 is configured.
Program Code Definitions (280 to 379 I/O Parameters) ______________________________________________ Section 6 - 122
________________________________________________________________________________________ DanLoad 6000 (v6.00)
6.14
I/O Parameters (continued)
313 Pulse per unit output 1
This program code assigns a physical discrete control output for the pulse per unit output 1 logical function. The drive logic for this output is setup by program code 128 Number of pulse per unit outputs, 129 Control meters, 130 Factor, 131 Pulse width
(ms).
315 Trip 1 output
This program code assigns a physical discrete control output for the trip 1 output logical function. Output is ON during low flow startup (indicates low flow startup phase to external device).
314 Pulse per unit output 2
This program code assigns a physical discrete control output for the pulse per unit output 2 logical function. The drive logic for this output is setup by program code 128 Number of pulse per unit outputs, 132 Control meters, 133 Factor, 134 Pulse width
(ms).
316 Trip 2 output
This program code assigns a physical discrete control output for the trip 2 output logical function. Output is ON during low flow startup and high flow (indicates low flow startup and high flow phases to external device).
317 Trip 3 output
This program code assigns a physical discrete control output for the trip 3 output logical function. Output is ON from start of delivery to final trip (OFF at same time as Solenoid 1 for sequential unit type) (indicates delivery phase to external device).
Program Code Definitions (280 to 379 I/O Parameters) ______________________________________________ Section 6 - 123
________________________________________________________________________________________ DanLoad 6000 (v6.00)
6.14
I/O Parameters (continued)
PC # / Function
(Four Meters)
318 / 324 / 330 / 336 Meter X temp input
319 / 325 / 331 / 337 Meter X offset (Ohms)
320 / 326 / 332 / 338 Meter X pres input
321 / 327 / 333 / 339 Meter X dens input
322 / 328 / 334 / 340 Meter X flow input
Range <Default> OR Option (* = Default)
0 to number of RTD inputs
-20.00 to +20.00
0 to number of 4 to 20 mAdc inputs
0 to number of 4 to 20 mAdc inputs
0 to max. discrete input,
51 to (50 + max. discrete input) <0>
318 / 324 / 330 / 336 Meter X temp input
This program code assigns a physical RTD process temperature input, corresponding to a flow meter, to the RTD input logical function.
319 / 325 / 331 / 337 Meter X offset (Ohms)
This program code sets the resistance compensation for wiring between the RTD and the DanLoad 6000 RTD input terminals.
The offset is applied only to RTD inputs on the 2- and 8-channel analog inputs boards, not to the RTD input on the v2 CPU board.
Program Code Definitions (280 to 379 I/O Parameters) ______________________________________________ Section 6 - 124
________________________________________________________________________________________ DanLoad 6000 (v6.00)
6.14
I/O Parameters (continued)
320 / 326 / 332 / 338 Meter X pres input
This program code assigns the physical 4 to 20 mAdc input, corresponding to a flow meter, to the meter pressure logical function.
321 / 327 / 333 / 339 Meter X dens input
This program code assigns the physical 4 to 20 mAdc input, corresponding to a flow meter, to the meter density logical function.
322 / 328 / 334 / 340 Meter X flow input
This program code, if configured, disables the “authorized flow alarms” (no flow detected, flow rate too low and flow rate too high) for the meter while the input is open, i.e. deenergized, and can be used to prevent spurious “authorized flow alarms” in an application where the DanLoad 6000 does not have direct control of the valve. Input numbers 51 and above are “inverted”, i.e. the actual input is the input number minus 50, but the state (“open” or closed”) is inverted. Zero indicates “not used”. The default value is zero, i.e. not used.
Program Code Definitions (280 to 379 I/O Parameters) ______________________________________________ Section 6 - 125
________________________________________________________________________________________ DanLoad 6000 (v6.00)
6.14
I/O Parameters (continued)
PC # / Function
341 # cpmt inputs
342 Start method
343 Auto/manual change-over
344 Primary alarm reset
341 # cmpt inputs
See section 3.12 for a summary of operating instructions. This is the number of compartment size inputs. Safety circuit 4 input is used as compartment size input 1, safety circuit 5 input is used as compartment size input 2, etc. Using safety circuit inputs as compartment size inputs prevents their use as safety circuit inputs. The alarm action of any safety circuit that is used as a compartment size input should be set to "Off". Special processing is performed if the configured number of
Range <Default> OR Option (* = Default)
0 to 4 <0>
0 Normal *
1 Immed.
0 to max. discrete input,
51 to (50 + max. discrete input) <0>
0 to max. discrete input,
51 to (50 + max. discrete input) <0> compartment size inputs is greater than zero. If the configured number of compartment size inputs is greater than zero, the preset quantity is calculated (when the "ENTER" key is pressed while the DanLoad 6000 is prompting for a preset quantity IN
THE MANUAL OPERATING MODE) as the minimum of the quantity entered by the operator (if any) and the smallest compartment size indicated by any compartment size inputs that are closed. There is a two-second delay after the "ENTER" key is pressed to allow the compartment size inputs to be scanned.
Program Code Definitions (280 to 379 I/O Parameters) ______________________________________________ Section 6 - 126
________________________________________________________________________________________ DanLoad 6000 (v6.00)
6.14
I/O Parameters (continued)
Compartment
Size Input
3
4
1
2
Compartment
Size
PC 644 x 100
PC 645 x 100
PC 646 x 100
PC 647 x 100
Program Code for Physical
Discrete Input
349
350
351
352
Program Code for Alarm
Action
257
259
261
263
Compartment
Size Low
Limit
Compartment
Size High
Limit
NA NA
PC 650 x 100 PC 651 x 100
NA NA
PC 652 x 100 PC 653 x 100
"Error conditions" on the compartment size inputs are handled as follows: If multiple compartment size inputs are closed, the DanLoad
6000 uses the lowest compartment size indicated by the closed inputs, e.g. if compartment size inputs 2 and 4 are closed, the compartment size corresponding to compartment size input 2 is used. If none of the compartment size inputs is closed, the compartment size in
"undefined" and a batch cannot be authorized.
Program Code Definitions (280 to 379 I/O Parameters) ______________________________________________ Section 6 - 127
________________________________________________________________________________________ DanLoad 6000 (v6.00)
6.14
I/O Parameters (continued)
342 Start method
This program code defines the method by which a batch is started. The default value is "Normal". Select one of the following:
# "Normal". A batch is started by punching in a [valid] preset quantity and pressing the "ENTER" key (at which point the preset quantity is validated) followed by the
"START" key.
# "Immed.". Immediate. A batch is started by punching in a [valid] preset quantity and pressing the "START" key or the "ENTER" key. When the DanLoad 6000 is prompting for a preset quantity, the "ENTER" key and the "START" key do the same thing. This method is useful where the operator does not have direct access to the DanLoad
6000's keypad and the "START" key has been wired to a
"remote start push-button", e.g. attached to the loading arm, via a "START/STOP interface only" or
"START/STOP remote display interface" board (part numbers 3-6000-147 and -149 respectively).
343 Auto/manual change-over
This program code assigns a physical discrete status input for the auto/manual mode change-over logical function. This input selects the Auto Mode or Manual Mode of operation (input
CLOSED = Auto Mode, input OPEN = Manual Mode). The function is used to enable manual operation of the DanLoad 6000 in case of a failure of the terminal automation system. Input numbers 51 and above are “inverted”, i.e. the actual input is the input number minus 50, but the state (“open” or closed”) is inverted. Reference program code 025 for operating mode.
344 Primary alarm reset
This program code assigns a physical discrete status input for the primary alarm reset logical function. Normal state = OPEN, a momentary CLOSE of the input circuit resets oldest active primary alarm. All primary alarms can be reset in this manner.
Input numbers 51 and above are “inverted”, i.e. the actual input is the input number minus 50, but the state (“open” or closed”) is inverted.
Program Code Definitions (280 to 379 I/O Parameters) ______________________________________________ Section 6 - 128
________________________________________________________________________________________ DanLoad 6000 (v6.00)
CONTINUE
Program Code Definitions (280 to 379 I/O Parameters) ______________________________________________ Section 6 - 129
________________________________________________________________________________________ DanLoad 6000 (v6.00)
6.14
I/O Parameters (continued)
PC# / Function
345 Safety circuit 1
346 Safety circuit 2
347 Safety circuit 3
348 Safety circuit 4
349 Safety circuit 5 or compartment size input 1
350 Safety circuit 6 or compartment size input 2
351 Safety circuit 7 or compartment size input 3
352 Safety circuit 8 or compartment size input 4
353 RTD range
354 Delay after outputs
(msec)
Range <Default> OR Option (* = Default)
0 to max. discrete input, 51 to (50 + max. discrete input) <0>
0 to max. discrete input, 51 to (50 + max. discrete input) <0>
0 to max. discrete input, 51 to (50 + max. discrete input) <0>
0 to max. discrete input, 51 to (50 + max. discrete input) <0>
0 to max. discrete input, 51 to (50 + max. discrete input) <0>
0 to max. discrete input, 51 to (50 + max. discrete input) <0>
0 to max. discrete input, 51 to (50 + max. discrete input) <0>
0 to max. discrete input, 51 to (50 + max. discrete input) <0>
0 Std *
1 Hi
2 Low
0 to 9999 <0>
Program Code Definitions (280 to 379 I/O Parameters) ______________________________________________ Section 6 - 130
________________________________________________________________________________________ DanLoad 6000 (v6.00)
6.14
I/O Parameters (continued)
345 Safety circuit 1
This program code assigns a physical discrete status input for the safety circuit 1 logical function. Logical control of this safety circuit is performed by program codes 249 and 250. Input numbers 51 and above are “inverted”, i.e. the actual input is the input number minus 50, but the state (“open” or closed”) is inverted.
Input numbers 51 and above are “inverted”, i.e. the actual input is the input number minus 50, but the state (“open” or closed”) is inverted.
346 Safety circuit 2
This program code assigns a physical discrete status input for the safety circuit 2 logical function. Logical control of this safety circuit is performed by program codes 251 and 252. Input numbers 51 and above are “inverted”, i.e. the actual input is the input number minus 50, but the state (“open” or closed”) is inverted.
348 Safety circuit 4 or Recipe selection input
This program code assigns a physical discrete status input for the safety circuit 4 logical function. Logical control of this safety circuit is performed by program codes 255 and 256. An additional function of this parameter is to enable the six recipe selection inputs program code 361 / 362 / 363 / 364 / 365 / 366
Recipe x input. To enable this feature, set program code 348
Safety circuit 4 to 0 and assign program code 361 / 362 / 363 /
364 / 365 / 366 Recipe x input to discrete inputs as required by the installation configuration. Input numbers 51 and above are
“inverted”, i.e. the actual input is the input number minus 50, but the state (“open” or closed”) is inverted. Zero indicates “redirect to recipe selection inputs” for recipes 1 through 6.
347 Safety circuit 3
This program code assigns a physical discrete status input for the safety circuit 3 logical function. Logical control of this safety circuit is performed by program codes 253, 254 and 425.
Program Code Definitions (280 to 379 I/O Parameters) ______________________________________________ Section 6 - 131
________________________________________________________________________________________ DanLoad 6000 (v6.00)
6.14
I/O Parameters (continued)
349 Safety circuit 5 or compartment size input 1
This program code assigns a physical discrete status input for the safety circuit 5 logical function. Logical control of this safety circuit is performed by program codes 257, 258, and 265. Input numbers 51 and above are “inverted”, i.e. the actual input is the input number minus 50, but the state (“open” or closed”) is inverted. This can also be used as compartment size input 1 (see program code 341 for details and special considerations).
350 Safety circuit 6 or compartment size input 2
This program code assigns a physical discrete status input for the safety circuit 6 logical function. Logical control of this safety circuit is performed by program codes 259, 260, and 266. Input numbers 51 and above are “inverted”, i.e. the actual input is the input number minus 50, but the state (“open” or closed”) is inverted. This can also be used as compartment size input 2 (see program code 341 for details and special considerations).
351 Safety circuit 7 or compartment size input 3
This program code assigns a physical discrete status input for the safety circuit 7 logical function. Logical control of this safety circuit is performed by program codes 261, 262, and 267. Input numbers 51 and above are “inverted”, i.e. the actual input is the input number minus 50, but the state (“open” or closed”) is inverted. This can also be used as compartment size input 3 (see program code 341 for details and special considerations).
352 Safety circuit 8 or compartment size input 4
This program code assigns a physical discrete status input for the safety circuit 8 logical function. Logical control of this safety circuit is performed by program codes 263, 264, and 268. Input numbers 51 and above are “inverted”, i.e. the actual input is the input number minus 50, but the state (“open” or closed”) is inverted. This can also be used as compartment size input 4 (see program code 341 for details and special considerations).
Program Code Definitions (280 to 379 I/O Parameters) ______________________________________________ Section 6 - 132
________________________________________________________________________________________ DanLoad 6000 (v6.00)
6.14
I/O Parameters (continued)
353 RTD range
This program code matches the type of RTD inputs on the analog inputs board for various temperature ranges. All the RTD inputs on a DanLoad 6000's analog inputs board must be the same temperature range. The RTD input on the v2 CPU board is always -20 to 55 degrees Celsius. Select one of the following:
# Std
Analog inputs board with RTD inputs from - 40 degrees to + 110 degrees Celsius.
# Hi
Analog inputs board with RTD inputs from + 50 degrees to + 200 degrees Celsius.
# Low
Analog inputs board with RTD inputs from -200 degrees to -50 degrees Celsius.
354 Delay after outputs
Delay in milliseconds between energizing the recipe and component combination outputs and checking the safety circuit inputs. Enables an automation system to energize an output based on status of inputs it receives from the DanLoad 6000.
Program Code Definitions (280 to 379 I/O Parameters) ______________________________________________ Section 6 - 133
________________________________________________________________________________________ DanLoad 6000 (v6.00)
6.14
I/O Parameters (continued)
PC# / Function
355 Primary LCD type
356 Primary LCD min light
357 Primary LCD max light
358 Secondary LCD type
359 Secondary LCD min light
360 Secondary LCD max light
Range <Default> OR Option (* = Default)
0 Unknown
1 Standish
2 Optrex *
3 Old Optrex
0 to 1023 <455>
0 to 1023 <405>
0 Unknown
1 Standish
2 Optrex *
3 Old Optrex
0 to 1023 <455>
0 to 1023 <405>
Program Code Definitions (280 to 379 I/O Parameters) ______________________________________________ Section 6 - 134
________________________________________________________________________________________ DanLoad 6000 (v6.00)
6.14
I/O Parameters (continued)
355 / 358 <Primary / Secondary> LCD type
This program code identifies the type of LCD (Liquid Crystal
Display) installed in the local DanLoad 6000. When the LCD type is known, this information is used to “auto-adjust” the
LCD’s contrast for internal temperature variations and also enables the display failure alarm, i.e. keypad/display disconnected, or internal temperature too high. There is no need to detect an internal temperature too-low condition. The default value is “Optrex". A few early DanLoad 6000's had “Old Optrex"
LCD’s marked “Y-LY” on the back of Optrex’s LCD board (not on Daniel’s display board attached to the Optrex display board).
Most DanLoad 6000's shipped since 1993 have “Optrex" LCD’s, usually marked “YJ-LY” on the back of the Optrex LCD board, although a few of the earlier “Optrex" LCD’s had the same mark as the “Old Optrex" LCD’s. Select one of the following:
# Unknown
Automatic contrast adjustment, automatic backlighting adjustment and display failure alarm disabled.
#
#
#
Standish
The Standish LCD has a maximum internal temperature of 70 degrees Celsius with the temperature sensor located just below the top edge of the display.
Optrex
The Optrex extended range (maximum internal temperature = 70 degrees Celsius) LCD has the temperature sensor located just below the top edge of the display. This is the usual setting. Post-1996 Optrex
“extended range” LCD’s may be of the transflective type.
Old Optrex
Standard range (maximum internal temperature = 60 degrees Celsius) LCD with the temperature sensor located just below the top edge of the display.
Program Code Definitions (280 to 379 I/O Parameters) ______________________________________________ Section 6 - 135
________________________________________________________________________________________ DanLoad 6000 (v6.00)
6.14
I/O Parameters (continued)
356 / 359 <Primary / Secondary> LCD minimum light
This program code sets the relative level of ambient light used to set the backlighting of the display to maximum brightness.
# 0 to 1023
A relative number related to the level of ambient light (default is
455).
357 / 360 <Primary / Secondary> LCD maximum light
This program code sets the relative level of ambient light used to set the backlighting of the display to minimum brightness
(backlighting off).
# 0 to 1023
A relative number related to the level of ambient light (default is
405).
Program Code Definitions (280 to 379 I/O Parameters) ______________________________________________ Section 6 - 136
________________________________________________________________________________________ DanLoad 6000 (v6.00)
CONTINUE
Program Code Definitions (280 to 379 I/O Parameters) ______________________________________________ Section 6 - 137
________________________________________________________________________________________ DanLoad 6000 (v6.00)
6.14
I/O Parameters (continued)
PC# / Function
361 Recipe 1 input
362 Recipe 2 input
363 Recipe 3 input
364 Recipe 4 input
365 Recipe 5 input
366 Recipe 6 input
367 Recipe 1 output
368 Recipe 2 output
369 Recipe 3 output
370 Recipe 4 output
371 Recipe 5 output
372 Recipe 6 output
373 End output method
374 Level input
375 Hatch input
376 Swing 1 input
377 Swing 2 input
378 Low flow input
379 Alarm output 2
Range <Default> OR Option (* = Default)
0 to max. discrete input, 51 to (50 + max. discrete input) <0>
0 to max. discrete input, 51 to (50 + max. discrete input) <0>
0 to max. discrete input, 51 to (50 + max. discrete input) <0>
0 to max. discrete input, 51 to (50 + max. discrete input) <0>
0 to max. discrete input, 51 to (50 + max. discrete input) <0>
0 to max. discrete input, 51 to (50 + max. discrete input) <0>
0 to number of discrete outputs <0>
0 to number of discrete outputs <0>
0 to number of discrete outputs <0>
0 to number of discrete outputs <0>
0 to number of discrete outputs <0>
0 to number of discrete outputs <0>
0 Ba only *
1 Tr only
2 Both
0 to max. Discrete input, 51 to (50 + max. Discrete input) <0>
0 to max. Discrete input, 51 to (50 + max. Discrete input) <0>
0 to max. discrete input, 51 to (50 + max. discrete input) <0>
0 to max. discrete input, 51 to (50 + max. discrete input) <0>
0 to max. discrete input, 51 to (50 + max. discrete input) <0>
0 to number of discrete outputs <0>
Program Code Definitions (280 to 379 I/O Parameters) ______________________________________________ Section 6 - 138
________________________________________________________________________________________ DanLoad 6000 (v6.00)
6.14
I/O Parameters (continued)
361 / 362 / 363 / 364 / 365 / 366 Recipe X input
This program code selects the physical discrete input that is used to allow or permit the corresponding recipe. This feature permits manual switch or relay selection of one of six recipes from a remote source (input CLOSE = recipe allowed; input OPEN = recipe not allowed). Input numbers 51 and above are “inverted”, i.e. the actual input is the input number minus 50, but the state
(“open” or closed”) is inverted.
If for recipes 1 through 6 only, safety circuit 4's input (program code 348 Safety circuit 4) is not configured and a recipe’s selection input is configured, the recipe can be loaded only if the recipe’s selection input is closed. If the recipe’s selection input is open, the DanLoad 6000 behaves as if safety circuit 4's input is configured and open, i.e. safety circuit 4's input is “redirected” to the recipe selection input determined by the selected recipe.
367 / 368 / 369 / 370 / 371 / 372 Recipe X output
This program code selects a physical discrete output that is energized during an active batch load when that recipe is selected.
The corresponding output is energized at batch start or restart (before the pump delay) and deenergized at batch end after flow has stopped.
373 End output method
Configures whether the end output (program code 423), end input
(program code 424) and end time (program code 279) processing
(see program code 423 for details) is performed only at the end of a batch, only at the end of a transaction, or both at the end of a batch and at the end of a transaction. The default value is “Ba only”. Select one of the following:
# Ba only
Perform end output processing only at the end of a batch.
# Tr only
#
Perform end output processing only at the end of a transaction.
Both
Perform end output processing both at the end of a batch and at the end of a transaction. (The timer is not restarted if it is already running.)
Program Code Definitions (280 to 379 I/O Parameters) ______________________________________________ Section 6 - 139
________________________________________________________________________________________ DanLoad 6000 (v6.00)
6.14
I/O Parameters (continued)
374 Level input
If configured, the DanLoad 6000 performs “intermediate level input” logic. This logic works specifically with compartment size inputs 1, 2 and 4 as described in the pseudo code description below. Input numbers 51 and above are "inverted", i.e. the actual input is “input number minus 50" but the state ("open" or
"closed") is inverted. Zero indicates "not used". The default value is zero. If the level input is closed, only a preset quantity less than 1000 can be authorized.
The pre-authorization batch check is performed only in manual mode after a preset quantity has been entered/calculated and prior to authorizing a batch:
////
IF Operating mode is manual
AND Compartment size inputs are being used
AND Level input is configured
AND Level input is closed
AND Preset quantity >= Compartment size 1 THEN
BEGIN
Display "Intermediate level input" briefly
Do not authorized batch
END
ELSE
BEGIN
DO AUTHORIZATION BATCH
END
END IF
//// i.e. if the level input is closed, only a preset quantity less than 1000 can be authorized.
During batch delivery in auto or manual, each and every time the level input closes ("edge triggered", if you like):
////
IF Compartment size inputs are being used
AND Level input is closed
BEGIN
IF (Batch gross loaded quantity < 900) // Hard-coded!
OR ((Cpmt size 2 lo < Gross loaded qty < Cpmt size 2 hi) AND (Cpmt size <= Cpmt size 2))
OR ((Cpmt size 4 lo < Gross loaded qty < Cpmt size 4 hi) AND (Cpmt size <= Cpmt size 4)) THEN
Allow batch to continue
ELSE
Raise "Level input" secondary alarm
IF (Level input was closed at < 900)
AND (Level input is still closed at < 900)
/* i.e. (which is the same as saying) “If the level input is closed at 900" */
Raise "Level input" secondary alarm
END
ELSE
Raise "Level input" secondary alarm
////
Program Code Definitions (280 to 379 I/O Parameters) ______________________________________________ Section 6 - 140
________________________________________________________________________________________ DanLoad 6000 (v6.00)
6.14
I/O Parameters (continued)
Compartment size 1 and 3 low and high limits do not exist. The compartment size 2 low (lo) and high (hi) limits are program codes 650 and 651 respectively (x 100). The compartment size
4 low (lo) and high (hi) limits are program codes 652 and 653 respectively (x 100). There is also an automation system communications status bit that indicates that the batch was stopped due to a level input alarm. Refer to the DanLoad 6000
Communications Spec.
NOTE: The pre-authorize batch check is performed only in manual, whereas the during batch delivery check is performed in auto and manual. The pre-authorized batch check is performed only if compartment size input are being used. The during batch delivery check performed is different depending on whether or not compartment size inputs are being used; if compartment size inputs are not being used, the during batch delivery check acts similarly to an "inverted safety circuit" (input "open" = safe/condition) with hard-coded secondary alarm action and hardcoded, language-dependent message text.
375 Hatch input
If configured and compartment size inputs are being used, the
DanLoad 6000 performs “hatch sensor input” logic. Input numbers 51 and above are "inverted", i.e. the actual input is
“input number minus 50", but the state ("open" or "closed") is inverted. Zero indicates "not used".
The default value is zero. The “hatch sensor input” logic allows batch to be authorized for compartment size 4 only if compartment size input 4 is closed and the hatch input is closed.
Compartment size 4 is program code 647.
376 Swing 1 input
This program code selects the discrete input swing-arm switch 1 input. When used, it corresponds to “Swing 1" (TB2-3) on the
CPU board. Input numbers 51 and above are “inverted”, i.e. the actual input is the input number minus 50, but the state (“open” or “closed”) is inverted. Zero indicates “not used”.
Program Code Definitions (280 to 379 I/O Parameters) ______________________________________________ Section 6 - 141
________________________________________________________________________________________ DanLoad 6000 (v6.00)
6.14
I/O Parameters (continued)
377 Swing 2 input
This program code selects the discrete input swing-arm switch 2 input. When used, it corresponds to “Swing 2" (TB2-1) on the
CPU board. Input numbers 51 and above are “inverted”, i.e. the actual input is the input number minus 50, but the state (“open” or “closed”) is inverted. Zero indicates “not used”.
379 Alarm output 2
Assign this discrete output to one of the physical discrete outputs.
This output is triggered based on enabling by program code 270
Alarm o/p 2 mask, the assigned action for the mask enabled alarm, and the alarm in the active state.
378 Low flow input
This program code defines the “stay in low flow input”. When configured, the batch is delivered in low flow, i.e. at the low flow start flow rate, if the input is closed when the batch is started or restarted. (This is achieved by overriding, i.e. temporarily increasing the low flow start quantity internally. For a sequential unit type, the low flow start quantity is per component. For an in-line unit type the low flow quantity is for the batch.) Input numbers 51 and above are inverted, i.e. the actual input is “input number minus 50", but the state (“open” or
“closed”) is inverted. Zero indicates “not used”.
Program Code Definitions (280 to 379 I/O Parameters) ______________________________________________ Section 6 - 142
________________________________________________________________________________________ DanLoad 6000 (v6.00)
CONTINUE
Program Code Definitions (280 to 379 I/O Parameters) ______________________________________________ Section 6 - 143
________________________________________________________________________________________ DanLoad 6000 (v6.00)
6.15
Additive I/O Parameters
PC# / Function
(Six additives)
380 / 383 / 386 / 389 / 392 / 395 Ratio/valve output
381 / 384 / 387 / 390 / 393 / 396 Feedback/meter input
382 / 385 / 388 / 391 / 394/ 397 Selection input
398 Clean line output
399 Flush output
Range <Default> OR Option (* = Default)
0 to number discrete outputs <0>
0 to number discrete inputs <0>
0 to max. discrete input,
51 to (50 + max. discrete input) <0>
0 to number discrete outputs <0>
0 to number discrete output <0>
Additive I/O Parameters contain data which defines control of automatic injection of one to six additives.
Program Code Definitions (380 to 399 Additive I/O Parameters) ______________________________________ Section 6 - 144
________________________________________________________________________________________ DanLoad 6000 (v6.00)
6.15
Additive I/O Parameters (continued)
380 / 383 / 386 / 389 / 392 / 395 Ratio/valve output
The output which is cycled according to the additive inject percentage (program code 137) and the additive's configured ratio quantity (program code 140) and injection method (program code
141). This output would normally be connected to an injector
"pak", additive flow control solenoid or a PLC. Zero indicates
"not used". The default value is zero.
382 / 385 / 388 / 391 / 394 / 397 Selection input
For the "Inputs" additive selection method (program code 136) this is the input which is used to select the additive either prior to or during loading. The additive remains selected while the input remains closed. Input numbers 51 and above are “inverted”, i.e.
the actual input is the input number minus 50, but the state
(“open” or closed”) is inverted. Zero indicates "not used". The default value is zero.
381 / 384 / 387 / 390 / 393 / 396 Feedback/meter input
The input which is used to verify additive injection or totalize additive (possibly for volumetric verification) using a pulse per volume or an additive meter K-factor. This input would normally be connected to an additive "pak's" feedback switch, a "smart" injector's verification pulse or an additive meter's pulse output.
Zero indicates "not used". The default value is zero.
398 Additive clean line output
This program code assigns a discrete control output that is energized during delivery of the quantity set by program code 138
Additive clean line qty at the end of a batch delivery. A typical use for this output is to connect the clean line volume to a smart
(microprocessor controlled) additive injector that over-injects at the start of a batch and stops injecting prior to the end of the batch. Another use is with a multi-stream injector where the additive clean line output should be connected to the block valve that allows product to flow to the (shared) additive ratio solenoid.
Zero indicates “not used”.
Program Code Definitions (380 to 399 Additive I/O Parameters) ______________________________________ Section 6 - 145
________________________________________________________________________________________ DanLoad 6000 (v6.00)
6.15
Additive I/O Parameters (continued)
399 Flush output
This program code selects the output to be energized during delivery of the (additive clean line quantity - 10) product units at the end of a batch. This output is intended to be used in multistream injection mode, but is available independent of the injection mode. In multi-stream injection mode (multiple additives with the same non-zero meter input), the additive flush output is energized only if an additive has been authorized. Zero indicates “not used”.
Note: The additive flush output is energized approximately 10 product units after the additive clean line output is energized, so the additive clean line quantity (program code 138) should be greater than 10 product units when using the additive flush output.
Program Code Definitions (380 to 399 Additive I/O Parameters) ______________________________________ Section 6 - 146
________________________________________________________________________________________ DanLoad 6000 (v6.00)
CONTINUE
Program Code Definitions (380 to 399 Additive I/O Parameters) ______________________________________ Section 6 - 147
________________________________________________________________________________________ DanLoad 6000 (v6.00)
6.16
Component I/O Parameters
PC# / Function
(Four components)
400 / 402 / 404 / 406 Block valve output
401 / 403 / 405 / 407 Block valve input
Range <Default> OR Option (* = Default)
0 to number discrete outputs
0 to max. discrete input,
51 to (50 + max. discrete input) <0>
Component I/O Parameters contain data which define automatic control and monitoring of component block valves, typically used in sequential blending applications. Block valve control discrete outputs can be assigned for single components or combinations of two, three, or four components.
400 / 402 / 404 / 406 Block valve output
This program code assigns a physical discrete control output for the corresponding component block valve output logical function.
The function of the block valve is changed in the following manner for “Side” stream in-line blending.
For "Side" stream In-line Blending, the user should assign an output to open a block valve to allow the side stream component
(e.g. Ethanol) to blend with the wild stream component (e.g.
Gasoline). For two component blending (One component must be the side stream component) the block valve output will be
"Closed" when corresponding wild stream component is used.
For more than two component blending ( One Component must be the side stream component) the block valve output will be
"Closed" when the recipe is defined with a corresponding wild stream component and that component uses the Midgrade primary blend stream meter defined in program code 063.
Program Code Definitions (400 through 425 Component I/O Parameters) ______________________________ Section 6 - 148
________________________________________________________________________________________ DanLoad 6000 (v6.00)
6.16
Component I/O Parameters (continued)
401 / 403 / 405 / 407 Block valve input
This program code assigns a physical discrete status input for the corresponding block valve input logical function. Input numbers
51 and above are “inverted”, i.e. the actual input is the input number minus 50, but the state (“open” or closed”) is inverted.
Program Code Definitions (400 through 425 Component I/O Parameters) ______________________________ Section 6 - 149
________________________________________________________________________________________ DanLoad 6000 (v6.00)
6.16
Component I/O Parameters (continued)
PC# / Function
408 1 1XXX
409 2 X2XX
410 3 12XX
411 4 XX3X
412 5 1X3X
413 6 X23X
414 7 123X
415 8 XXX4
416 9 1XX4
417 10 X2X4
418 11 12X4
419 12 XX34
420 13 1X34
421 14 X234
422 15 1234
Range <Default> OR Option (* = Default)
0 to number discrete outputs
0 to number discrete outputs
0 to number discrete outputs
0 to number discrete outputs
0 to number discrete outputs
0 to number discrete outputs
0 to number discrete outputs
0 to number discrete outputs
0 to number discrete outputs
0 to number discrete outputs
0 to number discrete outputs
0 to number discrete outputs
0 to number discrete outputs
0 to number discrete outputs
0 to number discrete outputs
Program Code Definitions (400 through 425 Component I/O Parameters) ______________________________ Section 6 - 150
________________________________________________________________________________________ DanLoad 6000 (v6.00)
6.16
Component I/O Parameters (continued)
Note
Component combination outputs indicate which components are included in the recipe being loaded. Recipe outputs
(program codes 367 to 372) indicate which recipe is being loaded (recipes 1 to 6 only).
410 3 12XX
This program code assigns a physical discrete control output to a block valve, block valves, or other device. This output is
CLOSED when the indicated components are being blended
(selected by the active recipe).
[components 1 and 2]
408 1 1XXX
This program code assigns a physical discrete control output to a block valve, block valves, or other device. This output is
CLOSED when the indicated components are being blended
(selected by the active recipe).
[component 1 only]
411 4 XX3X
This program code assigns a physical discrete control output to a block valve, block valves, or other device. This output is
CLOSED when the indicated components are being blended
(selected by the active recipe).
[component 3 only]
409 2 X2XX
This program code assigns a physical discrete control output to a block valve, block valves, or other device. This output is
CLOSED when the indicated components are being blended
(selected by the active recipe).
[component 2 only]
Program Code Definitions (400 through 425 Component I/O Parameters) ______________________________ Section 6 - 151
________________________________________________________________________________________ DanLoad 6000 (v6.00)
6.16
Component I/O Parameters (continued)
412 5 1X3X
This program code assigns a physical discrete control output to a block valve, block valves, or other device. This output is
CLOSED when the indicated components are being blended
(selected by the active recipe)
[components 1 and 3]
414 7 123X
This program code assigns a physical discrete control output to a block valve, block valves, or other device. This output is
CLOSED when the indicated components are being blended
(selected by the active recipe).
[components 1, 2, and 3]
413 6 X23X
This program code assigns a physical discrete control output to a block valve, block valves, or other device. This output is
CLOSED when the indicated components are being blended
(selected by the active recipe).
[components 2 and 3]
415 8 XXX4
This program code assigns a physical discrete control output to a block valve, block valves, or other device. This output is
CLOSED when the indicated components are being blended
(selected by the active recipe).
[component 4 only]
Program Code Definitions (400 through 425 Component I/O Parameters) ______________________________ Section 6 - 152
________________________________________________________________________________________ DanLoad 6000 (v6.00)
6.16
Component I/O Parameters (continued)
416 9 1XX4
This program code assigns a physical discrete control output to a block valve, block valves, or other device. This output is
CLOSED when the indicated components are being blended
(selected by the active recipe).
[components 1 and 4]
417 10 X2X4
This program code assigns a physical discrete control output to a block valve, block valves, or other device. This output is
CLOSED when the indicated components are being blended
(selected by the active recipe).
[components 2 and 4]
418 11 12X4
This program code assigns a physical discrete control output to a block valve, block valves, or other device. This output is
CLOSED when the indicated components are being blended
(selected by the active recipe).
[components 1, 2, and 4]
419 12 XX34
This program code assigns a physical discrete control output to a block valve, block valves, or other device. This output is
CLOSED when the indicated components are being blended
(selected by the active recipe).
[components 3 and 4]
Program Code Definitions (400 through 425 Component I/O Parameters) ______________________________ Section 6 - 153
________________________________________________________________________________________ DanLoad 6000 (v6.00)
6.16
Component I/O Parameters (continued)
420 13 1X34
This program code assigns a physical discrete control output to a block valve, block valves, or other device. This output is
CLOSED when the indicated components are being blended
(selected by the active recipe).
[components 1, 3, and 4]
422 15 1234
This program code assigns a physical discrete control output to a block valve, block valves, or other device. This output is
CLOSED when the indicated components are being blended
(selected by the active recipe).
[components 1, 2, 3, and 4]
421 14 X234
This program code assigns a physical discrete control output to a block valve, block valves, or other device. This output is
CLOSED when the indicated components are being blended
(selected by the active recipe).
[components 2, 3, and 4]
Program Code Definitions (400 through 425 Component I/O Parameters) ______________________________ Section 6 - 154
________________________________________________________________________________________ DanLoad 6000 (v6.00)
CONTINUE
Program Code Definitions (400 through 425 Component I/O Parameters) ______________________________ Section 6 - 155
________________________________________________________________________________________ DanLoad 6000 (v6.00)
6.16
Component I/O Parameters (continued)
PC# / Function
423 End output
424 End input
425 Flush pulses
Range < Default> OR Option (* = Default)
0 to 24 <0>
0 to max. discrete input,
51 to (50 + max. discrete input) <0>
0 to 999999999 <0>
Program Code Definitions (400 through 425 Component I/O Parameters) ______________________________ Section 6 - 156
________________________________________________________________________________________ DanLoad 6000 (v6.00)
6.16
Component I/O Parameters (continued)
423 End output
The end output (if configured) is energized at the end of a batch/transaction, depending on the configured end output method (program code 373), if the end input (program code 424) is open (deenergized) or not configured when the batch/transaction ends (not when a batch stops and is restartable).
The end output remains energized until the end input closes or a
"safety circuit 3" alarm is raised. A "safety circuit 3" alarm is raised if the end input does not close within "end time" (program code 279) seconds of the end batch output being energized.
Safety circuit 3 is used so that the alarm message (program code
254) can be configured, which allows the end output and input to be used for a variety of purposes. One application is controlling the mercaptan vessel fill for LPG loading. Zero indicates "not used". The default value is zero.
424 End input
See "End output" (program code 423) for details. Zero indicates
"not used". The default value is 0. Input numbers 51 and above are “inverted”, i.e. the actual input is input number minus 50, but the state (“open” or “closed”) is inverted.
425 Flush pulses
This program code sets the minimum number of pulses required from the additive meter during additive meter flushing, i.e. while the additive flush output (program code 399) is energized at the end of a batch, in order to prevent a safety circuit 3 alarm, e.g.
“Additive meter flush failure”, from being raised. Note that the
Safety circuit 3 alarm is shared with the safety circuit 3 input, and
“end” alarm processing. The additive meter flush pulse count
(data code 223) is checked only at the end of a batch, not continuously during additive meter flushing so that a batch will not be stopped (or ended) with a small number of units of product remaining. In multi-stream injection mode (multiple additives with the same non-zero meter input), the additive meter flush pulse count is checked only if more than one additive is authorized. It is important to understand that additive meter pulses are not added to the additive meter flush pulse count (data code 223) until the additive meter flush output (program code
339) has been energized. Zero disables “additive meter flush pulses” checking.
Program Code Definitions (400 through 425 Component I/O Parameters) ______________________________ Section 6 - 157
________________________________________________________________________________________ DanLoad 6000 (v6.00)
6.17
Temperature / Pressure / Density
PC# /Function
(Four Components)
426 Buoyancy
427 Temperature units
428 Density units
429 Pressure units
430 Reference temperature
Range <Default> OR Option (* = Default)
-9.9999 to 9.9999 <0>
0 C (Celsius) *
1 F (Fahrenheit)
0 lb/ft3 *
1 kg/m3
2 g/cm3
3 60/60 F
4 15/4 C
5 20/4 C
0 psi *
1 Pa
2 in. H2O
3 in. Hg
4 bar
5 mbar
6 kPa
7 kg/cm2
-99.9 to 999.9 <15.0>
Program Code Definitions (426 to 479 Temperature/Pressure/Density Parameters) ______________________ Section 6 - 158
________________________________________________________________________________________ DanLoad 6000 (v6.00)
PC# /Function
(Four Components)
431 Sample qty
432 / 435 / 438 / 441 Temperature option
433 / 436 / 439 / 442 Alpha
434 / 437 / 440 / 443 Backup temperature
Range <Default> OR Option (* = Default)
0 to 9999 <100>
0 Off *
1 Linear
2 API 6A
3 API 6B
4 API 6C
5 API 24A
6 API 24B
7 API 54A
8 API 54B
9 API 54C
10 IMP [Mexico (Pemex)]
11 Old 24
12 Old 54
13 P’bras [Brazil (Petrobras)]
14 TP-16
15 China
16 API 6D
17 API 54D
18 4311 1
19 CAN 54B
0.0002700 to 0.0016740 <0.0005100>
-99.9 to 999.9 <15.0>
Program Code Definitions (426 to 479 Temperature/Pressure/Density Parameters) ______________________ Section 6 - 159
426 Buoyancy
This program code sets the density adjustment for bouancy in air.
The position of the “floating decimal point” depends on the density/gravity scale (program code 46).
427 Temperature units
This program code selects the temperature units to be used in calculations, displays, and logs. The default value is “C”.
#
#
________________________________________________________________________________________ DanLoad 6000 (v6.00)
6.17
Temperature / Pressure / Density
(continued)
Temperature / Pressure / Density Parameters contain data that defines the calculation methods used to compute the values of C tl
(correction for the effect of temperature of the liquid) and C pl
(correction for the effect of pressure of the liquid).
428 Density units
This program code selects the density units mnemonic to be used in calculations, displays, printing and logs.
#
#
#
#
#
# lb/ft3 pounds per cubic foot
kg/m3 kilograms per cubic meter g/cm3
60/60 F
15/4 C
20/4 C grams per cubic centimeter relative density 60 deg. F / 60 deg. F relative density 15 deg. C / 4 deg. C relative density 20 deg. C / 4 deg. C
C
F
Celsius
Fahrenheit
Program Code Definitions (426 to 479 Temperature/Pressure/Density Parameters) ______________________ Section 6 - 160
________________________________________________________________________________________ DanLoad 6000 (v6.00)
6.17
Temperature / Pressure / Density
(continued)
429 Pressure units
This program code selects the pressure units mnemonic used in calculations, displays, printing and logs.
#
#
#
#
#
#
#
# psi
Pa in. H2O
Pounds per square inch
Pascals
Inches water column
in. Hg Inches mercury bar mbar kPa kg/cm2
Bar
Millibar
KiloPascals
Kilograms per centimeter square
430 Reference temperature
(Note: See program code 432 / 435 / 438 / 441 Temperature
option.) This program code sets the reference temperature for the
Linear equation or API tables 6C or 54C. (Note: Normal reference temperature for API tables 6C is 60.0 degrees
Fahrenheit. Normal reference temperature for API table 54C is
15.0 degrees Celsius. This program code allows a non-standard reference temperature to be used.)
431 Sample qty
This program code sets the quantity-based temperature sampling frequency used during a batch delivery. The process temperature is sampled at the start of a batch delivery and thereafter each time the quantity of units indicated by this parameter have been accumulated.
Program Code Definitions (426 to 479 Temperature/Pressure/Density Parameters) ______________________ Section 6 - 161
________________________________________________________________________________________ DanLoad 6000 (v6.00)
6.17
Temperature / Pressure / Density
(continued)
432 / 435 / 438 / 441 Temperature option
This program code selects the method of temperature compensation of the process liquid.
#
Note
Daniel Industries, Inc. and Daniel Measurement and Control
Products (“Daniel”) shall not be held responsible or liable in any way for loss or damage, including, but not limited to, consequential damage, resulting from the use of volume correction tables or related mathematical relationships or for violation of any federal, state, or municipal laws, regulations, or practices of the United States or of any foreign country.
Off
Disable temperature compensation. If the meter pulse input is not temperature compensated at the flow meter,
# the DanLoad 6000 calculations produce API gross
quantity which is the indicated quantity (meter registration) times the meter factor.
Linear
The following linear equation is used to calculate temperature compensation.
C
TL
= where: t
C
TL
T
"
T
=
=
=
=
Correction for the effect of temperature on a liquid.
Observed temperature from an RTD input or the fixed entry in program code
434/437/440/443 Backup temperature.
Reference temperature from program code
430 Reference temperature.
Coefficient of thermal expansion for the liquid at base temperature, from program code 433/436/439/442 Alpha.
Program Code Definitions (426 to 479 Temperature/Pressure/Density Parameters) ______________________ Section 6 - 162
________________________________________________________________________________________ DanLoad 6000 (v6.00)
6.17
Temperature / Pressure / Density
(continued)
# API Temperature Compensation Tables:
# API 6A
Standard reference temperature: 60 degrees F.
Temperature correction to a non-standard reference temperature via program code 430.
# API 6B
Standard reference temperature: 60 degrees F.
Temperature correction to a non-standard reference temperature via program code 430.
# API 6C
Standard reference temperature: 60 degrees F.
Temperature correction to a non-standard reference temperature via program code 430.
# API 24A
Standard reference temperature: 60 degrees F.
Temperature correction to a non-standard reference temperature via program code 430.
#
#
API 24B
Standard reference temperature: 60 degrees F.
Temperature correction to a non-standard reference temperature via program code 430.
API 54A
Standard reference temperature: 60 degrees F.
Temperature correction to a non-standard reference temperature via program code 430.
Program Code Definitions (426 to 479 Temperature/Pressure/Density Parameters) ______________________ Section 6 - 163
________________________________________________________________________________________ DanLoad 6000 (v6.00)
6.17
Temperature / Pressure / Density
(continued)
# API 54B
Standard reference temperature: 15 degrees C.
Temperature correction to a non-standard reference temperature via program code 430.
#
#
API 54C
IMP
Instituto Mexicano del Petroleo programa
Correccion de Volumen por Temperatura de los
Productos Petroliferos Evaluados a 20 grados
Celsius
#
Tables 1A/1B through 20A/20B are supported.
Since IMP’s method uses six significant digits with single precision floating point, the volume correction factor can vary by +/- 1 in the least significant digit. Standard reference temperature:
20 degrees C. Temperature correction to a nonstandard reference temperature via program code
430.
Old 24
Old ASTM-IP Table 24 “Reduction of Volume to 60 degrees F against Specific Gravity 60/60 degrees F” (ASTM D 1250, IP 200, API 2540).
Standard reference temperature: 60 degrees F.
Temperature correction to a non-standard reference temperature via program code 430.
Note: This table is not functional when the Side stream blending (Program code 023) is set to
“YES”.
Program Code Definitions (426 to 479 Temperature/Pressure/Density Parameters) ______________________ Section 6 - 164
________________________________________________________________________________________ DanLoad 6000 (v6.00)
6.17
Temperature / Pressure / Density
(continued)
#
#
Old 54
Old ASTM-IP Table 54 “Reduction of Volume to 15 degrees C against Density at 15 degrees
C” (ASTM D 1250, IP 200, API 2540).
Standard reference temperature: 60 degrees F.
Temperature correction to a non-standard reference temperature via program code 430.
P’bras (Petrobras - Brazil)
Petrobras Departamento Comercial - Divisão de
Controle das Movimentações -- Biblioteca Geral de Aplicativos para a Área de Movimentações de
Produto - Módulo 4: Programa para Cálculo de
The component density (program codes 457, etc.
per component) should be relative density 20/4 degrees C. Standard reference temperature: 20 degrees C. Temperature correction to a nonstandard reference temperature via program code
430.
Cálculo do Fator de Correção de Volume para
Program Code Definitions (426 to 479 Temperature/Pressure/Density Parameters) ______________________ Section 6 - 165
________________________________________________________________________________________ DanLoad 6000 (v6.00)
6.17
Temperature / Pressure / Density
(continued)
# TP-16
GPA TP-16 C factors for LPG’s, i.e. TP-16-1
TPL through TP-16-5. An appropriate relative density
60/60 degrees F (0.5010, 0.5050, etc.) Should be configured. For TP-16-1 through TP-16-5, i.e.
API 11.2.2 and the vapor pressure method should be TP-15. The published TP-16 assumes TP-15 with atmospheric pressure of 14.7 psia (see program code 822). “TP-16" actually selects Old
Table 24, except that the component average temperature is rounded to the nearest 0.5 degrees
24 (which is defined in 1 degree F intervals) are averaged. Standard reference temperature: 60 degrees F. Temperature correction to a nonstandard reference temperature via program code
430.
Note: This table is not functional when the Side stream blending (Program code 023) is set to
“YES”.
#
GPA TP-16-6 for natural gasoline (relative and the C factor given by the API 11.2.2. The
PL
DanLoad 6000 computes TP-16-6 by configuring the appropriate temperature and pressure correction options.
China
Standard reference temperature: 20 degrees C.
Temperature correction to a non-standard reference temperature via program code 430.
Similar to “Linear” CTL method, but uses a lookup table for the coefficient of thermal expansion
Program Code Definitions (426 to 479 Temperature/Pressure/Density Parameters) ______________________ Section 6 - 166
________________________________________________________________________________________ DanLoad 6000 (v6.00)
6.17
Temperature / Pressure / Density
(continued)
#
#
API 6D
API Table 6D for lubes: -10 to 45 degrees API, 0 to 300 degrees F. Standard reference temperature is 60.0 degrees F. Temperature correction to a non-standard reference temperature is done via program code 430.
Note: This table is not functional when the Side stream blending (Program code 023) is set to
“YES”.
API 54D to 150 degrees C. Standard reference temperature is 15 degrees C. Temperature correction to a nonstandard reference temperature is done via program code 430.
Note: This table is not functional when the Side stream blending (Program code 023) is set to
“YES”.
#
#
4311 1
ASTM D 4311 Table 1 for asphalts. Less than or equal to 34.9 degrees API, or greater than or equal degrees F. The input is degrees API if the density scale (program code 046) is 2, otherwise it is specific gravity. Standard reference temperature is 60.0 degrees F. Temperature correction to a non-standard reference temperature is via program code 430.
Note: This table is not functional when the Side stream blending (Program code 023) is set to
“YES”.
NH3
Note: This table is not functional when the Side stream blending (Program code 023) is set to
“YES”.
Program Code Definitions (426 to 479 Temperature/Pressure/Density Parameters) ______________________ Section 6 - 167
________________________________________________________________________________________ DanLoad 6000 (v6.00)
6.17
Temperature / Pressure / Density
(continued) sequential blender, i.e. more than one component through the same meter, then the backup temperature must be entered for all configured components.
# CAN 54B
Standard reference temperature: 15 degrees C.
Temperature correction to a non-standard reference temperature is via program code 430.
433 / 436 / 439 / 442 Alpha used by the linear equation or the API tables 6C or 54C. The default value is 0.0005100
434 / 437 / 440 / 443 Backup temperature
This program code sets the fixed temperature value to use for the corresponding component in case of a failure of the live temperature input from the RTD. The backup temperature can be set at any time by an automation system or can be entered manually in program mode/setup. (The backup temperature is per component to simplify the interface to an automation system, but could actually be per meter.) If a backup temperature is required and the DanLoad 6000 is configured as a multiple-component
Program Code Definitions (426 to 479 Temperature/Pressure/Density Parameters) ______________________ Section 6 - 168
________________________________________________________________________________________ DanLoad 6000 (v6.00)
CONTINUE
Program Code Definitions (426 to 479 Temperature/Pressure/Density Parameters) ______________________ Section 6 - 169
________________________________________________________________________________________ DanLoad 6000 (v6.00)
6.17
Temperature / Pressure / Density
(continued)
The Pressure options are not functional when the side stream blending is enabled (Program Code 023 set to “YES”).
PC#/ Function
(Four Components)
444 / 447 / 450 / 453 Pressure option
445 / 448 / 451 / 454 F-factor X 1000000000
446 / 449 / 452 / 455 Backup pressure
Range <Default> OR Option (* = Default)
0 Off *
1 Const
2 11.2.1
3 11.2.2
4 11.2.1M
5 11.2.2M
6 P’bras
7 P’bras LPG
8 NH3
0 to 999999999 <0>
0.0 to 9999.99 <0.00>
Program Code Definitions (426 to 479 Temperature/Pressure/Density Parameters) ______________________ Section 6 - 170
________________________________________________________________________________________ DanLoad 6000 (v6.00)
PC#/ Function
(Four Components)
456 / 458 / 460 / 462 Density/gravity option
457 / 459 / 461 / 463 Backup density/gravity
Range <Default> OR Option (* = Default)
0 Off *
1 DT
2 5A
3 5B
4 23A
5 23B
6 53A
8 53B
9 L1
10 L2
2
3
4
-9.9999 to 9.9999 <0>
Entry and scale dependent on program code 046
Density/gravity scale:
1 nnnn.n
nnn.nn
nn.nnn
n.nnnn
Program Code Definitions (426 to 479 Temperature/Pressure/Density Parameters) ______________________ Section 6 - 171
________________________________________________________________________________________ DanLoad 6000 (v6.00)
6.17
Temperature / Pressure / Density
(continued)
444 / 447 / 450 / 453 Pressure option
Program code 444 / 447 / 450 / 453 Pressure option selects the method of pressure compensation.
pressure compensation.
1
[1 - (operating pressure - equilibrium pressure) F-factor]
Note
Daniel Industries, Inc. and Daniel Measurement and Control
Products (“Daniel”) shall not be held responsible or liable in any way for loss or damage, including, but not limited to, consequential damage, resulting from the use of volume correction tables or related mathematical relationships or for violation of any federal, state, or municipal laws, regulations, or practices of the United States or of any foreign country.
The following selections are available.
# Off
Disable pressure compensation.
# Const
The following linear equation is used to calculate where:
C
PL operating pressure
=
= equilibrium pressure =
F-factor =
Correction for the effect of pressure on a liquid.
The pressure obtained from a pressure transmitter.
The equilibrium vapor pressure obtained from program code
446 / 449 / 452 / 455 Pe pressure.
The compressibility factor for the liquid obtained from program code
445 / 448 / 451 / 454 F-factor X
1000000000.
Program Code Definitions (426 to 479 Temperature/Pressure/Density Parameters) ______________________ Section 6 - 172
________________________________________________________________________________________ DanLoad 6000 (v6.00)
6.17
Temperature / Pressure / Density
(continued)
#
#
API Pressure Compensation Tables:
11.2.1
Hydrocarbon liquids, correction of volume to 0 pounds per square inch against API gravity at 60 degrees
Fahrenheit. The table inputs are API gravity at 60 degrees
Fahrenheit obtained live or from program code 457 / 459
/ 461 / 463 Backup density/gravity and the F-factor obtained from program code 445 / 448 / 451 / 454 F-
factor X 1000000000 and the operating pressure obtained from a pressure transmitter, ranges for the table are:
API Gravity Temp.(deg.F) Pressure (PSI)
0 to 90 -20 to +200 0 to 1500
# 11.2.2
Light hydrocarbon liquids, correction of volume to 0 pounds per square inch against relative density 60/60 degrees Fahrenheit. The table inputs are relative density at 60/60 degrees Fahrenheit obtained live or from program code 457 / 459 / 461 / 463 Backup
density/gravity and the F-factor obtained from program code 445 / 448 / 451 / 454 F-factor X 1000000000 and the operating pressure obtained from a pressure transmitter, ranges for the table are:
Rel.Density Temp.(dg.F) Press(PSI)
0.350 to 0.637
-50 to +140 0 to 2200
Program Code Definitions (426 to 479 Temperature/Pressure/Density Parameters) ______________________ Section 6 - 173
________________________________________________________________________________________ DanLoad 6000 (v6.00)
6.17
Temperature / Pressure / Density
(continued)
# 11.2.1M
Hydrocarbon liquids, correction of volume to 0 kiloPascals against absolute density at 15 degrees Celsius.
The table inputs are absolute density at 15 degrees Celsius obtained live or from program code 457 / 459 / 461 / 463
Backup density/gravity and the F-factor obtained from program code 445 / 448 / 451 / 454 F-factor X
1000000000 and the operating pressure obtained from a pressure transmitter, ranges for the table are:
Abs.Dns.(kg/m3) Temp.(deg.C) Press(kPa)
638 to 1074 -30 to +90 0 to 10300
# 11.2.2M
Light hydrocarbon liquids, correction of volume to 0 kiloPascals against absolute density at 15 degrees Celsius. The table inputs are absolute density at 15 degrees Celsius obtained live or from program code 457 / 459 / 461 / 463 Backup
density/gravity and the F-factor obtained from program code 445 / 448 / 451 / 454 F-factor X
1000000000 and the operating pressure obtained from a pressure transmitter, ranges for the table are:
Abs.Dns(kg/m3) Temp.(deg.C) Press(kPa)
350 to 637 -46 to +60 0 to 15200
Program Code Definitions (426 to 479 Temperature/Pressure/Density Parameters) ______________________ Section 6 - 174
________________________________________________________________________________________ DanLoad 6000 (v6.00)
6.17
#
#
Temperature / Pressure / Density
(continued)
P’bras
Pressure correction using degrees C and relative density 20/4 degrees C per Petrobras, Brazil. The relative density is converted and API Table
11.2.1M is used.
P’bras LPG
Pressure correction for LPG’s using degrees C and relative density 20/4 degrees C per Petrobras,
Brazil. The temperature and relative density are converted and API Table 11.2.2 is used.
The default value is “Off”.
# NH3
This option is available only in specially programmed DanLoad 6000 units. The supporting calculations, though not the selection, is disabled in the standard DanLoad 6000.
This option is specific to anhydrous ammonia
(NH3), and as such the component density is should be configured as “NH3". The temperature codes 239 and 240. The pressure range is 50 to
350 psig (inclusive). Note program codes 244 and
245. The pressure option has been programmed such that the CTL, CPL and CTPL factors will be set to 1.0 and a pressure failure alarm will be raised if the input pressure is less than the calculated vapor pressure.
Program Code Definitions (426 to 479 Temperature/Pressure/Density Parameters) ______________________ Section 6 - 175
________________________________________________________________________________________ DanLoad 6000 (v6.00)
6.17
Temperature / Pressure / Density
(continued)
445 / 448 / 451 / 454 F-factor X 1000000000
This program code sets the constant F-factor used in pressure compensation calculations (CPL). The entry value is multiplied code 444 Pressure option is set to Const, since the other C
PL options calculate the F-Factor based on the temperature and density.
446 / 449 / 452 / 455 Backup pressure
This is the component's backup pressure in pressure units appropriate to the configured pressure correction option (kPa for
API Table 11.2.1M, psi for API Table 11.2.1, etc.), interpreted as either static pressure (P ) or differential pressure (P ) depending m d on the configured PT type (program code 818). A non-zero value is used in standard quantity computations (pressure correction) only, i.e. not for valve control. The effect on standard quantity measurement accuracy should be considered very carefully before using a backup pressure. The default value is 0.00, i.e. don't use backup pressure.
456 / 458 / 460 / 462 Density/gravity option
This program code selects the status of using density inputs in the flow calculations.
#
#
#
#
#
#
#
#
#
#
Off
DT
5A
5B
23A
Use configured backup density (program codes
457, etc.).
Use density from density transmitter input
(program codes 321, etc.).
Not used
Not used
Not used
23B Not used
53A Not used
53B Not used
L1 From an LNG table, density (lb/ft3) against pressure (45 to 201 psia) for pure methane
(Liquified Natural Gas).
L2 From an LNG table, density (lb/ft3) against temperature (-230.7 to -177.8 degrees F) for pure methane (Liquified Natural Gas).
Program Code Definitions (426 to 479 Temperature/Pressure/Density Parameters) ______________________ Section 6 - 176
________________________________________________________________________________________ DanLoad 6000 (v6.00)
6.17
Temperature / Pressure / Density
(continued)
457 / 459 / 461 / 463 Backup density/gravity
This program code sets the value of the density (or gravity) to used in calculations when a live analog input is not available.
Entries in this field are validated in the following manner:
Temperature Option Valid Entry
6A, 6B, 6C
24A, 24B
Off, Linear,
54A, 54B, 54C
0.00 to 100.00 API gravity
0.6110 to 1.0760
relative density
610.5 to 1075.0 kg/m3
Program Code Definitions (426 to 479 Temperature/Pressure/Density Parameters) ______________________ Section 6 - 177
________________________________________________________________________________________ DanLoad 6000 (v6.00)
6.17
Temperature / Pressure / Density
(continued)
PC# / Function
(Four Meters)
464 / 468 / 472 / 476 Pressure @4 mA
465 / 469 / 473 / 477 Pressure @20 mA
466 / 470 / 474 / 478 Density @4 mA
467 / 471 / 475 / 479 Density @20 mA
Range <Default> OR Option (* = Default)
0 to 9999.99 <0.00>
0 to 9999.99 <0.00>
-9.9999 to 9.9999 <0>
-9.9999 to 9.9999 <0>
Program Code Definitions (426 to 479 Temperature/Pressure/Density Parameters) ______________________ Section 6 - 178
________________________________________________________________________________________ DanLoad 6000 (v6.00)
6.17
Temperature / Pressure / Density
(continued)
464 / 468 / 472 / 476 Pressure @4 mA
Zero scale for pressure input from transmitter. Engineering unit specified by program code 429 Pressure units.
465 / 469 / 473 / 477 Pressure @20 mA
Full scale for pressure input from transmitter. Engineering units specified by program code 429 Pressure units.
466 / 470 / 474 / 478 Density @4 mA
Zero scale for density input from transmitter. The position of the
“floating decimal point” depends on the density/gravity scale
(program code 46).
467 / 471 / 475 / 479 Density @20 mA
Full scale for density input from transmitter. The position of the
“floating decimal point” depends on the density/gravity scale
(program code 46).
Program Code Definitions (480 to 661 Recipe Parameters) __________________________________________ Section 6 - 179
________________________________________________________________________________________ DanLoad 6000 (v6.00)
6.18
Recipes
PC# / Function
(Recipes 1 through 10)
480 Number of recipes
481 / 487 / 493 / 499 / 505 / 511 / 517 / 523 / 529 / 535 Name
482 / 488 / 494 / 500 / 506 / 512 / 518 / 524 / 530 / 536 Comp 1 %
483 / 489 / 495 / 501 / 507 / 513 / 519 / 525 / 531 / 537 Comp 2 %
484 / 490 / 496 / 502 / 508 / 514 / 520 / 526 / 532 / 538 Comp 3 %
485 / 491 / 497 / 503 / 509 / 515 / 521 / 527 / 533 / 539 Comp 4 % or ratio qty
486 / 492 / 498 / 504 / 510 / 516 / 522 / 528 / 534 / 540 Sequence or low proportion
Range <Default> OR
Option (* = Default)
0 to 30 <1>
1 to 16 chars <Recipe #1>
0 to 100 <100>
0 to 100
0 to 100
0 to 300 nnnn
Program Code Definitions (480 to 661 Recipe Parameters) __________________________________________ Section 6 - 180
________________________________________________________________________________________ DanLoad 6000 (v6.00)
6.18
Recipes (continued)
PC# / Function
(Recipes 11 through 20)
541 / 547 / 553 / 559 / 565 / 571 / 577 / 583 / 589 / 595 Name
542 / 548 / 554 / 560 / 566 / 572 / 578 / 584 / 590 / 596 Comp 1 %
543 / 549 / 555 / 561 / 567 / 573 / 579 / 585 / 591 / 597 Comp 2 %
544 / 550 / 556 / 562 / 568 / 574 / 580 / 586 / 592 / 598 Comp 3 %
545 / 551 / 557 / 563 / 569 / 575 / 581 / 587 / 593 / 599 Comp 4 % or ratio qty
546 / 552 / 558 / 564 / 570 / 576 / 582 / 588 / 594 / 600 Sequence or low proportion
Range <Default> OR
Option (* = Default)
1 to 16 chars
0 to 100
0 to 100
0 to 100
0 to 300 nnnn
Program Code Definitions (480 to 661 Recipe Parameters) __________________________________________ Section 6 - 181
________________________________________________________________________________________ DanLoad 6000 (v6.00)
6.18
Recipes (continued)
PC# / Function
(Recipes 21 through 30)
601 / 607 / 613 / 619 / 625 / 631 / 637 / 643 / 649 / 655 Name
602 / 608 / 614 / 620 / 626 / 632 / 638 / 644 / 650 / 656 Comp 1 %
603 / 609 / 615 / 621 / 627 / 633 / 639 / 645 / 651 / 657 Comp 2 %
604 / 610 / 616 / 622 / 628 / 634 / 640 / 646 / 652 / 658 Comp 3 %
605 / 611 / 617 / 623 / 629 / 635 / 641 / 647 / 653 / 659 Comp 4 % or ratio qty
606 / 612 / 618 / 624 / 630 / 636 / 642 / 648 / 654 / 660 Sequence or low proportion
661 # add calib cycles
NOTE:
Range <Default> OR
Option (* = Default)
1 to 16 chars
0 to 100
0 to 100
0 to 100
0 to 300 nnnn
1 to 9999 <1>
1.
2.
PC#’s 644/645/647 (compartment sizes) are used in conjunction with PC#’s 349/350/351/352 (compartment size inputs) when PC# 341 (# cmpt inputs) is configured.
PC#’s 650/651/652/653 are the low and high limits for compartment sizes 2 and 4 respectively. Compartment sizes
1 and 3 do not have low and high limits associated with them.
Program Code Definitions (480 to 661 Recipe Parameters) __________________________________________ Section 6 - 182
________________________________________________________________________________________ DanLoad 6000 (v6.00)
6.18
Recipes (continued)
Recipe Parameters contain data which defines the percentage of each of one to four components that can be blended into a composite liquid for deliveries. Single components are assigned recipe names so that the component can be referred to by a common name (example: Gasoline in place of Component 2). In the case of a single component delivery, program code 482 / ...
/ 656 Component # % value for that component is 100 percent.
480 Number of recipes
This program code sets the total number of recipes. At least one recipe must be defined.
481 / ... / 655 Name
This program code contains the name used in displays and logs to identify the recipe. The last two characters in this field can also be used to select the additive using the configured additive selection method.
482 / ... /656 Component 1 %
This program code sets the percentage of this component used in the delivered blend. Zero means component is not used.
483 / ... / 657 Component 2 %
This program code sets the percentage of this component used in the delivered blend. Zero means the component is not used.
484 / ... / 658 Component 3 %
This program code sets the percentage of this component used in the delivered blend. Zero means the component is not used.
485 / ... / 659 Component 4 % or ratio volume
This program code sets the percentage of this component used in the delivered blend or the additive ratio quantity for the “Multi-
Rate” additive selection method (which limits the DanLoad 6000 to a maximum of three components). Zero means that the component is not used in the recipe.
Program Code Definitions (480 to 661 Recipe Parameters) __________________________________________ Section 6 - 183
________________________________________________________________________________________ DanLoad 6000 (v6.00)
6.18
Recipes (continued)
486 / ... / 660 Sequence or low proportion
Note: Applicable to Unit type (026) = Seq. (Auto or Man)
This program code selects the sequence to deliver the components. The sum of the recipe selected component percentages must equal 100 percent.
Example: Sequence to load = 312 means component 3 is loaded, then component 1 is loaded, then component 2 is loaded. If the
DanLoad 6000 is configured for only one component, this value must be “1".
Note: Applicable to Unit type (026) = In-line
A '0' or a '1' in each component position (nnnn = 1234) indicates that the corresponding component is either a highproportion component (0) or a low-proportion component (1).
Example: Sequence to load = 0100 means that component 2 is a low-proportion component for a 4-component blend. If the
DanLoad 6000 is configured for only one component, this value must be “0".
Low-proportion components must be indicated so that the
DanLoad 6000 can load these components at the normal flow rates during the first part of the loading time period. This method of loading is performed because the DanLoad 6000 cannot keep a constant blend ratio correct without allowing the flow rate of a low-proportion component to fall below the minimum flow rate of the component’s meter. Therefore, as the loading progresses, the quantity of the low-proportion components exceeds the quantity desired by the batch ratio. The high-proportion components continue to be loaded throughout the total time period of the batch delivery. At the end of the batch delivery, the blend ratio is correct.
Low proportion products are those whose flow rates, if allowed to be loaded proportionally (in proper blend ratio throughout the load), would fall below the minimum rating of the meter. These components are therefore loaded at a specific rate (refer to product code 715) which is within the meter’s rating. The
DanLoad 6000 calculates the quantity of this required component, allows the primary component(s) to load the Low Flow Start quantity, then loads the low-proportional component at the specified rate. When this quantity has been loaded, the valve for this component closes and the batch continues normally for the other component(s). The blend ratio will not be correct until the end of the batch delivery.
Program Code Definitions (480 to 661 Recipe Parameters) __________________________________________ Section 6 - 184
________________________________________________________________________________________ DanLoad 6000 (v6.00)
6.18
Recipes (continued)
661 # add calib cycles
The number of additive injection cycles that are performed when
“START” is pressed in the additive calibration screen (refer to
Additive Meter Calibration - Section 3.10.3). The default value is 1, i.e. one additive injection cycle each time the “START” key is pressed in the additive calibration screen.
Program Code Definitions (480 to 661 Recipe Parameters) __________________________________________ Section 6 - 185
________________________________________________________________________________________ DanLoad 6000 (v6.00)
6.19
Data Communications
Ch. A
662
663
PC#
Ch. B
662
668
Function
Address
Mode
664 669
665 670
666 671
667 672
Data Rate
Word Size
Stop Bits
Parity
Range <Default> OR Option (* = Default)
0 to 255 <0>
0 Not used *
1 Modbus RTU
2 ASCII
3 Data logging (ch. B only)
0 300 bps
1 600 bps
2 1200 bps
3 2400 bps
4 4800 bps
5 9600 bps
6 19200 bps
7 38400 bps
0 5 bits
1 6 bits
2 7 bits
3 8 bits
0 1 bit
1 1-1/2 bits
2 2 bits
0 None
1 Odd
2 Even
Program Code Definitions (662 to 672 Data Communications Parameters) ______________________________ Section 6 - 186
________________________________________________________________________________________ DanLoad 6000 (v6.00)
6.19
Data Communications (continued)
Data Communications Parameters contain data which defines operating parameters for the one or two serial ports and the network port. Serial ports can be used for communications with a Terminal Automation System, host computer, and data logging printer or device. The network port can be used for communications with a Terminal Automation System or other host computer. On the v1 CPU board, the DUART is on a daughter board with an address switch that is read on power-up.
On the v2 CPU board, the DUART is built-in and is addressed via program code 662.
662 Address
The communications address for the Modbus RTU protocol and to identify the unit on data logs. This should typically be modified from the default value prior to placing the unit in service. The default value is 0 in order to avoid conflict with another unit on the same multidrop.
663 / 668 Mode
This program code selects the protocol used for data communications with an external device, such as a data printer, a terminal automation system, or other host computer.
# Not used
This port is not assigned.
# Modbus RTU
Modicon Modbus RTU (binary) protocol.
# ASCII
Not used.
# Data logging
Send data logs to this port, can be connected to an alphanumeric data printer or other data logging device. (For use with RS-232 channel B only.)
Program Code Definitions (662 to 672 Data Communications Parameters) ______________________________ Section 6 - 187
________________________________________________________________________________________ DanLoad 6000 (v6.00)
6.19
Data Communications (continued)
664 / 669 Data rate
This program code selects the bits per second data rate used by this port.
Note: If 38400 bps is selected for Channel B then 19200 bps is not available on Channel A. This is due to the SCN2681's
Auxiliary Control Register’s Baud Rate Generator Set Select. On the DanLoad 6000, Channel B controls the available set of baud rates. 38400 bps is not intended for normal operational use.
665 / 670 Word size
This program code selects the data word length in bits.
666 / 671 Stop bits
This program code selects of the number of stop bits used in serial data transmission.
667 / 672 Parity
This program code selects the parity checking method.
# None
Parity checking in not performed.
# Odd
Odd parity checking is performed.
# Even
Even parity checking is performed.
Program Code Definitions (662 to 672 Data Communications Parameters) ______________________________ Section 6 - 188
________________________________________________________________________________________ DanLoad 6000 (v6.00)
CONTINUE
Program Code Definitions (662 to 672 Data Communications Parameters) ______________________________ Section 6 - 189
________________________________________________________________________________________ DanLoad 6000 (v6.00)
6.20
Dynamic Data Display
PC# / Function
679 Mode
680 Line 1 data code
681 Line 2 data code
682 Line 3 data code
683 Line 4 data code
684 Line 5 data code
685 Line 6 data code
686 Line 7 data code
687 Line 8 data code
Range <Default> OR
Option (* = Default)
Off
Standard *
All
3 digit data display code
3 digit data display code
3 digit data display code
3 digit data display code
3 digit data display code
3 digit data display code
3 digit data display code
3 digit data display code
PC# / Function
688 Line 9 data code
689 Line 10 data code
690 Line 11 data code
691 Line 12 data code
692 Line 13 data code
693 Line 14 data code
694 Line 15 data code
695 Line 16 data code
Range <Default> OR
Option (* = Default)
3 digit data display code
3 digit data display code
3 digit data display code
3 digit data display code
3 digit data display code
3 digit data display code
3 digit data display code
3 digit data display code
Program Code Definitions (679 to 695 Dynamic Data Display Parameters) _____________________________ Section 6 - 190
________________________________________________________________________________________ DanLoad 6000 (v6.00)
6.20
Dynamic Data Display (continued)
Dynamic Data Display Parameters contain program codes which define data values that can be viewed when the DanLoad 6000 is prompting for a preset quantity or a batch delivery is in progress.
The viewable data lines are displayed in pages with four lines in each page. The data variables that can be assigned to each line are selected by entry of a one to three digit identifying number
(Dynamic Data Display Data Code). These Data Codes are listed in Section 6.20.1.
679 Mode
This program code controls how the dynamic data display items are presented. The default value is “Standard”.
# Off
The dynamic data display is disabled.
# Standard
The dynamic data display can be invoked by pressing the
“SELECT” key in the loading screen. Four pages, each with four data codes (identified by program codes 680 through 695), are displayed.
# All
The dynamic data display can be invoked by pressing the
"SELECT" key in the loading screen. Four pages, each with four data codes (identified by program codes 680 thru 695), are displayed, plus additional pages for data codes 1 thru
<maximum> in ascending order.
Example: Four configurable pages
1 Grs batch qty 150
2 Std batch qty 152
3 Mtr 1 grs total 23838017
4 Mtr 1 std total 23839223
5 Mtr 1 grs batch 150
6 Mtr 1 std batch 152
7 Mtr 1 grs unauth 0.0
8 Mtr 1 flw rate 597
9 Mtr 1 factor 1.0000
10 Mtr 1 grs ld 149.72
11 Mtr 1 pls cnt 3821
12 Mtr 1 max flw rate 602
Program Code Definitions (679 to 695 Dynamic Data Display Parameters) _____________________________ Section 6 - 191
________________________________________________________________________________________ DanLoad 6000 (v6.00)
6.20
Dynamic Data Display (continued)
13 Mtr 1 curr temp 42.6
14 Cmp 1 ave temp 42.6
15 Cmp 1 ave vlv cls 230
16 Arm position 1
Data codes 1 through <maximum>
001Arm position 1
002Grs batch qty 150
003Std batch qty 152
004Mtr 1 grs total 23838017
005Mtr 1 std total 23839223
006Mtr 1 grs batch 150
007Mtr 1 std batch 152
008Mtr 1 flw rate 597 etc.
680 Line 1 data code
This program code selects display of the description and data value associated with the specified data code at page 1, line 1 in the Dynamic Data Display.
681 Line 2 data code
This program code selects display of the description and data value associated with the specified data code at page 1, line 2 in the Dynamic Data Display.
682 Line 3 data code
This program code selects display of the description and data value associated with the specified data code at page 1, line 3 in the Dynamic Data Display.
683 Line 4 data code
This program code selects display of the description and data value associated with the specified data code at page 1, line 4 in the Dynamic Data Display.
Program Code Definitions (679 to 695 Dynamic Data Display Parameters) _____________________________ Section 6 - 192
________________________________________________________________________________________ DanLoad 6000 (v6.00)
6.20
Dynamic Data Display (continued)
684 Line 5 data code
This program code selects display of the description and data value associated with the specified data code at page 2, line 1 in the Dynamic Data Display.
685 Line 6 data code
This program code selects display of the description and data value associated with the specified data code at page 2, line 2 in the Dynamic Data Display.
687 Line 8 data code
.
This program code selects display of the description and data value associated with the specified data code at page 2, line 4 in the Dynamic Data Display.
688 Line 9 data code
This program code selects display of the description and data value associated with the specified data code at page 3, line 1 in the Dynamic Data Display.
686 Line 7 data code
This program code selects display of the description and data value associated with the specified data code at page 2, line 3 in the Dynamic Data Display.
689 Line 10 data code
This program code selects display of the description and data value associated with the specified data code at page 3, line 2 in the Dynamic Data Display.
Program Code Definitions (679 to 695 Dynamic Data Display Parameters) _____________________________ Section 6 - 193
________________________________________________________________________________________ DanLoad 6000 (v6.00)
6.20
Dynamic Data Display (continued)
690 Line 11 data code
This program code selects display of the description and data value associated with the specified data code at page 3, line 3 in the Dynamic Data Display.
693 Line 14 data code
This program code selects display of the description and data value associated with the specified data code at page 4, line 2 in the Dynamic Data Display.
691 Line 12 data code
This program code selects display of the description and data value associated with the specified data code at page 3, line 4 in the Dynamic Data Display.
692 Line 13 data code
This program code selects display of the description and data value associated with the specified data code at page 4, line 1 in the Dynamic Data Display.
694 Line 15 data code
This program code selects display of the description and data value associated with the specified data code at page 4, line 3 in the Dynamic Data Display.
695 Line 16 data code
This program code selects display of the description and data value associated with the specified data code at page 4, line 4 in the Dynamic Data Display.
Program Code Definitions (679 to 695 Dynamic Data Display Parameters) _____________________________ Section 6 - 194
________________________________________________________________________________________ DanLoad 6000 (v6.00)
6.20.1
Dynamic Data Display Data Codes
Up to sixteen of the Dynamic Data Display Data Codes listed below can be selected for inclusion in the Dynamic Data Display.
The label and the current value of these variables can be displayed in a window, superimposed in the center area of the
Loading Display. Up to four windows, each window containing four dynamic data lines can be defined. The dynamic data is displayable while in the Loading Mode by pressing the SELECT key. The 9 and 8 arrow keys are used to change the display pages. The CLEAR key removes the Dynamic Data Display window from the Loading Display.
Code Display Data Function
Batch Data
001 Arm position swing arm position indicator
002 Grs batch qty gross batch quantity
003 Std batch qty standard batch quantity
Flow Meter 1 Data
004 Mtr 1 grs total gross totalizer quantity
005 Mtr 1 std total std totalizer quantity
006 Mtr 1 grs batch gross batch quantity
007 Mtr 1 std batch std batch quantity
008 Mtr 1 flw rate instantaneous flow rate
009 Mtr 1 CCF combined correction factor
010 Mtr 1 max flw rate maximum flow rate this batch
011 Mtr 1 factor meter factor
012 Mtr 1 pls cnt pulse count total (resets at 65535)
Code Display Data Function
013 Mtr 1 pls flrt1 pulse count at low flow rate (for load)
014 Mtr 1 pls flrt2 pulse count at flow rate 2 (for load)
015 Mtr 1 pls flrt3 pulse count at flow rate 3 (for load)
016 Mtr 1 pls flrt4 pulse count at flow rate 4 (for load)
017 Mtr 1 grs unauth unauthorized gross quantity
018 Mtr 1 std unauth unauthorized std quantity
019 Mtr 1 grs start start gross quantity
020 Mtr 1 std start start std quantity
Flow Meter 2 Data
021 Mtr 2 grs total gross totalizer quantity
022 Mtr 2 std total std totalizer quantity
023 Mtr 2 grs batch gross batch quantity
024 Mtr 2 std batch std batch quantity
025 Mtr 2 flw rate instantaneous flow rate
026 Mtr 2 CCF average flow rate
027 Mtr 2 max flwrate maximum flow rate this batch
028 Mtr 2 factor meter factor
029 Mtr 2 pls cnt pulse count total (resets at 65535)
030 Mtr 2 pls flrt1 pulse count at low flow rate (for load)
031 Mtr 2 pls flrt2 pulse count at flow rate 2 (for load)
032 Mtr 2 pls flrt3 pulse count at flow rate 3 (for load)
033 Mtr 2 pls flrt4 pulse count at flow rate 4 (for load)
034 Mtr 2 grs unauth unauthorized gross quantity
035 Mtr 2 std unauth unauthorized std quantity
036 Mtr 2 grs start start gross quantity
037 Mtr 2 std start start std quantity
Program Code Definitions (679 to 695 Dynamic Data Display Parameters) _____________________________ Section 6 - 195
________________________________________________________________________________________ DanLoad 6000 (v6.00)
6.20.1
Dynamic Data Display Data Codes
(continued)
Code Display Data Function
Flow Meter 3 Data
038 Mtr 3 grs total gross totalizer quantity
039 Mtr 3 std total std totalizer quantity
040 Mtr 3 grs batch gross batch quantity
041 Mtr 3 std batch std batch quantity
042 Mtr 3 flw rate instantaneous flow rate
043 Mtr 3 CCF average flow rate
044 Mtr 3 max flw rate maximum flow rate this batch
045 Mtr 3 factor meter factor
046 Mtr 3 pls cnt pulse count total (resets at 65535)
047 Mtr 3 pls flrt1 pulse count - low flow rate (for load)
048 Mtr 3 pls flrt2 pulse count at flow rate 2 (for load)
049 Mtr 3 pls flrt3 pulse count at flow rate 3 (for load)
050 Mtr 3 pls flrt4 pulse count at flow rate 4 (for load)
051 Mtr 3 grs unauth unauthorized gross quantity
052 Mtr 3 std unauth unauthorized std quantity
053 Mtr 3 grs start start gross quantity
054 Mtr 3 std start start std quantity
Code Display Data Function
Flow Meter 4 Data
055 Mtr 4 grs total gross totalizer quantity
056 Mtr 4 std total std totalizer quantity
057 Mtr 4 grs batch gross batch quantity
058 Mtr 4 std batch std batch quantity
059 Mtr 4 flw rate instantaneous flow rate
060 Mtr 4 CCF average flow rate
061 Mtr 4 max flw rate maximum flow rate this batch
062 Mtr 4 factor meter factor
063 Mtr 4 pls cnt pulse count total (resets at 65535)
064 Mtr 4 pls flrt1 pulse count - low flow rate (for load)
065 Mtr 4 pls flrt2 pulse count at flow rate 2 (for load)
066 Mtr 4 pls flrt3 pulse count at flow rate 3 (for load)
067 Mtr 4 pls flrt4 pulse count at flow rate 4 (for load)
068 Mtr 4 grs unauth unauthorized gross quantity
069 Mtr 4 std unauth unauthorized std quantity
070 Mtr 4 grs start start gross quantity
071 Mtr 4 std start start std quantity
Component 1 Data
072 Cmp 1 grs batch component gross quantity, batch
073 Cmp 1 std batch component std quantity, batch
074 Mtr 1 curr temp component current temperature
075 Cmp 1 ave temp component batch average temp
076 Cmp 1 ave vlv cls comp. average FCV closure time
077 Cmp 1 batch % component # % from recipe
Program Code Definitions (679 to 695 Dynamic Data Display Parameters) _____________________________ Section 6 - 196
________________________________________________________________________________________ DanLoad 6000 (v6.00)
6.20.1
Dynamic Data Display Data Codes
(continued)
Code Display Data Function
Component 2 Data
078 Cmp 2 grs batch component gross quantity, batch
079 Cmp 2 std batch component std quantity, batch
080 Mtr 2 curr temp component current temperature
081 Cmp 2 ave temp component batch average temp
082 Cmp 2 ave vlv cls comp. average FCV closure time
083 Cmp 2 batch % component # % from recipe
Component 3 Data
084 Cmp 3 grs batch component gross quantity, batch
085 Cmp 3 std batch component std quantity, batch
086 Mtr 3 curr temp component current temperature
087 Cmp 3 ave temp component batch average temp
088 Cmp 3 ave vlv cls comp. average FCV closure time
089 Cmp 3 batch % component # % from recipe
Component 4 Data
090 Cmp 4 grs batch component gross quantity, batch
091 Cmp 4 std batch component std quantity, batch
092 Mtr 4 curr temp component current temperature
093 Cmp 4 ave temp component batch average temp
094 Cmp 4 ave vlv cls comp. average FCV closure time
095 Cmp 4 batch % component # % from recipe
Code Display Data Function
Additive Injection Data (Batch)
096 Add 1 total accumulated additive volume
097 Add 2 total accumulated additive volume
098 Add 3 total accumulated additive volume
099 Add 4 total accumulated additive volume
100 Add 5 total accumulated additive volume
101 Add 6 total accumulated additive volume
Delivery Quantity Data
102 Preset quantity preset entry
103 Mtr 1 grs load accumulated total (n.nn)
104 Mtr 2 grs load accumulated total (n.nn)
105 Mtr 3 grs load accumulated total (n.nn)
106 Mtr 4 grs load accumulated total (n.nn)
Pressure and Density Data
107 Cmp 1 ave dens average density, component 1
108 Cmp 1 ave pres average pressure, component 1
109 Cmp 2 ave dens average density, component 2
110 Cmp 2 ave pres average pressure, component 2
111 Cmp 3 ave dens average density, component 3
112 Cmp 3 ave pres average pressure, component 3
113 Cmp 4 ave dens average density, component 4
114 Cmp 4 ave pres average pressure, component 4
Program Code Definitions (679 to 695 Dynamic Data Display Parameters) _____________________________ Section 6 - 197
________________________________________________________________________________________ DanLoad 6000 (v6.00)
6.20.1
Dynamic Data Display Data Codes
(continued)
Code Display Data Function
Additive Data for Batch
115 Add 1 batch additive 1 volume this/last batch
116 Add 2 batch additive 2 volume this/last batch
117 Add 3 batch additive 3 volume this/last batch
118 Add 4 batch additive 4 volume this/last batch
119 Add 5 batch additive 5 volume this/last batch
120 Add 6 batch additive 6 volume this/last batch
Total Flow Rate
121 Flow rate load flow rate
Component Blend Ratio
122 Cmp 1 adjust % comp 1 % for blend ratio adj
123 Cmp 2 adjust % comp 2 % for blend ratio adj
124 Cmp 3 adjust % comp 3 % for blend ratio adj
125 Cmp 4 adjust % comp 4 % for blend ratio adj
Quantity Correction Factor for Load
126 Mtr 1 CTL meter 1
127 Mtr 2 CTL meter 2
128 Mtr 3 CTL meter 3
129 Mtr 4 CTL meter 4
Batch Data
130 Power fail grs bch gross delivered vol. at power fail time
131 Power fail std bch std delivered qty at power fail time
132 Batch temperature average temperature during load
133 Batch density average density during load
134 Batch pressure average pressure during load
Code Display Data Function
Current Meter Pressure
135 Mtr 1 curr pres meter 1
136 Mtr 2 curr pres meter 2
137 Mtr 3 curr pres meter 3
138 Mtr 4 curr pres meter 4
Pressure Correction Factor for Load
139 Mtr 1 CPL meter 1
140 Mtr 2 CPL meter 2
141 Mtr 3 CPL meter 3
142 Mtr 4 CPL meter 4
Current Meter Density
143 Mtr 1 curr dens meter 1
144 Mtr 2 curr dens meter 2
145 Mtr 3 curr dens meter 3
146 Mtr 4 curr dens meter 4
Delivery Volume Data
147 Mtr 1 std ld accumulated total (n.nn)
148 Mtr 2 std ld accumulated total (n.nn)
149 Mtr 3 std ld accumulated total (n.nn)
150 Mtr 4 std ld accumulated total (n.nn)
Program Code Definitions (679 to 695 Dynamic Data Display Parameters) _____________________________ Section 6 - 198
________________________________________________________________________________________ DanLoad 6000 (v6.00)
6.20.1
Dynamic Data Display Data Codes
(continued)
Code Display Data Function
Component Quantity Totals
151 Cmp 1 grs total component 1 gross quantity, total
152 Cmp 1 std total component 1 std quantity, total
153 Cmp 2 grs total component 2 gross quantity, total
154 Cmp 2 std total component 2 std quantity, total
155 Cmp 3 grs total component 3 gross quantity, total
156 Cmp 3 std total component 3 std quantity, total
157 Cmp 4 grs total component 4 gross quantity, total
158 Cmp 4 std total component 4 std quantity, total
Recipe Quantity Totals
159 Rec 1 grs tot Recipe 1 gross quantity, total
160 Rec 1 std tot Recipe 1 std quantity, total
161 Rec 2 grs tot Recipe 2 gross quantity, total
162 Rec 2 std tot Recipe 2 std quantity, total
163 Rec 3 grs tot Recipe 3 gross quantity, total
164 Rec 3 std tot Recipe 3 std quantity, total
165 Rec 4 grs tot Recipe 4 gross quantity, total
166 Rec 4 std tot Recipe 4 std quantity, total
167 Rec 5 grs tot Recipe 5 gross quantity, total
168 Rec 5 std tot Recipe 5 std quantity, total
169 Rec 6 grs tot Recipe 6 gross quantity, total
170 Rec 6 std tot Recipe 6 std quantity, total
171 Rec 7 grs tot Recipe 7 gross quantity, total
172 Rec 7 std tot Recipe 7 std quantity, total
173 Rec 8 grs tot Recipe 8 gross quantity, total
174 Rec 8 std tot Recipe 8 std quantity, total
175 Rec 9 grs tot Recipe 9 gross quantity, total
176 Rec 9 std tot Recipe 9 std quantity, total
177 Rec 10 grs tot Recipe 10 gross quantity, total
178 Rec 10 std tot Recipe 10 std quantity, total
179 Rec 11 grs tot Recipe 11 gross quantity, total
180 Rec 11 std tot Recipe 11 std quantity, total
Code Display Data Function
181 Rec 12 grs tot Recipe 12 gross quantity, total
182 Rec 12 std tot Recipe 12 std quantity, total
183 Rec 13 grs tot Recipe 13 gross quantity, total
184 Rec 13 std tot Recipe 13 std quantity, total
185 Rec 14 grs tot Recipe 14 gross quantity, total
186 Rec 14 std tot Recipe 14 std quantity, total
187 Rec 15 grs tot Recipe 15 gross quantity, total
188 Rec 15 std tot Recipe 15 std quantity, total
189 Rec 16 grs tot Recipe 16 gross quantity, total
190 Rec 16 std tot Recipe 16 std quantity, total
191 Rec 17 grs tot Recipe 17 gross quantity, total
192 Rec 17 std tot Recipe 17 std quantity, total
193 Rec 18 grs tot Recipe 18 gross quantity, total
194 Rec 18 std tot Recipe 18 std quantity, total
195 Rec 19 grs tot Recipe 19 gross quantity, total
196 Rec 19 std tot Recipe 19 std quantity, total
197 Rec 20 grs tot Recipe 20 gross quantity, total
198 Rec 20 std tot Recipe 20 std quantity, total
199 Rec 21 grs tot Recipe 21 gross quantity, total
200 Rec 21 std tot Recipe 21 std quantity, total
201 Rec 22 grs tot Recipe 22 gross quantity, total
202 Rec 22 std tot Recipe 22 std quantity, total
203 Rec 23 grs tot Recipe 23 gross quantity, total
204 Rec 23 std tot Recipe 23 std quantity, total
205 Rec 24 grs tot Recipe 24 gross quantity, total
206 Rec 24 std tot Recipe 24 std quantity, total
207 Rec 25 grs tot Recipe 25 gross quantity, total
208 Rec 25 std tot Recipe 25 std quantity, total
209 Rec 26 grs tot Recipe 26 gross quantity, total
210 Rec 26 std tot Recipe 26 std quantity, total
211 Rec 27 grs tot Recipe 27 gross quantity, total
212 Rec 27 std tot Recipe 27 std quantity, total
Program Code Definitions (679 to 695 Dynamic Data Display Parameters) _____________________________ Section 6 - 199
________________________________________________________________________________________ DanLoad 6000 (v6.00)
6.20.1
Dynamic Data Display Data Codes
(continued)
Code Display Data Function
213 Rec 28 grs tot Recipe 28 gross quantity, total
214 Rec 28 std tot Recipe 28 std quantity, total
215 Rec 29 grs tot Recipe 29 gross quantity, total
216 Rec 29 std tot Recipe 29 std quantity, total
217 Rec 30 grs tot Recipe 30 gross quantity, total
218 Rec 30 std tot Recipe 30 std quantity, total
Meter Calibration Status
219 Mtr 1 calib stat meter 1
220 Mtr 2 calib stat meter 2
221 Mtr 3 calib stat meter 3
222 Mtr 4 calib stat meter 4
223 Flush pls cnt Multi-Stream Additive Injection
Flush pulse count
Current safety circuit state
224 Safety 1 State of safety circuit 1
225 Safety 2 State of safety circuit 2
226 Safety 3 State of safety circuit 3
227 Safety 4 State of safety circuit 4
228 Safety 5 State of safety circuit 5
229 Safety 6 State of safety circuit 6
230 Safety 7 State of safety circuit 7
231 Safety 8 State of safety circuit 8
232 Cpmt qty Compartment quantity based on compartment size inputs
233 Add 1 fail code Additive 1 failure reason code
234 Add 2 fail code Additive 2 failure reason code
235 Add 3 fail code Additive 3 failure reason code
236 Add 4 fail code Additive 4 failure reason code
237 Add 5 fail code Additive 5 failure reason code
238 Add 6 fail code Additive 6 failure reason code
239 Add 1% Additive #1 % of required additive
240 Add 2% Additive #2 % of required additive
241 Add 3% Additive #3 % of required additive
242 Add 4% Additive #4 % of required additive
243 Add 5% Additive #5 % of required additive
244 Add 6% Additive #6 % of required additive
245 Power fail preset Power fail preset quantity
246 Power fail remain Power fail remaining quantity
Program Code Definitions (679 to 695 Dynamic Data Display Parameters) _____________________________ Section 6 - 200
________________________________________________________________________________________ DanLoad 6000 (v6.00)
CONTINUE
Program Code Definitions (679 to 695 Dynamic Data Display Parameters) _____________________________ Section 6 - 201
________________________________________________________________________________________ DanLoad 6000 (v6.00)
6.21
Data Logging
Program Code / Function
696 Batch summary
697 Transaction summary
698 Alarm log
699 Power fail log
700 Program mode entry/exit
701 W &M switch opened/closed
702 Program value change log
703 Configuration summary
704 Crash memory summary
705 Totalizers
706 Transaction ticket
707 Transaction ticket reprint
708 Throughput
709 Sequence Numbers
710 Cutoff hour
Range <Default> OR
Option (* = Default)
0 Off *
1 PR
2 PRFF
3 PR1
4 PR1FF
5 PR2
6 PR2FF
7 PR3
8 PR3FF
9 PR4
10 PR4FF
0 Off *
1 On
0 to 23 <0>
Program Code Definitions (696 to 710 Data Logging Parameters) ____________________________________ Section 6 - 202
________________________________________________________________________________________ DanLoad 6000 (v6.00)
6.21
Data Logging (continued)
Data Logging program codes are used to control printing of several types of reports or event / alarm logs. Program codes 696 through 708 enable data printing to one of four printers or disable the printing of the related report. program code 709 Sequence numbers enables or disables printing of report sequence numbers on all reports. See Section 4.4 for a description of data spooling and printing with a code operated switch.
Data logging program codes with common option selections.
696 Batch summary
This program code controls spooling and printing of the fixed format batch summary report.
697 Transaction summary
This program code controls spooling and printing of the fixed format transaction summary report.
698 Alarm log
This program code controls spooling and printing of single line alarm logs.
699 Power fail log
This program code controls spooling and printing of single line power fail logs.
700 Program mode entry/exit
This program code controls spooling and printing of single line program mode change logs.
701 W&M switch opened/closed
This program code controls spooling and printing of single line
W&M switch status logs.
Program Code Definitions (696 to 710 Data Logging Parameters) ____________________________________ Section 6 - 203
________________________________________________________________________________________ DanLoad 6000 (v6.00)
6.21
Data Logging (continued)
702 Program code value change log
This program code controls spooling and printing of program code value change logs.
703 Configuration summary
The configuration summary data log (a log showing all program code values) can be printed from the diagnostics menu in the manual operating mode. The printer on which to print (via a
Code Operated Switch) and form feed control can be configured.
704 Crash memory summary
This program code controls spooling and printing of the Crash memory summary.
705 Totalizers
This program code enables/disables automatic printing every 24 hours (per program code 710 and manual reprinting (from the program mode menu) of meter, component, recipe and additive running totalizers. The printer on which to print (via a Code
Operated Switch) and form feed control can be configured.
706 Transaction ticket
This program code controls spooling and printing of the current user defined transaction ticket. See Section 3.10 for a complete description of transaction data storage and user defined transaction tickets.
707 Transaction ticket reprint
This program code controls spooling and printing of a copy of a completed user defined transaction ticket from the archive of up to 10,000 transaction tickets. See Section 3.10 for a complete description of transaction data storage and ticket printing.
708 Recipe throughput
This program code controls spooling and printing of the Recipe
Throughput report every 24-hours.
Program Code Definitions (696 to 710 Data Logging Parameters) ____________________________________ Section 6 - 204
________________________________________________________________________________________ DanLoad 6000 (v6.00)
6.21
Data Logging (continued)
The following option selections apply to each of the program codes 696 through 708.
#
#
#
Off
Disable spooling and printing for this data log.
PR
Enable spooling and printing for this data log. (No code operated switch)
PRFF
Same as PR above, except send form feed control to printer at end of report.
#
#
#
#
PR1
Enable spooling for this report and direct this report to printer number 1 via control code to code operated switch.
PR1FF
Same as PR1 above, except send form-feed control to printer at end of report.
PR2
Enable spooling for this report and direct this report to printer number 2 via control code to code operated switch.
PR2FF
Same as PR2 above, except send form-feed control to printer at end of report.
Program Code Definitions (696 to 710 Data Logging Parameters) ____________________________________ Section 6 - 205
________________________________________________________________________________________ DanLoad 6000 (v6.00)
6.21
Data Logging (continued)
#
#
#
#
PR3
Enable spooling for this report and direct this report to printer number 3 via control code to code operated switch.
PR3FF
Same as PR3 above, except send form-feed control to printer at end of report.
PR4
Enable spooling for this report and direct this report to printer number 4 via control code to code operated switch.
PR4FF
Same as PR4 above, except send form-feed control to printer at end of report.
709 Sequence numbers
This program code globally enables or disables printing of data log sequence numbers on all reports. Up to four counters, one for each data printer enabled, are maintained by the DanLoad
6000. Each counter maintains the current sequence number of any report printed to one data printer. The sequence is 0000 to
9999 with automatic rollover to 0000 after report 9999 is printed.
Sequence numbers are generated on a per printer basis and each printed report or alarm / event printed line is assigned a sequence number which is printed if this function is enabled. Note that the report sequence numbers are not related to transaction or batch sequence numbers.
# Off (default)
Enable printing of report sequence numbers on each report.
# On
Disable printing of report sequence numbers.
Program Code Definitions (696 to 710 Data Logging Parameters) ____________________________________ Section 6 - 206
________________________________________________________________________________________ DanLoad 6000 (v6.00)
6.21
Data Logging (continued)
710 Cutoff hour
The hour (24-hour clock/military time) at which a cutoff (end of day) processing is run by the DanLoad 6000. Cutoff processing is
“postponed” until any batch in progress is ended. Cutoff processing includes storing and printing meter, component, recipe and additive totalizers. The default is 0, i.e. cutoff at midnight.
Once a second, the DanLoad 6000 compares the current hour with the configured cutoff hour, the current day with the last cutoff day and the current hour with the last cutoff hour as follows: if (CurrentHour IS EQUAL TO ConfiguredCutoffHour)
BEGIN if ( (CurrentDay IS NOT EQUAL TO LastCutoffDay)
OR (CurrentHour IS GREATER THAN LastCutoffHour))
BEGIN
RunCutoff( )
END
END
This allows multiple cutoffs per day to be run per day by increasing the configured cutoff hour (program code 710).
Program Code Definitions (696 to 710 Data Logging Parameters) ____________________________________ Section 6 - 207
________________________________________________________________________________________ DanLoad 6000 (v6.00)
6.22
Blending
PC# / Function
711 Ramp down %
712 Rate reduction
713 Low flow start qty
714 Clean line qty
715 Low prop fac
716 Correct after qty
717 Alarm after qty
718 Adjustment qty
719 Comp % display
720 Add calib delay (s)
Range <Default> OR Option (* = Default)
0 to 100 <50>
0 to 9999 <100>
0 to 99999 <50>
0 to 9999 <0>
1 to 4 <1>
0 to 9999 <100>
0 to 9999 <200>
0 to 9999 <50>
0 Gross *
1 Std
0 to 9999 <0>
Program Code Definitions (711 to 799 Blending Parameters) __________________________________________ Section 6 - 208
________________________________________________________________________________________ DanLoad 6000 (v6.00)
6.22
Blending (continued)
Blending Parameters, program codes 710 to 770 are used to define the method of handling a product blending process.
Various parameters in this group interact with other parameters, dependent on the type of blending process defined by program code 026 Unit type. Details on configuration of each type of blending operation are contained in Section 3 - Setup.
711 Ramp down %
The percentage of the blend’s desired flow rate to which the blend’s flow rate is initially reduced when there is insufficient pressure to maintain the blend’s desired flow rate during an inline blend. The blend’s flow rate is not reduced below the blend’s low flow rate. The default value is 50.
712 Rate reduction
This program code defines the flow rate reduction [high
(normal) flow rate minus program code 712 Rate reduction] that is used if the high flow rate cannot be maintained.
713 Low flow start qty
This program code defines the quantity to load at the low flow rate before increasing the flow rate to high (normal) flow rate.
714 Clean line qty
This program code defines the quantity of the primary component to load at the end of the batch delivery to purge the blend from the loading lines. If, for a particular batch, the preset quantity is less than or equal to the clean line quantity, the batch is delivered as if there were no clean line quantity configured. The default value is 0.
715 Low prop fac
This program code defines the calibration point flow rate at which to deliver those components that are configured as low-proportion components in a recipe. The default value is 1.
716 Correct after qty
This program code defines the quantity of the blend to deliver before blend adjustment begins. The default value is 100.
Program Code Definitions (711 to 799 Blending Parameters) __________________________________________ Section 6 - 209
________________________________________________________________________________________ DanLoad 6000 (v6.00)
6.22
Blending (continued)
717 Alarm after qty
This program code defines the quantity of the blend to deliver before enabling the checking and action of the blend ratio alarm function that generates the message: Unable to maintain blend.
The default value is 200.
718 Adjustment qty
This program code defines the blend quantity to consider when adjusting the flow, via flow control valves, to maintain the blend ratio. A small value for this parameter causes the DanLoad 6000 to issue more clicks (adjustment commands) to flow control valves to correct errors in the blend ratio. The default value is 50.
719 Comp % display
#
#
This program code defines the display form for the quantities of the blend components, defined by the active recipe. The default is “Gross”.
Gross
Std
720 Add calib delay (s)
In the additive meter calibration screen (see Additive Meter
Calibration - Section 3.10.3), this is the time (in seconds) between pressing the “START” key and the beginning of the first additive injection cycle. This program code is intended to give the operator time to move from the preset to the additive injector, if necessary. The default value is 0.
Program Code Definitions (711 to 799 Blending Parameters) __________________________________________ Section 6 - 210
________________________________________________________________________________________ DanLoad 6000 (v6.00)
CONTINUE
Program Code Definitions (711 to 799 Blending Parameters) __________________________________________ Section 6 - 211
________________________________________________________________________________________ DanLoad 6000 (v6.00)
6.22
Blending (continued)
PC# / Function
722 Blend error method
723 Max dev %
724 Blend tol %
725 Max dev qty
726 Blend tol qty
727 Blend sample qty
Range <Default> OR Option (* = Default)
0 Grspctbatch *
1 Stdpctbatch
2 Grsqtydiff
3 Stdqtydiff
4 Grspctsmpl
5 Stdpctsmpl
6 Flrtsmpl
0 to 999 <2>
0 to 999 <5>
0 to 9999 <20>
0 to 9999 <40>
0 to 9999 <10>
Program Code Definitions (711 to 799 Blending Parameters) __________________________________________ Section 6 - 212
________________________________________________________________________________________ DanLoad 6000 (v6.00)
6.22
Blending (continued)
722 Blend error method
This program code defines the method for computing blend ratio adjustments and sensing blend ratio error conditions.
# Grspctbatch
Gross quantity percentages of each blend component are used in batch delivery calculations.
# Stdpctbatch
Standard quantity percentages of each blend component are used in the batch delivery calculations.
# Grsqtydiff
Gross quantity difference between each blend component are used in the batch delivery calculations.
# Stdqtydiff
Standard quantity difference between each blend component are used in the batch delivery calculations.
# Grspctsmpl
Samples of the gross quantity percentages of each blend component, relative to the gross quantity of the primary component set by program code 111 Primary component, are used in the batch delivery calculations.
# Stdpctsmpl
Samples of the std quantity percentages of each blend component, relative to the std quantity of the primary component set by program code 111 Primary component, are used in the batch delivery calculations.
# Flrtsmpl
The sampled flow rates of each blend component are used in the batch delivery calculations.
Program Code Definitions (711 to 799 Blending Parameters) __________________________________________ Section 6 - 213
________________________________________________________________________________________ DanLoad 6000 (v6.00)
6.22
Blending (continued)
723 Max dev %
This program code defines the maximum percentage deviation for the blend and is used in adjusting the ratio of each component of the blend. When the value is program code 723 Max dev % is reached, a blend ratio adjustment is performed.
726 Blend tol qty
This program code defines the maximum quantity tolerance allowed for the blend before generating an Unable to maintain blend alarm.
724 Blend tol %
This program code defines the maximum percentage tolerance allowed for the blend before generating an Unable to maintain blend alarm.
725 Max dev qty
This program code defines the maximum quantity deviation for the blend and is used in adjusting the ratio of each component of the blend.
727 Blend sample quantity
This program code defines the blend quantity to deliver between calculations of blend ratio by percentage methods ('Grspctsmpl' and 'Stdpctsmpl').
Program Code Definitions (711 to 799 Blending Parameters) __________________________________________ Section 6 - 214
________________________________________________________________________________________ DanLoad 6000 (v6.00)
CONTINUE
Program Code Definitions (711 to 799 Blending Parameters) __________________________________________ Section 6 - 215
________________________________________________________________________________________ DanLoad 6000 (v6.00)
6.22
Blending (continued)
PC# / Function(Four Meters)
728 / 734 / 740 / 746 Flow adj fac
729 / 735 / 741 / 747 Ratio adj fac
730 / 736 / 742 / 748 Ramp %
731 / 737 / 743 / 749 CALMON analysis method
PC# / Function MPMC
752 FPO basis
753 CALMON error limit
754 CALMON reset count
755 Calib fail alarm action
Range <Default> OR Option (* = Default)
0.00 to 9.99 <1.00>
1.00 to 9.99 <1.00>
0 to 110 <85>
Fuzzy *
Heuristic
Range <Default> OR Option (* = Default)
Raw *
Gross
Net
0 to 255 <25>
0 to 9999 <50>
0 Off
1 Info
2 Secondary
3 Primary *
Program Code Definitions (711 to 799 Blending Parameters) __________________________________________ Section 6 - 216
________________________________________________________________________________________ DanLoad 6000 (v6.00)
6.22
Blending (continued)
PC# / Function
(Four Components)
756 / 761 / 766 / 771 FPO
757 / 762 / 767 / 772 Number of blades
758 / 763 / 768 / 773 Max max char dev
759 / 764 / 769 / 774 Max tot char devs
760 / 765 / 770 / 775 Calibration sample
Range <Default> OR Option (* = Default)
0 to 2 <0>
0 to 50 <0>
0 to 65535 <100>
0 to 65535 <400>
0 Not acquired *
1 Acquired
Program Code Definitions (711 to 799 Blending Parameters) __________________________________________ Section 6 - 217
________________________________________________________________________________________ DanLoad 6000 (v6.00)
6.22
Blending (continued)
728 / 734 / 740 / 746 Flow adj fac
This program code defines a factor for each flow meter used in the blend. The factor provides fine tuning of individual flow rates for blend ratio adjustment. Reduce the value if the ramp up to normal flow rate is too fast. Increase the value if the ramp up to normal flow rate is too slow.
729 / 735 / 741 / 747 Ratio adj fac
This program code defines a factor for each component of the blend. The factor provides fine tuning for individual components for blend ratio adjustment.
730 / 736 / 742 / 748 Ramp %
[Sequential blending / digital flow control valves]
Percentage of desired flow rate to ramp up by a single click of the downstream solenoid valve, before switching to flow rate maintenance.
731 / 737 / 743 / 749 CALMON analysis method
This program code selects the “logic” used to perform a
“calibration monitoring analysis” with a MPMC board installed.
The default value is “Fuzzy”.
# Fuzzy
Calibration monitoring analysis incorporates “Fuzzy” logic with four inputs and one output. This is the recommended setting.
# Heuristic
Analysis operation using the Heuristic method.
In the DanLoad 6000's "Blending" setup group (setup group 20) there are twenty-three program codes (three "global" and five "per meter") associated with the "smart" 4-ch. meter pulse board's (4ch. meter pulse board with MPMC installed) factored pulse output (FPO) and calibration monitoring (CALMON) features.
Factored pulse outputs are supported by DanLoad 6000.
Program Code Definitions (711 to 799 Blending Parameters) __________________________________________ Section 6 - 218
________________________________________________________________________________________ DanLoad 6000 (v6.00)
6.22
Blending (continued)
752 FPO basis
The factor that is applied to the meter pulse inputs ("A" streams) in order to generate the factored pulse outputs (FPO's). The default value is "Raw". Select one of the following:
# "Raw". One-to-one, i.e. the factor is 1.0000. This is required for compatibility with the "prover outputs" on 2-ch. meter pulse boards.
#
#
"Gross". The factor is the (current) meter factor.
"Net". The factor is the (current) meter factor multiplied by the combined correction factor
(CCF).
753 CALMON error limit
The number of "bad meter analyses" per CALMON reset count
(program code 754) calibration monitoring analyses above which a calibration failure alarm is raised for the meter during monitoring. The default value is 10.
754 CALMON reset count
The "total analyses", "good meter analyses" and "bad meter analyses" counters are zeroed every "CALMON reset count" calibration monitoring analyses during monitoring; a calibration failure alarm is raised for the meter if there are no "good meter analyses" in "CALMON reset count" calibration monitoring analyses during monitoring. This is also the number of attempts to auto-detect the number of blades (if necessary) and acquire a calibration sample before a calibration failure alarm is raised for the meter during calibration. The default value is 50.
755 Calib fail alarm action
This program code sets the calibration failure alarm action for calibration monitoring. Refer to MPMC v2.00 (“Calibration
Monitoring”) specifications for more information about this alarm and the pertinent operating conditions. Selections include “Off” which disables the alarm, “Info”, “Secondary” and “Primary”.
Primary is the default.
Program Code Definitions (711 to 799 Blending Parameters) __________________________________________ Section 6 - 219
________________________________________________________________________________________ DanLoad 6000 (v6.00)
6.22
Blending (continued)
756 / 761 / 766 / 771 FPO
The factored pulse output on the "smart" 4-ch. meter pulse board on which to generate factored pulses according to the configured
FPO basis (program code 752). The default value is zero, i.e.
FPO disabled.
757 / 762 / 767 / 772 Number of blades
The number of magnetic blades (or buttons) on the meter for calibration monitoring purposes. 0 disables calibration monitoring for the meter. Any other value enables calibration monitoring for the meter. 1 indicates that the number of blades should be auto-detected by the MPMC prior to acquiring a calibration sample. The default value is zero, i.e. calibration monitoring disabled for the meter.
758 / 763 / 768 / 773 Max max char dev
The maximum signature deviation computed during a calibration monitoring analysis above which a "bad meter" result may be indicated, i.e. the "bad meter" counter may be incremented. The default value (100) detects a 10% blade deviation corresponding to an average K-factor change of 0.3%.
759 / 764 / 769 / 774 Max tot char devs
The sum signature deviation computed during a calibration monitoring analysis above which a "bad meter" result may be indicated, i.e. the "bad meter" counter may be incremented. The default value (400) detects a 10% blade deviation corresponding to an average K-factor change of 0.3%.
760 / 765 / 770 / 775 Calibration sample
The current calibration status (according to DanLoad 6000's point of view). This program code can be used to force acquisition of a new calibration sample. The default value is "Not acquired".
Select one of the following:
#
#
Not acquired - The calibration sample has not been acquired or is invalid. (Calibration sample is requested if the number of blades is greater than
0.)
Acquired - The calibration sample has been acquired and is valid.
Program Code Definitions (711 to 799 Blending Parameters) __________________________________________ Section 6 - 220
________________________________________________________________________________________ DanLoad 6000 (v6.00)
6.22
Blending (continued)
The calibration monitoring (CALMON) status screen is selected using the "CALMON status" option in the program mode menu. The
DanLoad 6000 prompts for a meter number.
1234567890123456789012345678901234567890
CALMON status
Meter 9 <- Enter meter number.
Press ALT+CLEAR to exit
1234567890123456789012345678901234567890
Enter a valid meter number or press "ALT"+"CLEAR" to return to the program mode menu. (A valid meter number is any configured meter, i.e. 1 <= meter number <= program code 50.) If there is no 4-ch. MP and MPMC v2.00 board associated with the meter, or if the meter’s configured number of blades is zero, then zeros are displayed for all calibration monitoring data. If there is an error reading from the MPMC board, then the maximum possible value is displayed for unsigned values and -1 is displayed for signed values. The DanLoad
6000 displays the calibration sample (two pages), the monitoring sample (two pages) and the calibration monitoring analysis (one page).
Use the "8" and "9" keys (as indicated on the display) to move up and down through the 5 pages. Use "ALT"+"CLEAR" to return to the
"Enter meter number" screen. Numbers are displayed in decimal (base 10) except for the blade ratios which are in hexadecimal (base 16).
Program Code Definitions (711 to 799 Blending Parameters) __________________________________________ Section 6 - 221
________________________________________________________________________________________ DanLoad 6000 (v6.00)
6.22
Blending (continued)
Calibration sample (two pages)
1234567890123456789012345678901234567890
XXXXX Calibration sample Not acquired <- Meter ID, heading and calibration sample status
Sample freq 99999 <- unsigned int
Freq stability x 100 99999 <- unsigned int (max. rot dev)
Mean blade dev x 100 99999 <- unsigned int
Sample stability x 100 99999 <- unsigned int (max. blade ratio diff)
Sample count 99999 <- unsigned int
9
1234567890123456789012345678901234567890
The maximum blade ratio (ratios) has (have) a plus sign to the right of it (them). The minimum blade ratio (ratios) has (have) a minus sign to the right of it (them).
1234567890123456789012345678901234567890
XXXXX Calibration sample Not acquired <- Meter ID, heading and calibration sample status
XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX <- Up to 50 blade ratios x 1000 (unsigned int) in hex
XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX
XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX
XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX
XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX
XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX
XXXX XXXX
89
1234567890123456789012345678901234567890
Program Code Definitions (711 to 799 Blending Parameters) __________________________________________ Section 6 - 222
________________________________________________________________________________________ DanLoad 6000 (v6.00)
6.22
Blending (continued)
Monitoring sample (two pages)
1234567890123456789012345678901234567890
XXXXX Monitoring sample <- Meter ID and heading
Sample freq 99999 <- unsigned int
Freq stability x 100 99999 <- unsigned int (max. rot dev)
Mean blade dev x 100 99999 <- unsigned int
Sample stability x 100 99999 <- unsigned int (max. blade ratio diff)
Sample count 99999 <- unsigned int
89
1234567890123456789012345678901234567890
1234567890123456789012345678901234567890
XXXXX Monitoring sample <- Meter ID and heading
XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX <- Up to 50 blade ratios x 1000 (unsigned int) in hex
XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX
XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX
XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX
XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX
XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX
XXXX XXXX
89
1234567890123456789012345678901234567890
Program Code Definitions (711 to 799 Blending Parameters) __________________________________________ Section 6 - 223
________________________________________________________________________________________ DanLoad 6000 (v6.00)
6.22
Blending (continued)
Calibration monitoring analysis (one page)
If a "blade 1 fit", i.e. alignment of the monitoring sample with the calibration sample, was not possible then the MPMC sets "Max char dev" and "Tot char devs" to 65535.
1234567890123456789012345678901234567890
XXXXX CALMON analysis <- Meter ID and heading
Working number of blades 99 <- unsigned char
Freq stability x 100 99999 <- unsigned int (sum max. rot dev)
Max char dev 99999 <- unsigned int
Tot char devs 9999999999 <- long
Good 99999 Bad 99999 Reset 99999 <- unsigned int, unsigned int, unsigned int
MPMC board 9 MPMC alarms XXXX <- int, unsigned int (bonus data!)
8
1234567890123456789012345678901234567890
Program Code Definitions (711 to 799 Blending Parameters) __________________________________________ Section 6 - 224
________________________________________________________________________________________ DanLoad 6000 (v6.00)
CONTINUE
Program Code Definitions (711 to 799 Blending Parameters) __________________________________________ Section 6 - 225
________________________________________________________________________________________ DanLoad 6000 (v6.00)
6.22
Blending (continued)
PC# / Function
[(Recipes 1 through 10), (11 to 20), (21 to 30)]
776 / 778 / 780 / 782 / 784 / 786 / 788 / 790 / 792 / 794 /
796 / 798 Low flow rate
777 / 779 / 781 / 783 / 785 / 787 / 789 / 791 / 793 / 795 /
797 / 799 High flow rate
Range <Default> OR Option (* = Default)
0 to 99999 <200>
0 to 99999 <600>
776 / ... / 798 Low flow rate
This program code defines the low flow rate setpoint for the batch recipe loading profile. Recipes 1 through 10 each have independent low flow rate setpoints. Recipes 11 through 20 share one low flow rate setpoint. Recipes 21 through 30 share one low flow rate setpoint.
777 / ... / 799 High flow rate
This program code defines the high flow rate setpoint for the batch recipe loading profile. Recipes 1 through 10 each have independent high flow rate setpoints. Recipes 11 through 20 share one common high flow rate setpoint. Recipes 21 through
30 share one common high flow rate setpoint.
Program Code Definitions (711 to 799 Blending Parameters) __________________________________________ Section 6 - 226
________________________________________________________________________________________ DanLoad 6000 (v6.00)
CONTINUE
Program Code Definitions (711 to 799 Blending Parameters) __________________________________________ Section 6 - 227
________________________________________________________________________________________ DanLoad 6000 (v6.00)
6.23
Additive Pumps / Block Valves
PC# / Function
(Six Additives)
800 / 803 / 806 / 809 / 812 / 815 Pump output
801 / 804 / 807 / 810 / 813 / 816 Block valve output
Range <Default> OR Option (* = Default)
0 to number of discrete outputs <0>
0 to number of discrete outputs <0>
Program Code Definitions (800 to 816 Additive Pump/Block Valve Parameters) _________________________ Section 6 - 228
________________________________________________________________________________________ DanLoad 6000 (v6.00)
6.23
Additive Pumps / Block Valves (continued)
This group of parameters is used to assign the discrete control outputs which control additive injector pumps and additive line block valves. Assigned and active additive pumps and control valves are opened when the batch load is started. Additives are then injected under control of program code 380 / 383 / 386 / 389
/ 392 / 395 Ratio output for each additive. An additive block valve is closed after the last program code 380 / 383 / 386 / 389
/ 392 / 395 Ratio output for the batch delivery is completed. An additive pump is stopped at the time the batch delivery is stopped.
800 / 803 / 806 / 809 / 812 / 815 Pump output
This program code assigns a physical discrete output for controlling RUN / STOP of an additive injector pump. The default value is 0.
801 / 804 / 807 / 810 / 813 / 816 Block valve output
This program code assigns a physical discrete output for controlling OPEN / CLOSE of an additive line block valve. The default value is 0.
Program Code Definitions (800 to 816 Additive Pump/Block Valve Parameters) _________________________ Section 6 - 229
________________________________________________________________________________________ DanLoad 6000 (v6.00)
6.24
LPG / Pressure
This group of parameters contains program codes that control the pressure control function used when loading liquefied petroleum gas. Pressure control is intended to maintain sufficient operating pressure in the meter stack to prevent flashing (vaporizing) of the liquid due to the pressure drop created by the devices in the meter stack. The general equation for the minimum back pressure required for light hydrocarbon liquids is stated below.
BP
MIN where:
= (2 * DP
WATER
) + (1.25 * AVP
TMAX
)
BP
MIN
DP
WATER
AVP
TMAX
=
=
=
Minimum back pressure required pressure drop flowing water at maximum flow rate
(. 4 PSIG for turbine meters) absolute vapor pressure of the liquid at maximum temperature
Refer to Appendix C for an example of a “LPG Loading
Configuration Checklist”.
Program Code Definitions (818 to 833 LPG / Pressure Parameters) _____________________________________ Section 6 - 230
________________________________________________________________________________________ DanLoad 6000 (v6.00)
CONTINUE
Program Code Definitions (818 to 833 LPG / Pressure Parameters) _____________________________________ Section 6 - 231
________________________________________________________________________________________ DanLoad 6000 (v6.00)
6.24
LPG / Pressure (continued)
PC# / Function
818 PT type
819 Pe method
820 Pinch back method
821 Pinch back pressure
822 Atmospheric pressure
823 Pinch back qty
824 T1
825 Pe at T1
826 T2
Range <Default> OR Option (* = Default)
0 Pm - Static pressure inputs *
1 Pd - Differential pressure inputs
0 Const Pe - Constant Pe
1 2 point - Use Pe for T1 and T2
2 3 point - Use Pe for T1, T2, and T3
3 Hillburn - Correlation for Pe per Hillburn (1968)
4 TP-15 - Correlation for Pe per Reid *
0 Off - Disable pressure control
1 Sw -
2 Pm
3 Pd
0 to 9999.99
0 to 9999.99
0 to 999999 <0>
-999.9 to +999.9 <0.0>
0.0 to 9999.99 <0.0>
-999.9 to +999.9 <0.0>
Program Code Definitions (818 to 833 LPG / Pressure Parameters) _____________________________________ Section 6 - 232
________________________________________________________________________________________ DanLoad 6000 (v6.00)
PC# / Function
827 Pe at T2
828 T3
829 Pe at T3
830 Circuit 1 type
831 Circuit 2 type
832 Circuit 3 type
833 Circuit 4 type
Range <Default> OR Option (* = Default)
0.0 to 9999.99 <0.0>
-999.9 to +999.9 <0.0>
0.0 to 9999.99 <0.0>
0 to 2 <0>
0 to 2 <0>
0 to 2 <0>
0 to 2 <0>
Program Code Definitions (818 to 833 LPG / Pressure Parameters) _____________________________________ Section 6 - 233
________________________________________________________________________________________ DanLoad 6000 (v6.00)
6.24
LPG / Pressure (continued)
This group of parameters is used to define the method for backpressure control. The flow control valve is used to pinch back the flow in order to maintain a preset or calculated minimum backpressure in the meter stack. The back-pressure is necessary to prevent very light hydrocarbon liquids, such as LPG (liquified petroleum gas) from flashing (vaporizing) due to the pressure drop present in the piping system.
818 PT type
This program code defines the type of pressure transmitter inputs.
# Pm
The pressure inputs are static pressure. The DanLoad 6000 calculates Pd = Pm - Pe for pressure correction and valve control.
# Pd
The pressure inputs are pressure differential (Pm - Pe).
819 Pe method
This program code defines the method of back-pressure calculation.
# Const Pe
Program code 825 is the vapor pressure.
# 2 point
Vapor pressure is determined via program codes 824 to 827.
# 3 point
Vapor pressure is determined via program codes 824 to 829.
Program Code Definitions (818 to 833 LPG / Pressure Parameters) _____________________________________ Section 6 - 234
________________________________________________________________________________________ DanLoad 6000 (v6.00)
6.24
LPG / Pressure (continued)
# Hillburn
Old correction for Pe per Hillburn (1968). Program code 825 is the vapor pressure at 100 degrees F.
# TP-15
New correlation for Pe per Reid. Vapor pressure is computed via
GPA TP-15 with temperature (degrees F) and relative density
60/60 degrees F as inputs.
820 Pinch back method
This program codes selects the method to use to maintain the minimum back-pressure setpoint specified by program code 821
Pinch back pressure.
With pressure control enabled, response to a low pressure condition also depends on:
026 Unit type
027 Valve type
# Off
Disable pressure control
# Sw
Pressure switch inputs, assigned by program codes 296 / 301 /
306 / 311 Close input, control the OPEN / CLOSE state of the flow control valves.
# Pm
A static pressure input for each meter us used to implement pressure control. Flow meters are assigned pressure transmitters by program codes 320 / 326 / 332 / 338 Meter X pres input.
# Pd
A pressure differential input for each meter is used to implement pressure control. Flow meters are assigned pressure transmitters by program codes 320 / 326 / 332 / 338 Meter X pres input.
Program Code Definitions (818 to 833 LPG / Pressure Parameters) _____________________________________ Section 6 - 235
________________________________________________________________________________________ DanLoad 6000 (v6.00)
6.24
LPG / Pressure (continued)
821 Pinch back pressure
The static or differential pressure, depending on program code
820, below which the DanLoad 6000 ramps down to a lower
("fall back") flow rate or raises a pressure failure alarm when pressure maintenance is configured (program code 820).
822 Atmospheric pressure
This is used to convert absolute pressures to gage pressures, e.g.
the output from GPA TP-15 (vapor pressure computation). The default value is 14.70, which is the "standard atmospheric pressure" for GPA TP-16 (which uses GPA TP-15).
API's standard atmospheric pressure is 14.73, so GPA's matches this rounded to one decimal place. The "normal" atmosphere is
14.696 psia and the "technical" atmosphere is 14.223 psia.
The six program codes below define three temperature and vapor pressure pairs for two or three point linearization. Values should be entered in order of increasing temperature, i.e. T1 < T2 < T3.
Program Code Definitions (818 to 833 LPG / Pressure Parameters) _____________________________________ Section 6 - 236
________________________________________________________________________________________ DanLoad 6000 (v6.00)
6.24
LPG / Pressure (continued)
823 Pinch back qty
The gross quantity at the start of a batch for which pressure control (see program code 820) is disabled. This can be used to suppress problems starting a batch, such as alarms due to "surge" and "flashing", when the pressure in the receiving tank is much lower than in the loading arm and supply pipe.
* The DanLoad raises a pressure alarm when the sampled pressure is not within the pressure tables specified by “Pressure
Option” (program code 444). This alarm is also disabled at the start of the batch, and is enabled after the “Pinch back qty” has been delivered.
WARNING: It should be understood that entering a non-zero value simply suppresses the alarm, and may hide a real problem that should possibly be solved by other means. The default value is zero.
825 Pe at T1
826 T2
827 Pe at T2
1
P at temperature T . The default value is 0.0.
e
828 T3
2
824 T1 829 Pe at T3
3
Program Code Definitions (818 to 833 LPG / Pressure Parameters) _____________________________________ Section 6 - 237
________________________________________________________________________________________ DanLoad 6000 (v6.00)
6.24
LPG / Pressure (continued)
830 Circuit 1 type
See program code 265 for more information. The default value is 0, i.e. check safety circuit independent of side, for compatibility with older versions.
833 Circuit 4 type
See program code 265 for more information. The default value is 0, i.e. check safety circuit independent of side, for compatibility with older versions.
831 Circuit 2 type
See program code 265 for more information. The default value is 0, i.e. check safety circuit independent of side, for compatibility with older versions.
832 Circuit 3 type
See program code 265 for more information. The default value is 0, i.e. check safety circuit independent of side, for compatibility with older versions.
Program Code Definitions (818 to 833 LPG / Pressure Parameters) _____________________________________ Section 6 - 238
________________________________________________________________________________________ DanLoad 6000 (v6.00)
6.25
Transaction Data Storage
Program Code Range <Default> OR Option (* = Default)
834 Transaction record length 0 to 250 bytes <0>
835 Start page and # pages 600 to 1510 pages divided as start/# 6/00 to 15/10 <602>
836 Batch record length
837 Start page and # pages
0 to 250 bytes <0>
600 to 1510 pages divided as start/# 6/00 to 15/10 <808>
838 Tr tk format 0 Lock *
1 Clear
2 Fmt 1
3 Fmt 2
4 Fmt 3
839 Time out tr No *
Yes
Program Code Definitions (834 to 902 Transaction Data Storage Parameters) ___________________________ Section 6 - 239
________________________________________________________________________________________ DanLoad 6000 (v6.00)
6.25
Transaction Data Storage (continued)
Transaction data storage program codes allocate random access memory space and assign data variables in the DanLoad 6000 for storage of various parameters that define loading transactions and batch operations. A detailed description of this group of program codes is provided in Section 3.10. This group of program codes
MUST BE defined if transaction storage is required when the
DanLoad 6000 is a slave unit in a terminal automation system or when user defined transaction tickets are printed.
834 Transaction record length
This program code allocates memory storage area for fixed length transaction records. The value of this program code can only be determined after the transaction storage codes have been selected and located with program codes 840 to 875. The default value of
0 disables storage of any transaction records.
divisor of 10,000.
835 Start page and # pages
Note
When entering the “start page” and “# pages” for the transaction (tr) and batch (ba) files in program codes 835 and
837, the DanLoad 6000 simply verifies that the start page is between 6 and 15 and the # pages is between 0 and 10 for each file, i.e. no cross validation is performed. However, on power-up/reset the DanLoad 6000 validates the start pages and # pages for both files. The # pages must be an exact
The memory start page (between 6 and 15) and the number of memory pages to allocate for the transaction file which holds the transaction records. Each page is 8192 bytes in size. The # pages defines the number of pages to allocate for the transaction file.
The default value is 602 which allocated two memory pages, starting with page 6, to the transaction file. A total of 16,384 bytes are allocated for storage. An entry of 600 (no pages allocated) disables transaction storage.
Program Code Definitions (834 to 902 Transaction Data Storage Parameters) ___________________________ Section 6 - 240
________________________________________________________________________________________ DanLoad 6000 (v6.00)
6.25
Transaction Data Storage (continued)
836 Batch record length
This program code allocates memory storage area for fixed length batch records. The value of this program code can only be determined after the batch storage codes have been selected and located with program codes 880 to 901. The default value of 0 disables storage of any batch records.
837 Start page and # pages
The memory start page (between 6 and 15) and the number of memory pages to allocate for the batch file which holds the batch records. Each page is 8192 bytes in size. The # pages defines the number of pages to allocate for the batch file. The default value is 808 which allocated eight memory pages, starting with page 8, to the transaction file. A total of 65,536 bytes are allocated for storage. An entry of 600 (no pages allocated) disables transaction storage.
838 Tr tk format
This program code defines control of the user defined transaction ticket storage area in memory. Three internally defined transaction ticket formats are also selectable by this program code. The internally defined transaction ticket formats are useful for obtaining quick printouts of predefined data on blank sheets.
Formatting actual user defined transaction tickets is described in
Section 3.10.
# Lock <default option>
Prevents the selected default Fmt 1, Fmt 2, or
Fmt 3 internally defined ticket formats from overwriting a modification of one of these formats during power-up.
# Clear
Command to clear the transaction storage memory and transaction ticket configuration.
Program Code Definitions (834 to 902 Transaction Data Storage Parameters) ___________________________ Section 6 - 241
________________________________________________________________________________________ DanLoad 6000 (v6.00)
6.25
Transaction Data Storage (continued)
# Fmt 1, Fmt 2, Fmt 3
Automatic configuration of transaction storage and transaction ticket per internally defined configurations. (Fmt 1 is ticket without batch data; Fmt 2 is ticket with batch data; Fmt 3 is ticket with only batch data) All three default formats assume that only one component is configured.
839 Time out tr
This program code determines whether or not a transaction in progress in the manual operating mode, that has neither a batch in progress nor a primary alarm active, should be timed out and ended automatically after prompt time-out (program code 036) seconds. The time-out is useful when working with a
"monitoring only" ticket printing system if the operator/user/driver is likely to forget to press the "STOP" key to end the transaction after the last batch on the transaction has been loaded. Note that when the time-out is enabled, a transaction may be ended prematurely, i.e. prior to the last batch being loaded, in which case a further transaction would be required to complete loading. The default value is "No" for compatibility with earlier versions. Select one of the following:
# "No". Don't time out and end a transaction in progress automatically.
# "Yes". Time out and end a transaction in progress automatically.
Program Code Definitions (834 to 902 Transaction Data Storage Parameters) ___________________________ Section 6 - 242
________________________________________________________________________________________ DanLoad 6000 (v6.00)
6.25
Transaction Data Storage (continued)
Program Code (Transaction Storage Code)
840 1 Addr
841 2 Tr seq #
842 3 Recipe #
843 4 Recipe name
844 5 Side
845 6 Prompt 1
846 7 Prompt 2
847 8 Prompt 3
848 9 Prompt 4
849 10 Prompt 5
850 11 Data item 1
851 12 Data item 2
852 13 Data item 3
853 14 Data item 4
854 15 Data item 5
Range <Default> O R
Option (* = Default)
0 to 250 bytes <0>
0 to 250 bytes <0>
0 to 250 bytes <0>
0 to 250 bytes <0>
0 to 250 bytes <0>
0 to 250 bytes <0>
0 to 250 bytes <0>
0 to 250 bytes <0>
0 to 250 bytes <0>
0 to 250 bytes <0>
0 to 250 bytes <0>
0 to 250 bytes <0>
0 to 250 bytes <0>
0 to 250 bytes <0>
0 to 250 bytes <0>
Program Code Definitions (834 to 902 Transaction Data Storage Parameters) ___________________________ Section 6 - 243
________________________________________________________________________________________ DanLoad 6000 (v6.00)
6.25
Transaction Data Storage (continued)
Program Code (Transaction Storage Code)
855 16 Start date
856 17 End date
857 18 Gross
858 19 Std
859 20 Temp
860 21 Pres
861 22 Dens (Comp 1 backup density/gravity)
862 23 Start gross
863 24 Start std
864 25 End gross
865 26 End std
866 27 Alarm bit map
867 28 Prim alarm
868 29 Temp alarm
Range <Default> O R
Option (* = Default)
0 to 250 bytes <0>
0 to 250 bytes <0>
0 to 250 bytes <0>
0 to 250 bytes <0>
0 to 250 bytes <0>
0 to 250 bytes <0>
0 to 250 bytes <0>
0 to 250 bytes <0>
0 to 250 bytes <0>
0 to 250 bytes <0>
0 to 250 bytes <0>
0 to 250 bytes <0>
0 to 250 bytes <0>
0 to 250 bytes <0>
Program Code Definitions (834 to 902 Transaction Data Storage Parameters) ___________________________ Section 6 - 244
________________________________________________________________________________________ DanLoad 6000 (v6.00)
6.25
Transaction Data Storage (continued)
Program Code (Transaction Storage Code)
869 30 Add 1
870 31 Add 2
871 32 Add 3
872 33 Add 4
873 34 Add 5
874 35 Add 6
875 36 Op mode
876 37 Gross units
877 38 Std units
840 to 874 <name>
Program codes in this group define the start locations within the user defined transaction record template for storing the corresponding variables. The default value <0> disables storage of the corresponding variable. The first actual storage start location is 1. The process is described in detail in Section 3.9.
Range <Default> O R
Option (* = Default)
0 to 250 bytes <0>
0 to 250 bytes <0>
0 to 250 bytes <0>
0 to 250 bytes <0>
0 to 250 bytes <0>
0 to 250 bytes <0>
0 to 250 bytes <0>
0 to 250 bytes <0>
0 to 250 bytes <0>
875 to 877 <name>
The offset from the start of the user-configurable part of the transaction record at which to store the value associated with transaction storage codes 036 through 038 respectively, i.e. the gross product units mnemonic (program code 218).
Program Code Definitions (834 to 902 Transaction Data Storage Parameters) ___________________________ Section 6 - 245
________________________________________________________________________________________ DanLoad 6000 (v6.00)
6.25
Transaction Data Storage (continued)
Program Code (Batch Storage Code)
880 1 Addr
881 2 Ba seq #
882 3 Tr seq #
883 4 Temp
884 5 Pres
885 6 Dens
886 7 Preset
887 8 Gross
888 9 Std
889 10 Comp gross
890 11 Comp std
891 12 Comp temp
892 13 Comp dens
893 14 Comp pres
894 15 Comp %
Range <Default> O R
Option (* = Default)
0 to 250 bytes <0>
0 to 250 bytes <0>
0 to 250 bytes <0>
0 to 250 bytes <0>
0 to 250 bytes <0>
0 to 250 bytes <0>
0 to 250 bytes <0>
0 to 250 bytes <0>
0 to 250 bytes <0>
0 to 250 bytes <0>
0 to 250 bytes <0>
0 to 250 bytes <0>
0 to 250 bytes <0>
0 to 250 bytes <0>
0 to 250 bytes <0>
Program Code Definitions (834 to 902 Transaction Data Storage Parameters) ___________________________ Section 6 - 246
________________________________________________________________________________________ DanLoad 6000 (v6.00)
6.25
Transaction Data Storage (continued)
Program Code (Batch Storage Code)
895 16 Add 1
896 17 Add 2
897 18 Add 3
898 19 Add 4
899 20 Add 5
900 21 Add 6
901 22 Op mode
902 23 CCF
Range <Default> O R
Option (* = Default)
0 to 250 bytes <0>
0 to 250 bytes <0>
0 to 250 bytes <0>
0 to 250 bytes <0>
0 to 250 bytes <0>
0 to 250 bytes <0>
0 to 250 bytes <0>
0 to 250 bytes <0>
880 to 902 <name>
Program codes in this group define the start locations within the user defined batch record template for storing the corresponding variables. The default value <0> disables storage of the corresponding variable. The first actual storage start location is
1. The process is described in detail in Section 3.9.
Program Code Definitions (834 to 902 Transaction Data Storage Parameters) ___________________________ Section 6 - 247
________________________________________________________________________________________ DanLoad 6000 (v6.00)
6.26
Transaction Ticket Format (Print Coordinates)
Program Code (Transaction Storage Code)
920 1 Addr
921 2 Tr seq #
922 3 Recipe #
923 4 Recipe name
924 5 Side
925 6 Prompt 1
926 7 Prompt 2
927 8 Prompt 3
928 9 Prompt 4
929 10 Prompt 5
930 11 Data item 1
931 12 Data item 2
932 13 Data item 3
933 14 Data item 4
934 15 Data item 5
Range <Default> O R
Option (* = Default) rrrcc <0> rrrcc <0> rrrcc <0> rrrcc <0> rrrcc <0> rrrcc <0> rrrcc <0> rrrcc <0> rrrcc <0> rrrcc <0> rrrcc <0> rrrcc <0> rrrcc <0> rrrcc <0> rrrcc <0>
Program Code Definitions (920 to 982 Transaction Ticket Format Parameters) __________________________ Section 6 - 248
________________________________________________________________________________________ DanLoad 6000 (v6.00)
6.26
Transaction Ticket Format (Print Coordinates) (continued)
Program Code (Transaction Storage Code)
935 16 Start date
936 17 End date
937 18 Gross
938 19 Std
939 20 Temp
940 21 Pres
941 22 Dens (Comp 1 backup density/gravity)
942 23 Start gross
943 24 Start std
944 25 End gross
945 26 End std
946 27 Alarm bit map
947 28 Prim alarm
948 29 Temp
Range <Default> O R
Option (* = Default) rrrcc <0> rrrcc <0> rrrcc <0> rrrcc <0> rrrcc <0> rrrcc <0> rrrcc <0> rrrcc <0> rrrcc <0> rrrcc <0> rrrcc <0> rrrcc <0> rrrcc <0> rrrcc <0>
Program Code Definitions (920 to 982 Transaction Ticket Format Parameters) __________________________ Section 6 - 249
________________________________________________________________________________________ DanLoad 6000 (v6.00)
6.26
Transaction Ticket Format (Print Coordinates) (continued)
Program Code (Transaction Storage Code)
949 30 Add 1
950 31 Add 2
951 32 Add 3
952 33 Add 4
953 34 Add 5
954 35 Add 6
955 36 Op mode
956 37 Gross units
957 36 Std units
920 to 957 <name>
Program codes in this group define the row (rrr) and column
(cc) coordinates to print the corresponding transaction storage code variables on user defined transaction tickets. See Section
3.10 for a detailed description of transaction ticket format. The default value of 0 disables printing of the corresponding variable.
Range <Default> OR
Option (* = Default) rrrcc <0> rrrcc <0> rrrcc <0> rrrcc <0> rrrcc <0> rrrcc <0> rrrcc <0> rrrcc <0> rrrcc <0>
Program Code Definitions (920 to 982 Transaction Ticket Format Parameters) __________________________ Section 6 - 250
________________________________________________________________________________________ DanLoad 6000 (v6.00)
CONTINUE
Program Code Definitions (920 to 982 Transaction Ticket Format Parameters) __________________________ Section 6 - 251
________________________________________________________________________________________ DanLoad 6000 (v6.00)
6.26
Transaction Ticket Format (Print Coordinates) (continued)
Program Code (Batch Storage Code)
960 1 Addr
961 2 Ba seq #
962 3 Tr seq #
963 4 Temp
964 5 Pres
965 6 Dens
966 7 Preset
967 8 Gross
968 9 Std
969 10 Comp gross
970 11 Comp std
971 12 Comp temp
972 13 Comp dens
973 14 Comp pres
974 15 Comp %
Range <Default> O R
Option (* = Default) rrrcc <0> rrrcc <0> rrrcc <0> rrrcc <0> rrrcc <0> rrrcc <0> rrrcc <0> rrrcc <0> rrrcc <0> rrrcc <0> rrrcc <0> rrrcc <0> rrrcc <0> rrrcc <0> rrrcc <0>
Program Code Definitions (920 to 982 Transaction Ticket Format Parameters) __________________________ Section 6 - 252
________________________________________________________________________________________ DanLoad 6000 (v6.00)
6.26
Transaction Ticket Format (Print Coordinates) (continued)
960 to 981 <name>
Program Code (Batch Storage Code)
975 16 Add 1
976 17 Add 2
977 18 Add 3
978 19 Add 4
979 20 Add 5
980 21 Add 6
981 22 Op mode
982 23 CCF
Range <Default> O R
Option (* = Default) rrrcc <0> rrrcc <0> rrrcc <0> rrrcc <0> rrrcc <0> rrrcc <0> rrrcc <0> rrrcc <0>
982 CCF
Combined correction factor for temperature and presssure compensation of the liquid components.
Program codes in this group define the row (rrr) and column
(cc) coordinates to print the corresponding batch storage code variables on user defined transaction tickets. See Section 3.10 for a detailed description of transaction ticket format. The default value of 0 disables printing of the corresponding variable.
PL
Program Code Definitions (920 to 982 Transaction Ticket Format Parameters) __________________________ Section 6 - 253
________________________________________________________________________________________ DanLoad 6000 (v6.00)
6.27
Analog Inputs
Program Code (Batch Storage Code)
983 RTD Alpha
984 LL cnt (4-20 mA input)
985 LH cnt (4-20 mA input)
986 HL cnt (4-20 mA input)
987 HH cnt (4-20 mA input)
988 LL cnt (RTD input)
989 LH cnt (RTD input)
990 HL cnt (RTD input)
991 HH cnt (RTD input)
Range <Default> O R
Option (* = Default)
0 3850 *
1 3902
0 to 9999 <0>
0 to 9999 <0>
0 to 9999 <0>
0 to 9999 <0>
0 to 9999 <0>
0 to 9999 <0>
0 to 9999 <0>
0 to 9999 <0>
This section is specific to RTD inputs and 4-20 mA inputs on the v2 CPU board. The v2 CPU board’s 4-20 mA and RTD inputs each use two A/D channels on the CPU-2 microcontroller. An input’s overall range is subdivided with low input values handled by the “low” A/D channel and high input values handled by the “high” A/D channel. The A/D channel to use, and its value, are determined using the channel’s low and high calibration values. Program codes 984 to 987 are for the 4-20 mA input, and program codes 988 to 991 apply to the RTD input.
Program Code Definitions (983 to 991 Analog Inputs) ________________________________________________ Section 6 - 254
________________________________________________________________________________________ DanLoad 6000 (v6.00)
6.27
Analog Inputs (continued)
983 RTD Alpha
The alpha value is set for temperature calculations. All RTD’s connected to the DanLoad 6000's CPU board and analog inputs boards must have the same alpha. There are two possible selections:
“3850" BS 1904:1984 and DIN 43760
" = 0.003850
" = 0.003902
“3902"
984 LL cnt
The count, i.e. A/D value, for the CPU board’s 4-20 mA input’s
Low channel’s Low calibration point, i.e. 4 mA. Enter value from label on CPU board (see Section 2) or calibrate using the procedure below.
986 HL cnt
The count, i.e. A/D value, for the CPU board’s 4-20 mA input’s
High channel’s Low calibration point, i.e. 12 mA.
987 HH cnt
The count, i.e. A/D value, for the CPU board’s 4-20 mA input’s
High channel’s High calibration point, i.e. 20 mA.
985 LH cnt
The count, i.e. A/D value, for the CPU board’s 4-20 mA input’s
Low channel’s High calibration point, i.e. 12 mA.
Program Code Definitions (983 to 991 Analog Inputs) ________________________________________________ Section 6 - 255
________________________________________________________________________________________ DanLoad 6000 (v6.00)
6.27
Analog Inputs (continued)
988 LL cnt
The count, i.e. A/D value, for the CPU board’s RTD input’s Low channel’s Low calibration point, i.e. R
-20°C
.
989 LH cnt
The count, i.e. A/D value, for the CPU board’s RTD input’s Low channel’s High calibration point, i.e. R
18°C
.
990 HL cnt
The count, i.e. A/D value, for the CPU board’s RTD input’s High channel’s Low calibration point, i.e. R
18°C
.
991 HH cnt
The count, i.e. A/D value, for the CPU board’s RTD input’s High channel’s High calibration point, i.e. R
55°C
.
Program Code Definitions (983 to 991 Analog Inputs) ________________________________________________ Section 6 - 256
__________________________________________________________ DanLoad 6000 (v6.00)
6.28
Step 1.
Step 2.
NOTE:
CPU Version 2 Analog Calibration
Equipment Required
A. Digital Voltmeter-- At least 4 digit
B. 4-20 mA - Current source or voltage equivalent, must drive 425S to 8.5
volts. An adjustable power supply with fine and course adjustments may be substituted for a current source.
C.
RTD simulator -- 100 S R-Box with 0.01 S steps
Setup
A.
Go into setup and enter a zero (0) into the following Program Codes:
C
C
C
C
C
C
C
C
PC 984 lolo (4-20 mA) = 0
PC 985 lohi (4-20 mA) = 0
PC 986 hilo (4-20 mA) = 0
PC 987 hihi (4-20 mA) = 0
PC 988 lolo (RTD) = 0
PC 989 lohi (RTD) = 0
PC 990 hilo (RTD) = 0
PC 991 hihi (RTD) = 0
B. Program Codes 318 = 1, 320 = 1 (Select Temperature and
Pressure Meter 1)
Record the following program codes: 464, 465and 695 then re-enter them when finished with the calibration.
C. Program Codes 464 = 9.00, 465 = 45.00 (Pressure Zero and Fullscale)
D. Program Code 695 = 135 (live pressure- Dymanic Data Display)
CPU Version 2 Analog Calibration ________________________________________ 6-257
DanLoad 6000 (v6.00) __________________________________________________________
Program Codes
PC 984 4-20 mA LoLo
PC 985 4-20 mA LoHi
PC 986 4-20 mA HiLo
PC 987 4-20 mA HiHi
PC 988 RTD LoLo
PC 989 RTD LoHi
PC 990 RTD HiLo
PC 991 RTD HiHi
Calibration Values
Copy this page and record values.
6-258 ________________________________________ CPU Version 2 Analog Calibration
__________________________________________________________ DanLoad 6000 (v6.00)
Step 3.
Analog Calibration Low Range
A.
Connect a Voltmeter across TP1-TP2.
B.
C.
With the test setup shown in Figure 1, adjust the 4-20 mA to 0.900V
across TP1-TP2.
Go to Program Menu to Input Output in the diagnostics, select 1 for the 4-20 mA input. Record the number on the DanLoad 6000 Display for 0.900 Volts. (Example 4-20 mA lo lo = 141)
D.
Adjust the 4-20ma signal to 2.700 volts across TP1-TP2. Record the number displayed for 2.700 Volts. (Example 4-20 ma lo hi = 956)
Set the R-Box to 92.16 S " = 0.00385 (-20°C.) E.
F.
In the diagnostics, select 1 for the RTD input. Record the number for
-20°C.(Example RTD lo lo = 92)
Set the R-Box to 107.02 S " = 0.00385 (18°C).
G.
H.
I.
Record the number displayed for 18 degrees. (Example RTD lo hi = 992)
Go into Setup, select the following program codes(PC) to enter the values previously recorded.
4-20 mA lo lo reading into PC 984 = (example 141) J.
K.
L.
4-20 mA lo hi reading into PC 985 = (example 956)
RTD lolo reading into PC 988 = (Example 92)
M.
RTD lohi reading into PC 989 = (Example 992)
CPU Version 2 Analog Calibration ________________________________________ 6-259
DanLoad 6000 (v6.00) __________________________________________________________
Step 4.
J.
K.
H.
I.
E.
F.
G.
Analog Calibration High Range
A.
Exit setup, and re-enter diagnostics and select 1 for 4-20 mA
B.
With the Voltage still set to 2.700 volts across TP1-TP2. Record the displayed number. (Example 4-20 mA hi lo = 41)
C.
D.
Adjust the 4-20 mA signal until 4.50 volts is across TP1-TP2. Record the displayed number. (Example 4-20 mA hi hi = 858)
In the Diagnostics, select 1 for RTD.With the R-Box still set to 107.02 S,
Record the number for 18 °C. (Example: RTD hi lo = 76)
Set the R-Box to 121.32 S " = 0.00385 (55° C.)
Record the number for 55 °C. (Example RTD hi hi = 998)
Go into Setup, select the following program codes to enter the values previously recorded.
4-20 mA hi lo reading into PC 986 = (example 41)
4-20 mA hi hi reading into PC 987 = (example 858)
RTD hi lo reading into PC 990 = (Example 76)
RTD hi hi reading into PC 991 = (Example 998)
6-260 ________________________________________ CPU Version 2 Analog Calibration
__________________________________________________________ DanLoad 6000 (v6.00)
Step 5.
Check Temperature Calibration
A.
Exit out of Setup, Go to the load menu and press Select. Scroll down into the Dynamic Data Display until Mtr 1 curr temp and Mtr 1 curr pres are
Displayed.
B.
C.
With the R-Box still set at 121.32 S, the displayed Current Temperature should read 55.0°C ± 0.1 °C.
Adjust the R-Box to 107.02 S. The displayed Current Temperatue should read 18.0°C ± 0.1 °C.
D.
Adjust the R-Box to 92.55 S. The displayed Current Temperature should read -19.0°C ± 0.1 °C.
Step 6.
Check Pressure Calibration
A.
With the Voltage still set to 4.500 volts across TP1-TP2. The displayed
Current Pressure should read 45.00 ± 0.05 psi.
B.
C.
Adjust the 4-20 mA input to 2.700 volts across TP1-TP2. The displayed
Current Pressure should read 27.00 ± 0.05 psi.
Adjust the 4-20 mA input to 1.000 volts across TP1-TP2. The displayed
Current Pressure should read 10.00 ± 0.05 psi.
CPU Version 2 Analog Calibration ________________________________________ 6-261
DanLoad 6000 (v6.00) __________________________________________________________
CPU v2 Analog Calibration Set Up
Figure 6-3
6-262 ________________________________________ CPU Version 2 Analog Calibration
__________________________________________________________ DanLoad 6000 (v6.00)
This appendix contains several tables that can be photocopied and used to enter parameter settings for records of DanLoad 6000 installations. The tables can be used as an aid in generating wire lists and drawings for the installations.
Daniel drawing BE-18204, Device Linkages - DanLoad 6000, shows the relationship between system devices, liquid components, and additives. Daniel drawing DE-18201, Program Code to
Device Assignments - DanLoad 6000, shows all devices that can be monitored and controlled by a
DanLoad 6000. In actual installations, only some of the devices will be installed. The program codes indicated in the drawing are the primary parameters that relate the devices to the proper flow meter / meter stream. Many additional parameters define and modify the operation of each device.
Use the program codes indicated in the drawing to reference the device parameters Tables A - 11 to
A - 28. These tables contain brief descriptions of the device related parameters. See Section 6 for a complete description of each parameter.
The flow meter is considered the primary device in the system. All other accessory devices, liquid components, and additives are assigned to a meter stream by either direct reference or indirect reference. Interrelations between physical devices, liquid components, and additives are established in the following manner.
# Any liquid component can flow through any flow meter and from two to four components, can flow, one at a time, through the same flow meter. This function is the reason that the meter factors (program codes 169 through 216) are assigned to the components. The meter factors are automatically applied to the active flow meter when the selected component is flowing through that flow meter.
# Pumps and block valves for liquid components are enabled specifically for each component by assigning corresponding physical discrete outputs (and discrete inputs in the case of block valves). Drawing DE-18201, Program Code to Device Assignments, indicates sequential numbering of all devices for ease of drawing layout. Note however, if component 1 were assigned to meter 3 (program code 067 Meter set to 3) then the pump for component 1 (P-1) and the block valve for component 1 (BV-1) are also assigned to meter stream 3. Actual device tags and system drawings for each unique installation should show this assignment correctly.
# Flow rate through any flow meter can be controlled by any one flow control valve and from two to four flow meters can share the same flow control valve. Drawing DE-18201,
Program Code to Device Assignments, indicates sequential numbering of all devices for ease of drawing layout. Note however, meter 1 could be assigned to flow control valve 3
(program code 052 Valve to be controlled set to 3) and meter 2 could be assigned to flow control valve 3 (program code 055 Valve to be controlled set to 3). Actual device tags and system drawings for each unique installation should show these assignments correctly.
Installation Worksheets _________________________________________ Appendix A - 1
DanLoad 6000 (v6.00) __________________________________________________________
#
#
Resistive temperature devices (RTD), pressure transmitters (PT), and density transmitters
(DT) are enabled specifically for each meter stream by assigning corresponding physical analog inputs.
Pumps and block valves for additives are enabled specifically for each additive by assigning corresponding physical discrete outputs (and discrete inputs in the case of block valves).
Daniel drawing DE-18201, Program Code to Device Assignments - DanLoad 6000, shows additive injection on each meter stream. In actual installations, additive injection is usually implemented in the primary component meter stream only.
Tables A - 1a to A - 9 can be used to provide a record of input / output signal assignments. Tables
A - 11 to A - 28 contain lists of all program codes (parameters) organized in device or functional groups. An overview of the tables is provided below.
A-6
A-7
A-8
A-9
Table Description
A-1a 2-Channel Meter Pulse Board Wiring
A-1b 4-Channel Meter Pulse Board Wiring
A-2 AC I/O Board Wiring
A-3a Enhanced I/O Board Wiring (Old)
A-3b Enhanced I/O Board Wiring (New)
A-4 DC I/O Board Wiring
A-5a 2-Channel Analog Input Board Wiring
A-5b 8-Channel Analog Input Board Wiring
Power Supply Wiring
Swing Arm Input Wiring
DUART Module Wiring
LAN Module Wiring
Slot Number
J5 or J6
J5 or J6
J1 or J2
J1 or J2
J1 or J2
J3 or J4
J7
J7
J0
CPU board
CPU module
Not implemented
Appendix A - 2 _________________________________________ Installation Worksheets
__________________________________________________________ DanLoad 6000 (v6.00)
Table Description
A-10 Base Level Program Codes for System Items
A-11 General Configuration Parameters
A-12 Flow Meter Parameters
A-13 Flow Control Valve Parameters
A-14 Component Parameters
A-15 Component Block Valve / Pump Parameters
A-16 Delivery Parameters
A-17 Blending Parameters
A-18 Temperature Compensation Parameters
A-19 Pressure Compensation Parameters
A-20 Density Compensation Parameters
A-21 Pulse Per Unit Output Parameters
A-22 Additives Parameters
A-23 LPG / Pressure Control Parameters
A-24 Dynamic Data Display Parameters / Codes
A-25 Communications / Data Logging Parameters
A-26 Transaction Storage Parameters
A-27 Transaction Ticket Parameters
A-28 Alarm Parameters
A-29 Analog Input Parameters (for v2 CPU)
Setup
Optional
Optional
Optional
Optional
Optional
Optional
Optional
Optional
Optional
Optional *
Optional
Required
Required
Required
Required
Required
Required
Optional
Optional
Notes:
# Only enabled and applicable program codes in each group are required to be configured.
# * Alarm parameters are set to default values. Some of these values and / or limits may require adjustment to prevent erroneous alarms.
Installation Worksheets _________________________________________ Appendix A - 3
DanLoad 6000 (v6.00) __________________________________________________________
A.1
Physical Configuration of the DanLoad 6000
The following inputs and outputs are fixed and are not reconfigurable.
#
#
#
One to four meter pulse inputs to meter pulse boards
Two swing arm status inputs to main processor board (not present on v2 CPU)
Two high-resolution pulse outputs from 2-channel meter pulse board (only with MPMC board on 4-channel meter pulse board)
#
#
Maximum physical input channels:
# 4 each RTD process temperature (5 for v2 CPU)
8 each 4 to 20 mAdc process pressure or density (9 for v2 CPU)
24 each discrete status functions
Maximum physical output channels:
# 28 each discrete control functions
Note
The number of functions that can be assigned to physical discrete input and output channels is greater than the number of available physical discrete channels. Some logical discrete input and output functions are mutually exclusive and cannot be active at the same time. The v2
CPU board (1997) has one 4-20 mA input, one RTD input and a DUART built in.
The unit number assigned to each DanLoad 6000 is derived as follows. If the DanLoad 6000 communicates with a data logging device or terminal automation system, each instrument must be assigned a unit number. This assignment is accomplished by DIP switches located on the DUART
(v1 CPU board) or by program code 662 (v2 CPU board). The range of the unit number is 1 to 255.
A Multi-drop network implemented with the RS-485 port (DUART) has an electrical limit of 32 units to one RS-485 master port. However, the unit numbers of these 32 units can be any unique number within the range of 1 to 255. If neither communications module is installed, it is advisable to use the same number range (1 to 255) for unit assignment numbers. Using numbers in this range may avoid the need to renumber the units if data logging and / or terminal automation system communications are added in the future.
Appendix A - 4 _________________________________________ Installation Worksheets
__________________________________________________________ DanLoad 6000 (v6.00)
Input and output signal channel identification numbers can be entered into the tables using the following channel number labels.
Process Tag
Input / Output Signal Identification
Channel Number
FT-# (1 to 4)
TE-# (1 to 4)
Description
Meter pulse input
RTD input
PT-# / DT-# (1 to 4)
ACI-# (1 to max AC inputs)
4 to 20 mAdc analog input
Discrete Vac input
ACO-# (1 to max AC outputs) Discrete Vac output
DCI-# (1 to max DC inputs) Discrete Vdc input
DCO-# (1 to max DC outputs) Discrete Vdc output
#
#
#
#
The initial setup procedure should be performed at this time. Section 3 provides information on the initial setup procedure. After the initial setup procedure has been performed, the assigned physical hardware channel for each input / output channel can be determined in the following manner. While operating in the Program Mode, press the ALT+0 key to display the physical hardware configuration of the instrument. The first display page shows the type of boards installed in slots J1 through J7. Scroll through the I/O assignment display pages using the 9 and 8 arrow keys.
Manually enter the assigned hardware channels indicated in the leftward column of the display pages into the Assigned Channel column of the corresponding Tables A - 1a through A - 22. Also enter the DanLoad 6000 Unit number and the physical slot, Jn number, where the board is located. The number and type of these assigned hardware channels determine the fixed input / output signal capability of the individual DanLoad 6000.
Enter the power supply wiring information into Table A - 7.
Enter the swing arm wiring information into Table A - 8. Enter a descriptive identification of the loading side, such as north, west, etc.
Enter the wiring information for the DUART, Table A-9 at this time.
The final step is to review and record the settings of the applicable program codes listed in
Tables A - 11 to A - 28.
Installation Worksheets _________________________________________ Appendix A - 5
DanLoad 6000 (v6.00) __________________________________________________________
The following two rules apply to assignment of a physical channel to an input or output function:
# The type of input / output signal board for the desired function must be installed in the
DanLoad 6000.
# The physical input or output channel should typically not have been previously assigned to some other function.
Physical input / output channel assignments are made, while in Program Mode, by using the 9 or
8 arrow key to place the box cursor over a physical channel number (rightward column) corresponding to a function displayed to the left of the physical channel number. The currently assigned physical channel identification number, obtained from Tables A - 1a through A - 22, is then verified or changed. Press the ENTER key to accept the assignment or the CLEAR key to reject the assignment and re-enter a number. If the entry is a valid assignment, the box cursor automatically steps to the next parameter in the group. If the hardware is not installed to support this physical channel or the number of supported physical channels is exceeded, the message Point does
not exist is displayed on the message line.
Appendix A - 6 _________________________________________ Installation Worksheets
__________________________________________________________ DanLoad 6000 (v6.00)
A.2
Functional Configuration of the DanLoad 6000
Table A - 10, Base Level Program Codes for Physical Components of the System, contains information on the primary program codes that enable devices, components, and additives. Several additional program code settings are required to fully configure the operation of the DanLoad 6000.
These additional program codes are organized in device and functional groups and listed in Tables
A - 11 to A - 28. Several program codes can be listed at several points within one table or can be listed in more than one table. This multiple listing is done for clarity due to the cross function of some program codes. In general, program code settings are used to enable and assign devices, components, and additives in the following manner.
# Program codes define the number of devices, components, and additives in the system. This definition controls the activation of the correct number of similar parameters dependent on the number of devices, components, and additives defined.
# Individual program codes for each device, component, and additive configure links or cross assignments between the devices, components, and additives.
# Individual program codes for each device, component, and additive assign actual physical input and output signal circuits to the logical devices, components, and additives. With the exception of meter pulse inputs, high resolution pulse outputs, and swing-arm status inputs, all input and output signals can be assigned to any available physical circuit of the corresponding type. (Note: Meter pulse inputs were assignable to meters in Version 3.0 and below of the DanLoad 6000.)
The minimal device configuration for a DanLoad 6000 is stated below. This configuration is for a one component sequential blender.
Minimal Configuration
Program code Value
050 Number of meters 1
048 Number of valves
052 Valve for meter 1
065 Number of components
067 Meter for component 1
1
1
1
1
Installation Worksheets _________________________________________ Appendix A - 7
DanLoad 6000 (v6.00) __________________________________________________________
This minimal configuration, though valid, is not typical. Normally, many other parameters will be configured, such as, a component pump defined by program code 288 Pump control output. The base DanLoad 6000 has one 4-Channel Meter Pulse board and one AC I/O board. Additional features such as additive injection control, volume correction for temperature / pressure / density, and pulse per unit outputs can be enabled as required.
Tables A - 11 to A - 29 contain additional information related to the basic Table A - 10. The corresponding program codes for each function implemented should be verified during initial setup of the DanLoad 6000. Section 6 of the manual contains detailed descriptions of each program code.
Appendix A - 8 _________________________________________ Installation Worksheets
__________________________________________________________ DanLoad 6000 (v6.00)
Function TB
Meter 1 preamp power (8 - 24 Vdc) 1
Meter 1 pulse input 2
Meter 1 preamp common 3
Board
Channel
1 or 3
Meter 2 preamp power (8 - 24 Vdc) 4
Meter 2 pulse input 5
Meter 2 preamp common 6
Meter 1 pulse output +
Meter 1 pulse output -
Meter 2 pulse output +
Meter 2 pulse output -
Control 2 switched + Vdc
Control 2 return - Vdc
2 or 4
7
8
9 2 or 4
10 2 or 4
11 2
12
1 or 3
1 or 3
Assigned
Channel
Control 1 switched + Vdc
Control 1 return - Vdc
P / S common
P / S common
13 1
14
15
16
2-Channel Meter Pulse Board Wiring (Slot J5 / J6)
(Drawing DE-12694)
Location:__________ Unit:________ Date:___________
Table A - 1a
Installation Worksheets _________________________________________ Appendix A - 9
DanLoad 6000 (v6.00) __________________________________________________________
Function
Meter preamp power (8 - 24 Vdc)
Meter 1A pulse input
Meter 1A preamp common
Meter preamp power (8 - 24 Vdc)
Meter 1B pulse input
Meter 1B preamp common
Meter 1 pulse output +
Meter 1 pulse output -
Meter 2 pulse output +
Meter 2 pulse output -
Control 2 switched + Vdc
Control 2 return - Vdc
Control 1 switched + Vdc
Control 1 return - Vdc
START (proof)
P / S common
Meter 2A pulse input
Meter 2A preamp common
Meter 2B pulse input
Meter 2B preamp common
TB
1
2
3
Board
Channel
1, 3, 5
4
5
6
2, 4, 6
7
8
9 2, 4, 6
10 2, 4, 6
11 2
12
1, 3, 5
1, 3, 5
Assigned
Channel
13 1
14
15
16
17 3, 5, 7
18
19 4, 6, 8
20
4-Channel Meter Pulse Board Wiring (Slot J5 / J6)
(Drawing CE-15532)
Location:__________ Unit:________ Date:___________
Table A - 1b
Appendix A - 10 _________________________________________ Installation Worksheets
__________________________________________________________ DanLoad 6000 (v6.00)
Function
Status 2 switched Vdc/Vac
Status 2 common
Status 1 switched Vdc/Vac
Status 1 common
Control 8 supply Vac
Control 8 switched Vac
Control 7 supply Vac
Control 7 switched Vac
Control 6 supply Vac
Control 6 switched Vac
Control 5 supply Vac
Control 5 switched Vac
Control 4 supply Vac
Control 4 switched Vac
Control 3 supply Vac
Control 3 switched Vac
Control 2 supply Vac
Control 2 switched Vac
Control 1 supply Vac
Control 1 switched Vac
AC I/O Board Wiring (Slot J1 / J3)
(Drawing CE-12695)
Location:__________ Unit:________ Date:___________
Table A - 2
3
4
TB
1
2
1
5
6 8
7
8 7
9
10 6
11
12 5
13
14 4
15
16 3
17
18 2
19
20 1
Board
Channel
2
Assigned
Channel
Installation Worksheets _________________________________________ Appendix A - 11
DanLoad 6000 (v6.00) __________________________________________________________
Function
Status 6 switched Vdc/Vac
Status 5/6 common
Status 5 switched Vdc/Vac
Status 4 switched Vdc/Vac
Status 3/4 common
Status 3 switched Vdc/Vac
Status 2 switched Vdc/Vac
Status 1/2 common
Status 1 switched Vdc/Vac
Control 6 switched Vac
Control 5/6 supply Vac
Control 5 switched Vac
Control 4 switched Vac
Control 3/4 supply Vac
Control 3 switched Vac
Control 2 switched Vac
Control 1/2 supply Vac
Control 1 switched Vac
7
8
9
4
5
6
TB
1
2
3
Board
Channel
6
5
4
3
2
1
10 6
11
12 5
13 4
14
15 3
16 2
17
18 1
Assigned
Channel
Enhanced I/O (Additive Injector) Board Wiring (Slot J1 / J2)
(Drawing CE-12697 or CE-19021)
Location:__________ Unit:________ Date:__________
Table A - 3
Appendix A - 12 _________________________________________ Installation Worksheets
__________________________________________________________ DanLoad 6000 (v6.00)
Function
Status 6 supply Vdc
Status 6 switched Vdc
Status 5 supply Vdc
Status 5 switched Vdc
Status 4 supply Vdc
Status 4 switched Vdc
Status 3 supply Vdc
Status 3 switched Vdc
Status 2 supply Vdc
Status 2 switched Vdc
Status 1 supply Vdc
Status 1 switched Vdc
Control 4 switched + Vdc
Control 4 return - Vdc
Control 3 switched + Vdc
Control 3 return - Vdc
Control 2 switched + Vdc
Control 2 return - Vdc
Control 1 switched + Vdc
Control 1 return - Vdc
TB
1
2 6
5
6
3
4 5
4
7
8 3
9
10 2
Board
Channel
11
12 1
13 4
14
15 3
16
17 2
18
19 1
20
Assigned
Channel
DC I/O Board Wiring (Slot J3 / J4)
(Drawing CE-12696)
Location:__________ Unit:________ Date:___________
Table A - 4
Installation Worksheets _________________________________________ Appendix A - 13
DanLoad 6000 (v6.00) __________________________________________________________
Function
Transmitter 1 power (24 Vdc)
Transmitter 1 input
Transmitter power common
+ Vsource
RTD 1 +
RTD 1 -
RTD current source
TB
1
2
3
4
5
6
7
1
2
2
Board
Channel
Assigned
Channel
2-Channel Analog Input Board Wiring (Slot J7)
(Drawing BE-12707)
Location:__________ Unit:________ Date:____________
Table A - 5
Appendix A - 14 _________________________________________ Installation Worksheets
__________________________________________________________ DanLoad 6000 (v6.00)
Function
Transmitter 1/2 power (24 Vdc)
Transmitter 1 input
Transmitter 2 input
Transmitter 3/4 power (24 Vdc)
Transmitter 3 input
Transmitter 4 input
Transmitter power common
+ Vsource
RTD 1 +
RTD 1 -
RTD loop tie point
RTD 2 +
RTD 2 -
RTD loop tie point
RTD 3 +
RTD 3 -
RTD loop tie point
RTD 4 +
RTD 4 -
RTD current source
14
15 7
16 7
17
18 8
19 8
20
8
9 5
10 5
11
12 6
13 6
TB
1
2
3
6
7
4
5
1
2
3
4
Board
Channel
Assigned
Channel
8-Channel Analog Input Board Wiring (Slot J7)
(Drawing CE-12698)
Location:__________ Unit:________ Date:____________
Table A - 6
Installation Worksheets _________________________________________ Appendix A - 15
DanLoad 6000 (v6.00) __________________________________________________________
Function TB Source /
Destination
Vac power hot
Vac safety ground
Vac neutral (230 Vac hot)
Space heater Vac hot (supply)
Space heater Vac neutral
Vac permissive power input
Vac permissive power neutral
Vac permissive power output (fused)
TB1-1
TB1-2
TB1-3
TB1-4
TB1-5
TB2-1
TB2-2
TB2-3
Power Supply Wiring (Slot J0)
(Drawing CE-12692)
Location:__________ Unit:________ Date:___________
Table A - 7
Function
Swing arm switch 1 1
Swing arm common
Swing arm switch 2
TB
Physical
Channel
Actual
Side Per program
code 312
2
3
1 (SW1)
(right)
(center)
2 (SW2)
(left)
Swing Arm Input Wiring (CPU Board)
(Drawing CE-12693 and BE-12789)
Location:__________ Unit:________ Date:___________
Table A - 8
Appendix A - 16 _________________________________________ Installation Worksheets
__________________________________________________________ DanLoad 6000 (v6.00)
Function
Channel A, RS-485 Rx+
Channel A, RS-485 Rx-
Channel A, RS-485 Tx+
Channel A, RS-485 Tx-
Channel B, RS-485 Rx+ or
Channel B, RS-232 RxD
Channel B, RS-485 Rxor
Channel B, RS-232 CTS (clear to send)
Channel B, RS-485 Tx+ or
Channel B, RS-232 TxD
Channel B, RS-485 Tx-
Channel B, RS-232 RTS (request to send)
Channel B, RS-232 common
TB
1
2
3
4
5
6
7
8
9
10
Destination
<not used>
DUART Module Wiring (CPU Module)
(Drawing CE-12693)
Location:__________ Unit:_______ Date:__________
Table A - 9
Installation Worksheets _________________________________________ Appendix A - 17
DanLoad 6000 (v6.00) __________________________________________________________
Device Assignment Program Codes
Device / Component / Additive
Assignment
LOADING ARM
³
(at)
M ET ERS *
1
050
2 3 4 5
ENABLE FCV’s * 048 flow control valve ³ meter(s) * 052 055 058 061 --
065 ENABLE COM PONENTS * meter ³ component(s) * block valve ³ component block valve ³ component(s) block valve ³ component pump ³ component
RTD x ³ meter x
PT x
³
meter x
DT x
³
meter x
067
400
408 to 422
401
288
318
320
321
070
402
403
289
324
326
327
073
404
405
290
330
332
333
076
406
407
291
336
338
339
--
--
--
--
--
--
--
ENABLE PULSE OUTPUTS 128
6
--
--
--
--
--
--
--
-pulse output
³
meter(s)
ENABLE ADDITIVES additive
³
meter(s) block valve ³ additive pump ³ additive
129
135
139
801
800
132
144
804
803
--
149
807
806
--
154
810
809
--
159
813
812
--
164
816
815
Program Code
Name
Number of meters
Number of valves
Valve to be controlled
Number of components
M eter
Block valve output
Component combination
Block valve input
Pump control output
M eter x temperature input
M eter x pres input
M eter x dens input
Number of pulse
per unit outputs
Control meters
Number of additives
Additive control meters
Block valve output
Pump output
Base Level Program Codes for Physical Components of the System
Table A - 10
Notes:
#
#
* In the assignment column indicates that these parameters must be defined in all installations.
Tables A - 11 to A - 29 follow this page.
Appendix A - 18 _________________________________________ Installation Worksheets
________________________________________________________________________________________ DanLoad 6000 (v6.00)
A.3
General Configuration Parameters Setup
TABLE A -11 General Parameters Location: Unit: Date:
Program Code Function
Global
Numeric passcode entry for operators and supervisors.
001 / 004 / 007 / 010 / 013 / 016 / 019 / 022
Passcode
217 Passcode per transaction Required passcode entry per each transaction (not implemented)
Configurable user name 002 / 005 / 008 / 011 / 014 / 017 / 020 / 023
User ID
003 / 006 / 009 / 012 / 015 / 018 / 021 / 024
Supervisor privilege
025 Operating mode
Enable supervisor data access
026 Unit type
027 Valve type
Select manual / auto mode for unit
Select type of blending
Select type of flow control valve
028 Language
030 Number of data item prompts
031 / 032 / 033 / 034 / 035 #x Prompt
036 Prompt time-out (s)
Select language for unit
Select quantity of prompts to user
Configurable prompt text
Set time to display prompt
Default
6000
Manual / Auto
Seq. (auto)
Std digital
English
0
<message>
60
Actual
Setup (Parameter Groups) _____________________________________________________________________ Appendix A - 19
________________________________________________________________________________________ DanLoad 6000 (v6.00)
TABLE A -11 General Parameters Location: Unit: Date:
Program Code Function
037 Check display
038 Date format
039 Date separator
Display diagnostic
Select date format
Select date units separator
040 Decimal separator
041 Data display rate
280 Slot 1 board
281 Slot 2 board
282 Slot 3 board
283 Slot 4 board
284 Slot 5 board
Select decimal separator
Select data display rate
Type of input / output board installed in J1
Type of input / output board installed in J2
Type of input / output board installed in J3
Type of input / output board installed in J4
Type of input / output board installed in J5
285 Slot 6 board
286 Slot 7 board
312 Side detect method
315 Trip 1 output
316 Trip 2 output
317 Trip 3 output
343 Auto/manual change-over
Type of input / output board installed in J6
Type of input / output board installed in J7
Swing-arm switch input sensing method ( v2 CPU does not have swing arm inputs)
ON during low-flow startup
ON during low-flow startup and high-flow
ON from start of loading to end of loading
Input CLOSED = automatic mode / input OPEN = manual mode
Default
Off mm/dd/yy
‘/’
‘.’
28000
Auto-detect
Auto-detect
Auto-detect
Auto-detect
Auto-detect
0
0
0
Auto-detect
Auto-detect
Sgl w/o sw
0
Actual
Setup (Parameter Groups) _____________________________________________________________________ Appendix A - 20
________________________________________________________________________________________ DanLoad 6000 (v6.00)
TABLE A -11 General Parameters Location: Unit: Date:
Program Code Function
355 Primary LCD type
356 Primary LCD minimum light
357 Primary LCD maximum light
Type of LCD display installed
Controls LCD backlighing intensity based on low ambient light level
Controls LCD backlighing intensity based on high ambient light level
358 Secondary LCD type
359 Secondary LCD minimum light
360 Secondary LCD maximum light
Type of LCD display installed
Controls LCD backlighing intensity based on low ambient light level
Controls LCD backlighting intensity based on high ambient light level
Default
Optrex
455
405
Optrex
455
405
Actual
Setup (Parameter Groups) _____________________________________________________________________ Appendix A - 21
________________________________________________________________________________________ DanLoad 6000 (v6.00)
A.4
Flow Meter Parameters Setup
TABLE A -12 Flow Meter Parameters Location: Unit: Date:
Program Code
050 Number of meters
Function
ENABLE 1 to 4 METERS FOR LOAD SPOT
029 Product units
045 Round method
Global Parameters
Label for volume units.
Select the method for rounding volume accumulations.
Individual Meter Configuration
Assign identification label to flow meter.
051 / 054 / 057 / 060 Meter ID
052 / 055 / 058 / 061 Valve to be controlled
233 Error limit (pulses)
Assign flow control valve to meter stream
Pulse Security
Accumulation of pulse errors to allow before triggering a Pulse security error meter x alarm. Set to 0 to disable feature.
234 Reset count (pulses)
222 Minimum flow rate
223 Low flow time (s)
221 Low flow alarm action
225 Maximum flow rate
226 High flow time (s)
224 High flow alarm action
Accumulated value of error counts at which the error counter is reset to zero. This counter is always reset to zero at the start of a loading operation.
Alarms
Low flow rate setpoint for alarm trigger.
Time period to ignore low flow rate before triggering alarm.
Action in response to low flow rate alarm.
High flow rate setpoint for alarm trigger.
Time period to ignore high flow rate before triggering alarm.
Action in response to high flow rate alarm.
Default
User input
Gal
Up
M#
0
10000
100
10
Primary
660
10
Primary
Actual
Not used
Setup (Parameter Groups) _____________________________________________________________________ Appendix A - 22
________________________________________________________________________________________ DanLoad 6000 (v6.00)
TABLE A -12 Flow Meter Parameters Location: Unit: Date:
Program Code Function
227 Overrun limit qty
229 Underflow limit qty
Quantity over preset that can be delivered before triggering an Unable to close valve
meter x alarm. This alarm is a Primary alarm.
Quantity under preset that can be delivered before triggering a Valve closed early
meter x alarm.
228 Underflow alarm action
231 No flow t-o time (s)
230 No flow t-o alarm action
232 Unauthorized flow limit qty
Action in response to an underflow alarm.
Time period allowed with no flow when flow is expected before triggering a Timed-
out - no flow detected meter x alarm.
Action in response to a no flow time-out alarm.
Quantity allowed to be measured when flow is not expected before triggering an
Unauthorized flow exceeds limit meter x alarm.
Enable alarms to output 1 (bit mask) 269 Alarm o/p mask 1
287 Alarm output 1
270 Alarm, o/p mask 2
379 Alarm output 2
Assign alarm output 1 to a discrete output.
Enable alarms to output 2 (bit mask)
Assign alarm output 2 to a discrete output.
Default
2.0
5.0
Off
5
Primary
10.0
0
0
16777215
4
Actual
Setup (Parameter Groups) _____________________________________________________________________ Appendix A - 23
________________________________________________________________________________________ DanLoad 6000 (v6.00)
A.5
Flow Control Valve Parameters Setup
TABLE A -13 Flow Control Valve Parameters Location: Unit: Date:
Program Code
048 Number of valves
052 / 055 / 058 / 061 Valve to be controlled
Function
ENABLE 1 to 4 FLOW CONTROL VALVES
Assign flow meter(s) to flow control valve
[flow control valve » flow meter(s)]
Delivery Parameters - Global
027 Valve type
049 Initial flow time (s)
108 Ramp clicks
109 Maintenance clicks
114 / 118 / 122 / 126
Maint click adjustment (s)
112 / 116 / 120 / 124 Low flow % error
Select type of valve
Startup time at initial state before beginning flow control
Delivery Parameters - Individual Components
Maximum attempts to ramp-up flow rate before maintaining lower flow rate
Maximum attempts to maintain flow rate before falling back to a lower flow rate
Normal valve control ON time plus the time specified by this parameter
113 / 117 / 121 / 125 High flow % error
115 / 119 / 123 / 127 Open method
Variation from low flow rate allowed before adjustment attempt is made
Variation from high flow rate allowed before adjustment attempt is made
Method to control FCV during initial flow time set by program code 049 Initial flow time (s)
Default
Std digital
0.200
30
30
0.040
5
2
Normal
Actual
Setup (Parameter Groups) _____________________________________________________________________ Appendix A - 24
________________________________________________________________________________________ DanLoad 6000 (v6.00)
TABLE A -13 Flow Control Valve Parameters Location: Unit: Date:
Program Code Function
NO solenoid on FCV 292 / 297 / 302 / 307
Solenoid 1 (upstream)
293 / 298 / 303 / 308
Solenoid 2 (downstream)
NC solenoid on FCV
Inputs
294 / 299 / 304 / 309
Stem Switch 1
295 / 300 / 305 / 310
Stem Switch 2
296 / 301 / 306 / 311 Close input
Unauthorized flow through FCV
Not used
276 Ramp down alarm action
277 Ramp down time (s)
Pressure control (“pinch back”)
Alarms
Action in response to loss of CLOSE control of the flow control valve.
Time period allowed to reduce flow rate without response before issuing an alarm.
Default
1
2
0
0
0
Primary
Actual
Not used
Setup (Parameter Groups) _____________________________________________________________________ Appendix A - 25
________________________________________________________________________________________ DanLoad 6000 (v6.00)
A.6
Component Parameters Setup
TABLE A - 14 Component Parameters Location: Unit: Date:
Program Code
065 Number of components
067 / 070 / 073 / 076 Meter
Function
ENABLE 1 to 4 COMPONENTS (PRODUCTS)
Assign component(s) to flow meter
[flow meter » component(s)]
Global Parameters
026 Unit type
045 Round method
111 Primary component
215 Master MF %
216 Adjacent MF %
066 / 069 / 072 / 075 Component ID
068 / 071 / 074 / 077 Mass adjustment
Specify loading / blending configuration
Select method for mathmatical rounding of accumulated totals
Component for blend error detection and / or line flushing
Maximum percent variance of any meter factor to corresponding master meter factor
169 Number of factors/component
170 Meter factor method
171 / 182 / 193 / 204 Nominal K-factor
172 / 183 / 194 / 205 Master meter factor
173 / 184 / 195 / 206 Stop rate Comp x
Maximum percent variance of any meter factor to adjacent meter factors.
Assign identification label to component
The component’s “mass computation adjustment factor”
Meter Factors
Specify the number of flow rate / meter factor combinations for the component through it’s flow meter
Select use of fixed or linearized meter factors
Pulses per engineering unit rounded to one decimal place. Obtained from meter nameplate.
Median value of meter factor for use in validation by program code 215 Master MF
%
Set the flow rate for low-flow stop quantity at end of inline batch
Default
1 or more
2
Fixed
23.0
1.0000
120
Seq.(auto)
Up
1
2.00
0.25
Component #n
0.000000
Actual
Setup (Parameter Groups) _____________________________________________________________________ Appendix A - 26
________________________________________________________________________________________ DanLoad 6000 (v6.00)
TABLE A - 14 Component Parameters Location: Unit: Date:
Program Code Function
174 / 185 / 196 / 207 Flow rate 1
175 / 186 / 197 / 208 Meter factor 1
176 / 187 / 198 / 209 Flow rate 2
Low calibration flow rate
Meter factor for low calibration flow rate
High or fallback calibraiton flow rate
177 / 188 / 199 / 210 Meter factor 2
178 / 189 / 200 / 211 Flow rate 3
179 / 190 / 201 / 212 Meter factor 3
180 / 191 / 202 / 213 Flow rate 4
181 / 192 / 203 / 214 Meter factor 4
Meter factor for calibration flow rate 2
High or fallback calibration flow rate
Meter factor for calibration flow rate 3
High calibraton flow rate
Meter factor for high calibration flow rate
Default
200
1.0000
600
1.0000
0
1.0000
0
1.0000
Actual
Setup (Parameter Groups) _____________________________________________________________________ Appendix A - 27
________________________________________________________________________________________ DanLoad 6000 (v6.00)
A.7
Component Block Valve / Pump Parameters Setup
TABLE A - 15 Block Valve / Pump Parameters Location: Unit: Date:
Program Code Function
400 / 402 / 404 / 406 Block valve output
Block Valve Control Parameters
Assign discrete output for block valve control
[block valve » component]
408 to 422 Component combination nn (cccc)
026 Unit type
089 Block valve delay (s)
354 Delay after outputs
Assign discrete output for block valve control
[block valve » component(s)]
DanLoad 6000 unit assignment for general control of block valves
Time between opening block valve and opening the FCV
486 / ... / 660 Sequence to load
401 / 403 / 405 / 407 Block valve input
480 Number of recipes
Time between energizing recipe and component combination outputs and checking safety circuits (used in conjunction with an automation system).
Block valve control sequence
Block Valve Status Parameters
Assign discrete input for block valve status
[block valve » component]
Recipes
Total number of recipes enabled
Default
0
0
Seq.(auto)
0
0
1
Actual
Setup (Parameter Groups) _____________________________________________________________________ Appendix A - 28
________________________________________________________________________________________ DanLoad 6000 (v6.00)
TABLE A - 15 Block Valve / Pump Parameters Location: Unit: Date:
Program Code Function
481 / ... / 655 Name
482 / ... / 656 Component 1 percentage
483 / ... / 657 Component 2 percentage
Configurable name for recipe
Percentage of Component 1 to load for Recipe rr
Percentage of Component 2 to load for Recipe rr
484 / ... / 658 Component 3 percentage
485 / ... / 659 Comp 4 percent or ratio qty
486 / ... / 660 Sequence or low proportion
288 / 289 / 290 / 291 Pump control output
087 Line pack delay (s)
088 Pump stop delay (s)
248 Block valve time (s)
Percentage of Component 3 to load for Recipe rr
Percent of Component 4 to load for Recipe rr or additive ratio quantity “Multi-rate”
[Sequential blending] Order to load components.
[In-line blending] High / low proportion component
Pump Control Parameters
Assign discrete output for pump control
[pump » component]
Time between pump start and FCV opening
Time between FCV closing and pump stop
Alarms
Time allowed for a block valve to close after deenergizing the block valve control output.
Enable alarm to output 1 (bit mask) 269 Alarm o/p mask 1
287 Alarm output 1
270 Alarm o/p mask 2
379 Alarm output 2
Discrete output for alarm mask 1
Enable alarm to output 2 (bit mask)
Discrete output for alarm mask 2
Default
Recipe rr
0
8 / ...
2
30
10
0
0
16777215
4
Actual
Setup (Parameter Groups) _____________________________________________________________________ Appendix A - 29
________________________________________________________________________________________ DanLoad 6000 (v6.00)
A.8
Delivery Parameters Setup
TABLE A - 16 Delivery Parameters Location: Unit: Date:
Program Code Function
078 Maximum preset qty Maximum quantity that can be preset in a single batch
079 Minimum preset qty
080 Preset/delivery type
081 Delivery display type
082 Stop key action
083 Fall back qty
108 Ramp clicks
109 Maintenance clicks
Minimum quantity that can be preset
Use uncompensated or compensated quantity in computing delivery quantity
Display delivery quantity as uncompensated or compensated quantity
Select method for terminating a batch delivery with the STOP key
Quantity to flow at a fall back flow rate before attempting to increase flow rate to highest flow rate
Number of attempts to increase flow rate before maintaining fall back flow rate
Number of attempts to maintain flow rate before decreasing flow rate to a fall back flow rate
The time between stopping delivery and deenergizing additive pump outputs 110 Additive pump stop (s)
111 Primary component
341 #cmpt inputs
342 Start method
084 / 090 / 096 / 102 Low flow start qty
085 / 091 / 097 / 103 Low flow restart qty
Primary component for blend ratio error detection and / or line flushing
Specify the number of “compartment size inputs”
Define the method used to start a batch delivery.
Component X
[Sequential delivery only] Quantity to load at startup flow rate before increasing to high flow rate
[sequential delivery only] Quantity to load at startup flow rate after restart from a suspended delivery operation. Active only if the Low flow start quantity has been delivered.
50
20
30
30
10
1
0
Normal
Default
3000
50
Gross
Gross
Low flow
1000
Actual
Setup (Parameter Groups) _____________________________________________________________________ Appendix A - 30
________________________________________________________________________________________ DanLoad 6000 (v6.00)
TABLE A - 16 Delivery Parameters Location: Unit: Date:
Program Code Function
086 / 092 / 098 / 104 Low flow stop qty [Sequential delivery] Quantity to load at the Flow rate 1 at the end of a delivery.
** OR **
[In-line delivery} Quantity to load at the component stop rate.
Time between component pump energization and opening the flow control valves 087 / 093 / 099 / 105 Line pack delay (s)
088 / 094 / 100 / 106 Pump stop delay (s)
089 / 095 / 101 / 107 Block valve delay (s)
Time between flow control valves closing and component pump deenergization
Time between opening the component block valve and opening the flow control valve.
480 Number of recipes
481 / ... / 655 Recipe name
482 / ... / 656 Component 1 percentage
483 / ... / 657 Component 2 percentage
484 / ... / 658 Component 3 percentage
485 / ... / 659 Comp 4 percent or ratio qty
486 / ... / 660 Sequence or low proportion
Recipes
Specify the number of recipes defined.
Configurable alpha-numeric name of recipe.
Percentage of component 1 used in blend.
Percentage of component 2 used in blend.
Percentage of component 3 used in blend.
Percentage of component 4 used in blend or additive ratio quantity for “Multi Rate”
[Sequential delivery] Sequence to load components.
[ In-line delivery] Specify high / low proportion components.
Recipe Selection Inputs
Must be set to 0 to enable the six nnn Recipe X input functions below.
348 Safety circuit 4
361 Recipe 1 input
362 Recipe 2 input
363 Recipe 3 input
364 Recipe 4 input
Assign discrete input for selection of recipe 1
Assign discrete input for selection of recipe 2
Assign discrete input for selection of recipe 3
Assign discrete input for selection of recipe 4
0
0
0
0
0
Default
50
2
30
0
0
1
Recipe XX
100
0
Actual
Setup (Parameter Groups) _____________________________________________________________________ Appendix A - 31
________________________________________________________________________________________ DanLoad 6000 (v6.00)
TABLE A - 16 Delivery Parameters Location: Unit: Date:
Program Code Function
365 Recipe 5 input
366 Recipe 6 input
Assign discrete input for selection of recipe 5
Assign discrete input for selection of recipe 6
Recipe Selection Outputs
367 Recipe 1 output
368 Recipe 2 output
369 Recipe 3 output
370 Recipe 4 output
Assign discrete output that is ON during batch delivery of recipe 1.
Assign discrete output that is ON during batch delivery of recipe 2.
Assign discrete output that is ON during batch delivery of recipe 3.
Assign discrete output that is ON during batch delivery of recipe 4.
371 Recipe 5 output
372 Recipe 6 output
373 End output method
374 Level input
375 Hatch input
Assign discrete output that is ON during batch delivery of recipe 5.
Assign discrete output that is ON during batch delivery of recipe 6.
Determine processing method for end of batch or transaction
Assign discrete input for ESSO Japan’s intermediate level logic
Assign discrete input for ESSO Japan’s hatch sensor logic
Default
0
0
0
0
0
0
0
0
0
0
Ba only
Actual
Setup (Parameter Groups) _____________________________________________________________________ Appendix A - 32
________________________________________________________________________________________ DanLoad 6000 (v6.00)
A.9
Blending Parameters Setup
TABLE A - 17 Blending Parameters Setup Location: Unit: Date:
Program Code Function
Global Parameters
341 #cmpt inputs
342 Start method
711 Ramp down %
712 Rate reduction
Define the number of “compartment size inputs”
Determine the method for starting batch delivery (not implemented)
Percent of desired flow rate to ramp to if unable to maintain blend do to low pressure
Reduction if flow rate when high flow rate cannot be maintained
713 Low flow start qty
714 Clean line qty
715 Low prop fac
716 Correct after qty
717 Alarm after qty
Quantity to load at low flow rate before ramping to high flow rate
Quantity of program code 111 Primary component to load at end of batch
[In-line blending] Flow rate to deliver low-proportion components set by program code 486 / ... / 660 Sequence to load
Quantity of blend to load before beginning blend ratio adjustment
Quantity of blend to load before checking blend ratio for purpose of generating
Unable to maintain blend alarm
718 Adjustment qty
719 Comp % display
720 Add calib delay (s)
722 Blend error method
723 Max dev %
724 Blend tol %
725 Max dev qty
Quantity segment of blend used to correct the blend ratio
Quantity accumulation type for display of batch component percentages
Time between pressing “START” and beginning of first additive injection cycle
Method of computing blend ratio error for adjustment and alarms
Maximum allowed percent deviation in the blend ratio
Maximum allowed percent tolerance in the blend
Maximum allowed quantity units variation in the blend
Default
50
0
1
0
Normal
50
100
100
200
50
Gross
0
Grspctbatch
2
5
20
Actual
Setup (Parameter Groups) _____________________________________________________________________ Appendix A - 33
________________________________________________________________________________________ DanLoad 6000 (v6.00)
TABLE A - 17 Blending Parameters Setup Location: Unit: Date:
Program Code Function
726 Blend tol qty
727 Blend sample qty
Maximum allowed quantity tolerance in the blend
The delivered blend quantity segment used to calculate blend ratio
Flow Meter Parameters
728 / 734 / 740 / 746 Flow adj fac
729 / 735 / 741 / 747 Ratio adj fac
730 / 736 / 742 / 748 Ramp %
Factor for rate of adjustment of flow rate during an in-line blend
Factor for rate of adjustment of blend ratio (for correction) during an in-line blend
[Sequential blending with digital flow control valve(s)]: Percentage of flow rate to ramp up with one ‘click’ before switching to flow rate maintenance mode.
“Logic” to use for calibration monitoring analysis 731 CALMON analysis method
752 FPO basis
753 CALMON error limit
754 CALMON reset count
756 / 761 / 766 / 771 FPO
757 / 762 / 767 / 772 Number of blades
758 / 763 / 768 / 773 Max max char dev
759 / 764 / 769 / 774 Max tot char devs
760 / 765 / 770 / 775 Calibration status
Factor applied to meter pulse inputs to generate factored pulse outputs
Number of bad analyses per CALMON reset count calibration monitoring
All analyses counters are zeroed out at this interval
The factored pulse output on the “smart” 4-ch meter pulse board
The number of magnetic blades on the meter for calibration purposes
Maximum signature deviation computed during a calibration analyses
Sum signature deviation computed during a calibration analyses
Select calibrated or not calibrated - can be used to force recalibration
Batch Profile Parameters
Low flow rate for Recipe n - Batch Profile n 776 / 778 / 780 / 782 / 784 / 786 / 788 / 790 /
792 / 794 / 796 / 798 Low flow rate
777 / 779 / 781 / 783 / 785 / 787 / 789 / 791 /
793 / 795 / 797 / 799 High flow rate
High flow rate for Recipe n - Batch Profile n
Default
40
10
1.00
1.00
85
300
600
Fuzzy
Raw
10
50
0
0
100
400
Not calibrated
Actual
Setup (Parameter Groups) _____________________________________________________________________ Appendix A - 34
________________________________________________________________________________________ DanLoad 6000 (v6.00)
A.10
Temperature Compensation Parameters Setup
TABLE A - 18 Temperature Compensation Parameters Location: Unit: Date:
Program Code
318 / 324 / 330 / 336 Meter x temp input
Function
ENABLE AND ASSIGN RTD TEMPERATURE INPUTS
TO FLOW METER STREAM
[RTD » meter stream]
353 RTD range
427 Temperaure units
430 Reference temperature
431 Sample qty
319 / 325 / 331 / 337 Meter x offset (Ohms)
432 / 435 /438 / 441 Temperature option
433 / 436 / 439 / 442 Alpha
Global Parameters
Specify range of RTD inputs on analog input board(s)
Engineering units: determine how meter temp is computed and control labeling
Linear equation reference temperature:
Table 6C and 24C use 60.0 degrees F.
Table 54C uses 15.0 degrees C.
Entering a non-standard reference temperature causes correction to same.
Measured quantity units between temperature readings to obtain temperature averages.
Individual RTD Configuration
3-wire RTD interconnecting wire resistance (not recommended)
Select method for calculation of C
T L
Coefficient of thermal expansion:
Default
0
Standard
C
15.0
100
0
Off
0.0005100
434 / 437 / 440 / 443 Backup temperature
239 Minimum temperature
240 Maximum temperature
Fixed temperature used if RTD input fails.
Alarms
Low temperature setpoint for alarm trigger
High temperature setpoint for alarm trigger
15.0
-40.0
110.0
Actual
Setup (Parameter Groups) _____________________________________________________________________ Appendix A - 35
________________________________________________________________________________________ DanLoad 6000 (v6.00)
TABLE A - 18 Temperature Compensation Parameters Location: Unit: Date:
Program Code Function
238 Temp fail alarm action
269 Alarm o/p 1 mask
Action in response to temperature alarm
Enable temperature failure alarm to output 1.
(Bit mask value = 512)
Assign a discrete output to alarm output 1.
287 Alarm output 1
270 Alarm o/p 2 mask
379 Alarm output 2
Enable temperature failure alarm to output 2.
(Bit mask value = 512)
Assign a discrete output to alarm output 2.
4
0
Default
Primary
16777215
0
Actual
Setup (Parameter Groups) _____________________________________________________________________ Appendix A - 36
________________________________________________________________________________________ DanLoad 6000 (v6.00)
A.11
Pressure Compensation Parameters Setup
TABLE A - 19 Pressure Compensation Parameters Location: Unit: Date:
Program Code
320 / 326 / 332 / 338 Meter x pres input
Function
Enable and assign pressure analog input to flow meter stream
[pressure transmitter » meter stream]
Global Parameters
429 Pressure units Engineering units
Individual PT Configuration
Pressure at zero scale transmitter input.
464 / 468 / 472 / 476 Pressure @4 mA
465 / 469 / 473 / 477 Pressure @20 mA
444 / 447 / 450 / 453 Pressure option
445 / 448 / 451 / 454 F-factor X 1000000000
Pressure at full scale transmitter input.
Select method for calculation of C
P L
Alarms
Low pressure setpoint for alarm trigger.
244 Minimum pressure
245 Maximum pressure
Note:
269 Alarm o/p 1 mask
High pressure setpoint for alarm trigger.
Action in response to pressure alarm is always Primary.
Enable pressure failure alarm to output 1.
(Bit mask value = 1024)
Assign a discrete output to alarm output 1.
287 Alarm output 1
270 Alarm o/p 2 mask
379 Alarm output 2
Enable pressure failure alarm to output 2.
(Bit mask value = 1024)
Assign a discrete output for alarm output 2.
4
0
Default
0 psi
0.00
0.00
Off
0
0.00
0.00
C388607
0
Actual
Setup (Parameter Groups) _____________________________________________________________________ Appendix A - 37
________________________________________________________________________________________ DanLoad 6000 (v6.00)
A.12
Density Compensation Parameters Setup
TABLE A - 20 Density Compensation Parameters Location: Unit: Date:
Program Code Function
321 / 327 / 333 / 339 Meter x dens input Enable and assign density analog input to flow meter stream
[density transmitter » meter stream]
Global Parameters
428 Density units
426 Buoyancy
046 Density/gravity scale
Engineering units for density measurements.
Density adjustment for buoyancy in air for mass calculation
Specify the number of digits following the decimal separator in density / gravity values.
Individual DT Configuration
Density at zero scale transmitter input.
466 / 470 / 474 / 478 Density @4 mA
467 / 471 / 475 / 479 Density @20 mA
456 / 458 / 460 / 462 Density/gravity option
457 / 459 / 461 / 463 Backup density/gravity
Density at full scale transmitter input.
Chose an available option or disable.
Fixed density/gravity used when live input is not available.
242 Minimum density/gravity
243 Maximum density/gravity
241 Density fail alarm action
269 Alarm o/p 1 mask
287 Alarm output 1
Alarms
Low density/gravity setpoint for alarm trigger.
High density/gravity setpoint for alarm trigger.
Action in response to density alarm.
Enable density failure alarm to output 1.
(Bit mask value = 4096)
Assign alarm output 1 to a discrete output.
Default
0
0
0
Off
0
16/ft3
0.0000
4
0
0
Primary
16777215
4
Actual
Setup (Parameter Groups) _____________________________________________________________________ Appendix A - 38
________________________________________________________________________________________ DanLoad 6000 (v6.00)
TABLE A - 20 Density Compensation Parameters Location: Unit: Date:
Program Code Function
270 Alarm o/p 2 mask
379 Alarm output 2
Enable density failure alarm to output 2.
(Bit mask value = 4096)
Assign alarm output 2 to a discrete output.
Default
0
0
Actual
Setup (Parameter Groups) _____________________________________________________________________ Appendix A - 39
________________________________________________________________________________________ DanLoad 6000 (v6.00)
A.13
Pulse Per Unit Output Parameters Setup
TABLE A - 21 Pulse Per Unit Output Parameters Location: Unit: Date:
Program Code
128 Number of pulse per unit outputs
129 / 132 Control meters
Function
ENABLE 1 or 2 PULSE PER UNIT OUTPUTS
Assign flow meters to pulse per unit output
[pulse per unit output » flow meter(s)]
Individual Pulse Per Unit Output Configuration
130 / 133 Factor
131 / 134 Pulse width (ms)
Output pulse = measured quantity / Factor
Pulse output ON time (milliseconds)
Outputs
313 Pulse per unit output 1
314 Pulse per unit output 2
Assign output 1 to a discrete output
Assign output 2 to a discrete output
0
0
Default
0
G per meter
1.0
20
Actual
Setup (Parameter Groups) _____________________________________________________________________ Appendix A - 40
________________________________________________________________________________________ DanLoad 6000 (v6.00)
A.14
Additive Parameters Setup
TABLE A - 22 Additives Parameters Location: Unit: Date:
Function Program Code
135 Number of additives ENABLE ADDITIVE INJECTION
139 / 144 / 149 / 154 / 159 / 164
Control meters
Assign combined flow meters to additive injectors
[additives » meter(s)]
Global Parameters
044 Additive units
136 Selection method
137 Inject %
138 Clean line qty
398 Clean line output
Engineering units for display and printing.
Specify how additives are selected
% of cycle at which injection begins
Specity quantity of product to load without additives at end of batch.
110 Additive pump stop (s)
Output energized during delivery of the quantity specified by program code
138 Clean line qty
Delay between load stop and additive pumps stop
Individual Additive Configuration
Quantity of product measured per each additive ratio output 140 / 145 / 150 / 155 / 160 / 165
Ratio qty
141 / 146 / 151 / 156 / 161 / 166
Injection method
142 / 147 / 152 / 157 / 162 / 167
Volume per pulse or K-factor
143 / 148 / 153 / 158 / 163 / 168
Additive per 1000
869 / 870 / 871 / 872 / 873 / 874 Add x
Select injection method: Mech, Handshake, Meter or Control
Measure additive volume (depends on injection method)
Additive units injected per 1000 units of product.
Assign space in transaction storage record for additive total
Default
0
G per meter cc
External
50
0
0
10
40
Mech
0.00
0.0000
0
Actual
Setup (Parameter Groups) _____________________________________________________________________ Appendix A - 41
________________________________________________________________________________________ DanLoad 6000 (v6.00)
TABLE A - 22 Additives Parameters Location: Unit: Date:
Program Code Function
949 / 950 / 951 / 952 / 953 / 954 Add x
895 / 896 / 897 / 898 / 899 / 900 Add x
975 / 976 / 977 / 978 / 979 / 980 Add x
Assign coordinates in transaction ticket for additive totals for transaction
Assign space in batch storage record for additive total
Assign coordinated in transaction ticket for additive totals for batch
Outputs
Assign additive injection control to a discrete output 380 / 383 / 386 / 389 / 392 / 395
Ratio/valve outputs
800 / 803 / 806 / 809 / 812 / 815
Pump output
801 / 804 / 807 / 810 / 813 . 816
Block valve output
398 Clean line output
ENABLE AND ASSIGN DISCRETE OUTPUT TO ADDITIVE PUMP
ENABLE AND ASSIGN DISCRETE OUTPUT TO ADDITIVE BLOCK VALVE
Energized during delivery of the quantity set by program code 138 Clean line qty
Inputs
External input to select additive 382 / 385 / 388 / 391 / 394 / 397
Selection input
381 / 384 / 387 / 390 / 393 / 396
Feedback/meter input
Verify and/or measure injected additive
Default
0
0
0
0
0
0
0
0
0
Actual
Setup (Parameter Groups) _____________________________________________________________________ Appendix A - 42
________________________________________________________________________________________ DanLoad 6000 (v6.00)
TABLE A - 22 Additives Parameters Location: Unit: Date:
Program Code Function
247 Additive feedback count
246 Additive error limit
247 Additive feedback count
Expected # feedback pulses/cycle “Mech” method or maximum feedback “on time”
“Handshake” injection in seconds.
Alarms
Accumulated additive injection error count for triggering Additive x failure alarm
(Mech and Handshake)
Maximum number of counts that an additive feedback input can be ON before an alarm is generated.
271 Unauth additive flow vol
272 Prod/add -%
273 Prod/add +%
Volume of unauthorized additive flow at which an additive X failure alarm is raised for the meter and control injection methods.
The low (minus) setpoint referenced to the value of program code 143 / 148 / 153 /
158 / 163 / 168 Additive per 1000 that triggers an additive failure alarm
The high (plus) setpoint referenced to the value of program code 143 / 148 / 153 / 158
/ 163 / 168 Additive per 1000 that triggers an additive failure alarm
Enable additive failure alarm to output 1 269 Alarm o/p mask 1
287 Alarm output 1
270 Alarm o/p mask 2
379 Alarm output 2
Assign alarm output 1 to a discrete output
Enable additive failure alarm to outpt 2
Assign alarm output 2 to a discrete output
Default
3
0
0
0
0
16777215
4
0
0
Actual
Setup (Parameter Groups) _____________________________________________________________________ Appendix A - 43
________________________________________________________________________________________ DanLoad 6000 (v6.00)
A.15
LPG / Pressure Control Parameters Setup
TABLE A - 23 LPG / Pressure Control Parameters Location: Unit: Date:
Program Code
820 Pinch back method
Function
ENABLE BACK-PRESSURE CONTROL
AND
SELECT SOURCE OF PRESSURE MEASUREMENT FOR CONTROL
821 Pinch back pressure
296 / 301 / 306 / 311 Close input
818 PT type
819 Pe method
446 / 449 / 452 / 455 Backup pressure
Low pressure setpoint to maintain by closing the flow control valve to a lower fall back flow rate setting
Assign discrete input for each flow control valve if pressure switch is used.
Select static pressure or differential pressure input type
Select method of vapor pressure calculation
Component backup pressure in kPa, psi, etc.
Used for quantity computation correction if > 0.
Constant used for absolute / gauge pressure conversion 822 Atmospheric pressure
823 Pinch back qty
026 Unit type
027 Valve type
Define the batch startup gross quantity for which pressure control is disabled
Select type of blender
Select type of flow control valve
Default
Off
0
0
Pm
TP-15
0.0
14.70
0
Seq.(auto)
Std. digital
Actual
Setup (Parameter Groups) _____________________________________________________________________ Appendix A - 44
________________________________________________________________________________________ DanLoad 6000 (v6.00)
TABLE A - 23 LPG / Pressure Control Parameters Location: Unit: Date:
Program Code Function
824 T1
825 Pe at T1
826 T2
827 Pe at T2
Temperature for low Pe
Low pressure Pe at temperature T1
Temperature for high Pe (2-point linearization)
OR
Temperature for mid Pe (3-point linearization)
High pressure Pe at temperature T2 (2-point linearization)
OR
Mid pressure Pe at temperature T2 (3-point linearization)
828 T3
829 Pe at T3
Temperature for high Pe (3-point linearization)
High pressure Pe at temperature T3 (3-point linearization)
Default
0.0
0.0
0.0
0.0
0.0
0.0
Actual
Setup (Parameter Groups) _____________________________________________________________________ Appendix A - 45
________________________________________________________________________________________ DanLoad 6000 (v6.00)
A.16
Dynamic Data Display Parameters Setup
TABLE A - 24 Dynamic Data Display Parameters Location: Unit: Date:
Program Code Function
Dynamic Data Display Configuration
680 Line 1 data code
681 Line 2 data code
682 Line 3 data code
683 Line 4 data code
Grs batch vol
Std batch vol
Mtr 1 grs total
Mtr 1 std total
684 Line 5 data code
685 Line 6 data code
686 Line 7 data code
687 Line 8 data code
688 Line 9 data code
689 Line 10 data code
690 Line 11 data code
691 Line 12 data code
Mtr 1 grs batch
Mtr 1 std batch
Mtr 1 grs unauth
Mtr 1 flw rate
Mtr 1 factor
Mtr 1 grs load
Mtr 1 pls cnt
Mtr 1 max flw rate
Default
006
007
017
008
011
103
002
003
004
005
012
010
Actual
Setup (Parameter Groups) _____________________________________________________________________ Appendix A - 46
________________________________________________________________________________________ DanLoad 6000 (v6.00)
TABLE A - 24 Dynamic Data Display Parameters Location: Unit: Date:
Program Code Function
Dynamic Data Display Configuration
692 Line 13 data code
693 Line 14 data code
Mtr 1 curr temp
Cmp 1 ave temp
694 Line 15 data code
695 Line 16 data code
Cmp 1 ave vlv cls
Arm position
Default
074
080
075
001
Actual
Setup (Parameter Groups) _____________________________________________________________________ Appendix A - 47
________________________________________________________________________________________ DanLoad 6000 (v6.00)
TABLE A - 24 Data Codes per Device
Device Function
001
002
003
102
121
130
131
Arm position
Grs batch qty
Std batch qty
Preset quantity
Flow rate
Power fail grs bch
Power fail std bch
Description
Global Variables
0, 1, or 2 indicates the parked, side 1, or side 2 position of the loading arm.
Sum of the accumulated quantitys accessible by data codes 072 / 078 / 084 / 090 Cmp x grs batch.
Gross quantity of the batch in whole numbers (0 to 999,999 quantity units).
Sum of the accumulated quantitys accessible by data codes 073 / 079 / 085 / 091 Cmp x std batch.
Standard quantity of the batch in whole number (0 to 999,999 quantity units).
Batch quantity to load.
Total (loading arm delivery) flow rate (0 to 99,999 quantity units per hour).
Accumulated gross quantity of the batch delivered at power fail time (0 to 999,999 quantity units).
Accumulated standard quantity of the batch delivered at power fail time (0 to 999,999 quantity units).
Setup (Parameter Groups) _____________________________________________________________________ Appendix A - 48
________________________________________________________________________________________ DanLoad 6000 (v6.00)
TABLE A - 24 Data Codes per Device
132
133
134
223
Device
004
005
006
021
022
023
038
039
040
Meter
055
056
057
Function
Batch temperature
Batch density
Batch pressure
Flush pulse count
Mtr x grs total
Mtr x std total
Mtr x grs batch
007
008
009
024
025
026
041
042
043
058
059
060
Mtr x std batch
Mtr x flow rate
Mtr x CCF
Description
The flow weighted average temperature of the product during the batch delivery.
The flow weighted average density of the product during the batch delivery.
The flow weighted average pressure of the product during the batch delivery.
Pulse count accumulation for flush action.
Flow Meters Variables
Accumulated gross quantity total (non-reset) for meter x (0 to 999,999,999 quantity units).
Accumulated standard quantity total (non-reset) for meter x (0 to 999,999,999 quantity units).
Accumulated gross quantity for the current batch delivery (0 to 999,999 quantity units). Value is rounded per program code 045 Round method.
Accumulated standard quantity for the current batch delivery (0 to 999,999 quantity units). Value is rounded per program code 045 Round method.
Current instantaneous flow rate for meter x (0 to 99,999 quantity units per hour).
Combined correction factor for meter x.
Setup (Parameter Groups) _____________________________________________________________________ Appendix A - 49
________________________________________________________________________________________ DanLoad 6000 (v6.00)
TABLE A - 24 Data Codes per Device
035
036
037
032
033
034
027
028
029
030
031
018
019
020
015
016
017
010
011
012
013
014
044
045
046
047
048
049
050
051
052
053
054
Device
061
062
063
064
065
066
067
068
069
070
071
Function
Mtr x max flw rate
Mtr x factor
Mtr x pls count
Mtr x pls flrt1
Mtr x pls flrt2
Mtr x pls flrt3
Mtr x pls flrt4
Mtr x grs unauth
Mtr x std unauth
Mtr x grs start
Mtr x std start
Description
The maximum flow rate for meter x.
The current meter factor for meter x.
Total pulse accumulation = Mtr x pls flrt1 + Mtr x pls flrt2 + Mtr x pls flrt3 + Mtr x pls flrt4
Pulse accumulation at Mtr x flow rate 1 (0 at start of load)
Pulse accumulation at Mtr x flow rate 2 (0 at start of load)
Pulse accumulation at Mtr x flow rate 3 (0 at start of load)
Pulse accumulation at Mtr x flow rate 4 (0 at start of load)
Accumulated unauthorized gross quantity for meter x.
Accumulated unauthorized standard quantity for meter x.
Accumulated gross quantity at start of batch ( 0 to 999,999,999 quantity units).
Accumulated standard quantity at start of batch (0 to 999,999,999 quantity units).
Setup (Parameter Groups) _____________________________________________________________________ Appendix A - 50
________________________________________________________________________________________ DanLoad 6000 (v6.00)
072
073
075
076
077
TABLE A - 24 Data Codes per Device
074
103
080
104
086
105
Device
092
106
Function
Mtr x curr temp
Mtr x grs load
126
135
139
143
147
219
127
136
140
144
148
220
128
137
141
145
149
221
129
138
142
146
150
222
Mtr x Ctl
Mtr x curr pres
Mtr x Cpl
Mtr x curr dens
Mtr x std ld data
Mtr x calib stat
Description
The current temperature (live or fixed) for meter stream x.
Accumulated gross quantity for the batch (0.0 to 999,999.99). These values are displayed to the hundredth of a quantity unit resolution for use in meter proving.
The internally calculated or fixed value of Ctl (correction factor for the affect of temperature on the quantity of the liquid).
The current pressure (live or fixed) for meter stream x.
Internally calculated or fixed value of Cpl (correction factor for the effect of pressure on the quantity of the liquid).
The current density (live or fixed) for meter stream x.
The delivery accumulted total volume data for meter x standard load.
Meter calibration status for up to 4 meters.
107
108
078
079
081
082
083
109
110
Component
084
085
087
088
089
111
112
090
091
093
094
095
113
114
Cmp x grs batch
Cmp x std batch
Cmp x ave temp
Cmp x ave vlv cls
Cmp x batch %
Cmp x ave dens
Cmp x ave pres
Component Variables
Accumulated gross quantity of component x for the batch delivery. Value is rounded per program code 045 Round method.
Accumulated standard quantity of component x for the batch delivery. Value is rounded per program code 045 Round method.
Flow weighted average temperature of component x for the batch delivery.
Average flow control valve closure time when flowing component x.
The percentage of component x in the current batch delivery. Quantitys are independent from the selection of program code 722 Blend error method.
Flow weighted average density of component x for the batch delivery. Format dependent on program code 046 Density/gravity scale.
Flow weighted average pressure of component x for the batch delivery.
Setup (Parameter Groups) _____________________________________________________________________ Appendix A - 51
________________________________________________________________________________________ DanLoad 6000 (v6.00)
TABLE A - 24 Data Codes per Device
122 123 124
Device
125
Function
Cmp x adjust %
151
152
153
154
160
172
184
196
208
159
171
183
195
207
162
174
186
198
210
161
173
185
197
209
224
230
225
231
155 157
156 158
Recipe
164
176
188
200
212
163
175
187
199
211
Safety Circuit
226 227
166
178
190
202
214
165
177
189
201
213
168
180
192
204
216
167
179
191
203
215
228
170
182
194
206
218
169
181
193
205
217
229
Cmp x grs total
Cmp x std total
Function
Rec x grs tot
Rec x std tot
Function
Circuit x safety state
Description
Percentage of component x, used to adjust blend ratio. Values are dependent on the selection of program code 722 Blend error method in the following manner.
Grspctbatch and Stdpctbatch use accumulated component quantity percentages of the batch for adjustment and alarm purposes.
Grspctsmpl and Stdpctsmpl use instantanous component quantity percentages, computed with quantitys specified by program code 727 Blend sample quantity, for adjustment and alarm purposes.
Flrtsmpl uses one second samples of the component flow rate for component percentage computations.
Accumulated gross total quantity for component x
Accumulated standard total quantity for component x
Description
Recipe x gross total quantity for delivery. Refer to program codes 480-661 for recipe parameters for up to 30 recipes.
Recipe x standard total quantity for delivery. Refer to program codes 480-661 for recipe parameters for up to 30 recipes.
Description
State of safety circuit x (up to 8 safety circuits).
096 097 098
Additive
099 100 101 Add x total
Additive Variables
Accumulated quantity of additive for transaction. (0 to 9,999,999 additive quantity units specified by program code 044 Additive units).
Setup (Parameter Groups) _____________________________________________________________________ Appendix A - 52
________________________________________________________________________________________ DanLoad 6000 (v6.00)
TABLE A - 24 Data Codes per Device
115 116 117
Device
118 119 120 Add x batch
Function Description
Accumulated quantity of additive for batch. (0 to 9,999,999 additive quantity units specified by program code 044 Additive units).
Setup (Parameter Groups) _____________________________________________________________________ Appendix A - 53
________________________________________________________________________________________ DanLoad 6000 (v6.00)
A.17
Communications / Data Logging Parameters Setup
TABLE A - 25 Communications Parameters Location: Unit: Date:
Program Code Function
Data Port Configuration
663 / 668 Mode
664 / 669 Data rate
665 / 670 Word size
666 / 671 Stop bits
Ch. A / B Data protocol selection
Ch. A / B Baud selection
Ch. A / Ch. B Bits in data word selection
Ch. A / Ch. B Stop bits selection
667 / 672 Parity
236 Time-out ch. A (s)
237 Time-out ch. B (s)
269 Alarm o/p mask 1
287 Alarm output 1
270 Alarm o/p mask 2
379 Alarm output 2
Ch. A / Ch. B Parity type selection
Time-out in seconds for comms failure on channel A.
Time-out in seconds for comms failure on channel B.
Enable alarms to output 1 (bit mask value = 2))
Assign alarm output 1 to discrete output
Enable alarms to output 2 (bit mask value = 2)
Assign alarm output 2 to a discrete output
696 Batch summary
697 Transaction summary
698 Alarm log
699 Power fail log
700 Program mode entry/exit
Data Logging
Configure printer output for standard Batch Summary report
Configure printer output for standard Transaction Summary report
Configure printer output for Alarm logging
Configure printer output for Power Fail logging
Configure printer output for Entry / Exit of Program Mode logging
Default
Off
Off
Off
Off
Off
4
0
0
Not used
9600
8
1
EVEN
10
10
16777215
Actual
Setup (Parameter Groups) _____________________________________________________________________ Appendix A - 54
________________________________________________________________________________________ DanLoad 6000 (v6.00)
TABLE A - 25 Communications Parameters Location: Unit: Date:
Program Code Function
701 W&M switch open/closed
702 Program code value change log
703 Configuration summary
Configure printer output for OPEN / CLOSE W&M switch logging
Configure printer output for modification of program code value logging
Configure printer output for configuration summary printing
704 Crash memory summary
705 Totalizers
706 Transaction ticket
707 Transaction ticket reprint
708 Thruput
709 Sequence numbers
710 Cutoff hour
235 Data logging alarm action
269 Alarm /p mask 1
287 Alarm output 1
270 Alarm o/p mask 2
379 Alarm output 2
Configure printer output for program crash memory logging
Enable / disable automatic printing every 24 hours OR manual printing
Configure printer output for printing user defined Transaction Ticket
Configure printer output for reprinting user defined Transaction Ticket
Enable / disable automatic printing every 24 hours of change in totalizers
Enable / disable printing of report / log sequence numbers on each report / log on a per printer basis.
The hour at which a cutoff (end of day) processing run is to be run.
Alarms - Data Logging
Action in response to a Data logging memory full alarm
Enable alarms to output 1
Assign alarm output 1 to discrete output
Enable alarms to output 2
Assign alarm output 2 to a discrete output
Off
Off
Off
Off
Off
Off
Default
Off
Off
Off
0 (midnight)
0
0
Info
16777215
4
Actual
Setup (Parameter Groups) _____________________________________________________________________ Appendix A - 55
________________________________________________________________________________________ DanLoad 6000 (v6.00)
A.18
Transaction Storage Parameters Setup
TABLE A - 26 Transaction Storage Parameters Location: Unit: Date:
Program Code Function
Transaction Storage - Global
042 Transaction #
043 Batch #
047 Batches/transaction
217 Passcode per transaction
Transaction sequence number (0000 to 9999)
Batch sequence number (0000 to 9999)
Maximum allowed batches in each transaction (0 to 10000) 0 = unlimited
Prompt for passcode entry for each transaction (not implemented)
834 Transaction record length
835 Start page and # pages
836 Batch record length
837 Start page and # pages
838 Tr tk format
839 Time out tr
Number of memory bytes allocated for each stored transaction record.
Allocation of the start page and number of pages in the transaction file.
Number of memory bytes allocated for each stored batch record.
Allocation of the start page and number of pages in the batch file.
Specify default transaction ticket
Specify whether or not a transaction should be timed out automatically
Transaction Record Storage Allocation
840 1 Addr
841 2 Tr seq #
842 3 Recipe #
843 4 Recipe name
844 5 Side
845 6 Prompt 1
Record offset for storage Unit Address
Record offset for storage of Transaction Sequence Number
Record offset for storage of Recipe Number
Record offset for storage of Recipe Name
Record offset for storage of Swing-arm side
Record offset for storage of Prompt 1
Default
0
0
0
0
0
0
0
0
0
602
Lock
No
9999
9999
0
No
Actual
Setup (Parameter Groups) _____________________________________________________________________ Appendix A - 56
________________________________________________________________________________________ DanLoad 6000 (v6.00)
TABLE A - 26 Transaction Storage Parameters Location: Unit: Date:
Program Code Function
846 7 Prompt 2
847 8 Prompt 3
848 9 Prompt 4
Record offset for storage of Prompt 2
Record offset for storage of Prompt 3
Record offset for storage of Prompt 4
849 10 Prompt 5
850 11 Data item 1
851 12 Data item 2
852 13 Data item 3
853 14 Data item 4
854 15 Data item 5
855 16 Start date
Record offset for storage of Prompt 5
Record offset for storage of Data item 1
Record offset for storage of Data item 2
Record offset for storage of Data item 3
Record offset for storage of Data item 4
Record offset for storage of Data item 5
Record offset for storage of Transaction Start Date
856 17 End date
857 18 Gross
858 19 Std
859 20 Temp
860 21 Pres
861 22 Dens
862 23 Start gross
863 24 Start std
864 25 End gross
865 26 End std
Record offset for storage of Transaction End Date
Record offset for storage of accumulated gross total for the tansaction
Record offset for storage of accumulated std total for tjhe transaction
Record offset for storage of average temperature for the tansaction
Record offset for storage of average pressure for the transaction
Record offset for storage of average density for the transaction
Record offset for storage of the accumulated gross total at the start of the transaction
Record offset for storage of the accumujlated std total at the start of the transaction
Record offset for storge of hte accumulated gross total at hte end of the transaction
Reocord offset for storage of the accumulated std total at te end of th transaction
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
Default
0
0
0
Actual
Setup (Parameter Groups) _____________________________________________________________________ Appendix A - 57
________________________________________________________________________________________ DanLoad 6000 (v6.00)
TABLE A - 26 Transaction Storage Parameters Location: Unit: Date:
Program Code Function
866 27 Alarm bit map
867 28 Prim alarm
868 29 Temp alarm
869 30 Add 1
Record offset for storage of a bit map of the alarms that occured during the transaction
Record offset for storage of a Primary alarm that occurred during the transaction
Record offset for storage of a Temperature alarm that occured during the transaction
Record offset for storage of the accumulated quantity of additive 1 during the transaction
870 31 Add 2
871 32 Add 3
872 33 Add 4
873 34 Add 5
874 35 Add 6
Record offset for storage of te accumulated quantity of additive 2 during the transaction
Record offset for storage of the accumulated quantity of additive 3 during the transaction
Record offset for storage of the accumulated quantity of additive 4 during the transaction
Record offset for storage of the accumulated quantity of additive 5 during the transaction
Record offset for storage of the accumulated quantity of additive 6 during the transaction
Record offset for storage of the operating mode during the transaction 875 36 Op mode
876 37 Gross units
877 38 Std units
Record offset for storage of the operating mode during the transaction
Record offset for storage of the operating mode during the transaction
Batch Record Storage Allocation
880 1 Addr
881 2 Ba seq #
882 3 Tr seq #
883 4 Temp
Record offset for storage of the Unit Address
Record offset for storage of the Batch Sequence Number
Record offset for storage of the Transaction Sequence Number
Record offset for storage of the average temperature during the batch
0
0
0
Default
0
0
0
0
0
0
0
0
0
0
0
0
0
Actual
Setup (Parameter Groups) _____________________________________________________________________ Appendix A - 58
________________________________________________________________________________________ DanLoad 6000 (v6.00)
TABLE A - 26 Transaction Storage Parameters Location: Unit: Date:
Program Code Function
884 5 Pres
885 6 Dens
886 7 Preset
Record offset for storage of the average pressure during the batch
Record offset for storage of the average density during the batch
Record offset for storage of the Preset value for the batch
887 8 Gross
888 9 Std
889 10 Comp gross
890 11 Comp std
891 12 Comp temp
892 13 Comp dens
893 14 Comp pres
894 15 Comp %
Record offset for storage of the accumulated gross quantity for the batch
Record offset for storage of hte accumulated standard quantity for the batch
Record offset for storage of the accumulated gross quantities of each component in the batch
Record offset for storage of the accumulated standard quantitys of each component in the batch
Record offset for storage of the average temperature of each component in the batch
Record offset for storage of the average density of each component in the batch
Record offset for storage of the aveerage pressure of each component in the batch
Record offset for storage of the percentage of each component in the batch
0
0
0
0
0
0
0
0
Default
0
0
0
Actual
Setup (Parameter Groups) _____________________________________________________________________ Appendix A - 59
________________________________________________________________________________________ DanLoad 6000 (v6.00)
TABLE A - 26 Transaction Storage Parameters Location: Unit: Date:
Program Code Function
895 16 Add 1
896 17 Add 2
897 18 Add 3
Record offset for storage of the accumulated quantityn of additive 1 for the batch
Record offset for storage of the accumulated quantityn of additive 2 for the batch
Record offset for storage of the accumulated quantityn of additive 3 for the batch
898 19 Add 4
899 20 Add 5
900 21 Add 6
901 22 Op mode
902 23 CCF
274 Storage alarm action
Record offset for storage of the accumulated quantityn of additive 4 for the batch
Record offset for storage of the accumulated quantityn of additive 5 for the batch
Record offset for storage of the accumulated quantityn of additive 6 for the batch
Record offset for storage of the operation mode during the batch
Record offset for storage of the combined correction factor during the batch
Alarms
Action in response to a memory full condition for transaction storage or batch storage memory.
0
0
0
0
0
Default
0
0
0
Off
Actual
Setup (Parameter Groups) _____________________________________________________________________ Appendix A - 60
________________________________________________________________________________________ DanLoad 6000 (v6.00)
A.19
Transaction Ticket Parameters Setup
TABLE A - 27 Transaction Ticket Parameters Location: Unit: Date:
Program Code Function
Ticket Coordinates for Transaction Storage Codes
920 1 Addr
921 2 Tr seq #
922 3 Recipe #
923 4 Recipe name
Transaction ticket coordinates for Unit Address
Transaction ticket coordinates for the Transaction Sequence Number
Transaction ticket coordinates for the Recipe Number
Transaction ticket coordinates for the Recipe Name
924 5 Side
925 6 Prompt 1
926 7 Prompt 2
927 8 Prompt 3
928 9 Prompt 4
929 10 Prompt 5
930 11 Data item 1
931 12 Data item 2
932 13 Data item 3
933 14 Data item 4
934 15 Data item 5
Transaction ticket coordinates for the Swing-Arm Side
Transaction ticket coordinates for Prompt 1
Transaction ticket coordinates for Prompt 2
Transaction ticket coordinates for Prompt 3
Transaction ticker coordinated for Prompt 4
Transaction ticket coordinates for Prompt 5
Transaction ticket t coordinates for Data item 1
Transaction ticket coordinates for Data item 2
Transaction ticket coordinates for Data item 3
Transaction ticket coordinates for Data item 4
Transaction ticket coordinates for Data item 5
Default
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
Actual
Setup (Parameter Groups) _____________________________________________________________________ Appendix A - 61
________________________________________________________________________________________ DanLoad 6000 (v6.00)
TABLE A - 27 Transaction Ticket Parameters Location: Unit: Date:
Program Code Function
935 16 Start date
936 17 End date
937 18 Gross
Transaction ticket coordinates for Start Transaction Date
Transaction ticket coordinates for End Transaction Date
Transaction ticket coordinates for accumulated gross quantity for the transaction
938 19 Std
939 20 Temp
940 21 Pres
941 22 Dens
942 23 Start gross
943 24 Start std
944 25 End gross
945 26 End std
946 27 Alarm bit map
947 28 Prim alarm
948 29 Temp alarm
Transaction ticket coordinates for accumulated standard quantity for the transaction
Transaction ticket coordinates for average temperature for the transaction
Transaction ticket coordinates for average pressure for the transaction
Transaction ticket coordinates for average pressure for the transaction
Transaction ticket coordinates for the gross totalizer reading at start of transaction
Transaction ticket coordinates for th std totalizer reading t start of transaction
Transaction ticket coordinates for the gross totalizer reading at end of transaction
Transaction ticket coordinates for the std totalizer reading at end of transaction
Transaction ticket coordinates for the alarm bit map
Transaction ticket coordinate for a Primary alarm
Transaction ticket coordinates for the Temperature alarm
0
0
0
0
0
0
0
0
0
0
0
Default
0
0
0
Actual
Setup (Parameter Groups) _____________________________________________________________________ Appendix A - 62
________________________________________________________________________________________ DanLoad 6000 (v6.00)
TABLE A - 27 Transaction Ticket Parameters Location: Unit: Date:
Program Code Function
949 30 Add 1
950 31 Add 2
951 32 Add 3
Transaction ticket coordinates for the total Additive 1 quantity for the transaction
Transaction ticket coordinates for the total Additive 2 quantity for the transaction
Transaction ticket coordinates for the total Additive 3 quantity for the transaction
952 33 Add 4
953 34 Add 5
954 35 Add 6
955 36 Op mode
956 37 Gross units
957 38 Std units
Transaction ticket coordinates for the total Additive 4 quantity for the transaction
Transaction ticket coordinates for the total Additive 5 quantity for the transaction
Transaction ticket coordinates for the total Additive 6 quantity for the transaction
Transaction ticket coordinates for the Operation Mode during the transaction
Transaction ticket coordinates for the Operation Mode during the transaction
Transaction ticket coordinates for the Operation Mode during the transaction
Ticket Coordinates for Batch Storage Codes
960 1 Addr
961 2 Ba seq #
962 3 Tr seq #
963 4 Temp
964 5 Pres
965 6 Dens
966 7 Preset
967 8 Gross
968 9 Std
969 10 Comp gross
Transaction ticket coordinates for the Unit Address during batch
Transaction ticket coordinates for the Batch Sequence Number
Transaction ticket coordinates for the Transaction Sequence Number
Transaction ticket coordinates for the average temperature during the batch
Transaction ticket coordinates for the average pressure during the batch
Transaction ticket coordinates for the average density during the batch
Transaction ticket coordinates for the batch Preset quantity
Transaction ticket coordinates for the batch gross quantity
Transaction ticket coordinates for the batch standard quantity
Transaction ticket coordinates for the component gross quantities for the batch
0
0
0
0
0
0
Default
0
0
0
0
0
0
0
0
0
0
0
0
0
Actual
Setup (Parameter Groups) _____________________________________________________________________ Appendix A - 63
________________________________________________________________________________________ DanLoad 6000 (v6.00)
TABLE A - 27 Transaction Ticket Parameters Location: Unit: Date:
Program Code Function
970 11 Comp std
971 12 Comp temp
972 13 Comp dens
973 14 Comp pres
Transaction ticket coordinates for the component standard quantities for the batch
Transaction ticket coordinates for the average temperatures of the components for the batch
Transaction ticket coordinations for the average density of the components for the batch
Transaction ticket coordinates for the average pressure of the components for the batch
974 15 Comp %
975 16 Add 1
976 17 Add 2
Transaction ticket coordinates for the component percentages for the batch
Transaction ticket coordinates for the Additive 1 quantity for the batch
Transaction ticket coordinates for the Additive 2 quantity for the batch
977 18 Add 3
978 19 Add 4
979 20 Add 5
980 21 Add 6
981 22 Op mode
982 23 CCF
Transaction ticket coordinates for the Additive 3 quantity for the batch
Transaction ticket coordinates for the Additive 4 quantity for the batch
Transaction ticket coordinates for the Additive 5 quantity for the batch
Transaction ticket coordinates for the Additive 6 quantity for the batch
Transaction ticket coordinates for the Operation Mode during the batch
Transaction ticket coordinates for the Combined Correction Factor during the batch
Default
0
0
0
0
0
0
0
0
0
0
0
0
0
Actual
Setup (Parameter Groups) _____________________________________________________________________ Appendix A - 64
________________________________________________________________________________________ DanLoad 6000 (v6.00)
A.20
Alarm Parameters Setup
TABLE A - 28 Alarm Parameters Location: Unit: Date:
Program Code Function
Safety Circuit Configuration
220 Secondary alarm reset (s)
222 Minimum flow rate
223 Low flow time (s)
221 Low flow alarm action
Time period to allow a secondary alarm to be active before it is reset automatically.
Setpoint for Flow rate too low meter x alarm trigger.
Time allowed at flow less than setpoint before triggering alarm.
Response to low flow alarm.
225 Maximum flow rate
226 High flow time (s)
224 High flow alarm action
227 Overrun limit qty
Setpoint for Flow rate too high meter x alarm trigger.
Time allowed at flow greater than setpoint before triggering alarm.
Response to high flow alarm.
Setpoint for Unable to close valve meter x alarm trigger. (PRIMARY)
229 Underflow limit qty
228 Underflow alarm action
231 No flow t-o time (s)
230 No flow t-o alarm action
232 Unauthorized flow limit qty
Setpoint for Valve closed early meter x alarm trigger.
Response to underflow alarm.
Setpoint for Timed-out - no flow detected meter x alarm trigger.
Response to no flow time-out alarm.
Setpoint for Unauthorized flow exceeds limit meter x alarm trigger. (PRIMARY)
Default
300
100
10
Primary
660
10
Primary
2.0
5.0
Off
5
Primary
10.0
Actual
233 Error limit (pulses)
234 Reset count (pulses)
235 Data logging alarm action
236 Time-out ch. A (s)
Setpoint for Pulse security error meter x alarm trigger. (PRIMARY)
Pulse error accumulation before RESET counter is issued.
Response to Data logging memory full alarm.
Set time out in seconds for Comms failure channel A
0
10000
Info
10
Setup (Parameter Groups) _____________________________________________________________________ Appendix A - 65
________________________________________________________________________________________ DanLoad 6000 (v6.00)
TABLE A - 28 Alarm Parameters Location: Unit: Date:
Program Code Function
237 Time-out ch. B (s)
239 Minimum temperature
240 Maximum temperature
Set time out in seconds for Comms failure channel B
Low setpoint for Temperature failure meter x alarm trigger.
High setpoint for Temperature failure meter x alarm trigger.
238 Temp fail alarm action
242 Minimum density/gravity
243 Maximum density/gravity
241 Density fail alarm action
244 Minimum pressure
245 Maximum pressure
246 Additive error limit
247 Additive feedback count
248 Block valve time (s)
Response to temperature failure alarm.
Low setpoint for Density failure component x alarm trigger.
High setpoint for Density failure component x alarm trigger.
Response to density failure alarm.
Low setpoint for Pressure failure meter x alarm trigger. (PRIMARY)
High setpoint for Pressure failure meter x alarm trigger.
Setpoint for Additive x failure alarm trigger. (PRIMARY)
345 Safety circuit 1
249 Circuit 1 alarm action
250 #1 Ground detector open
Expected number of feedback pulses per additive ratio cycle.
Setpoint for Unable to close block valve x alarm trigger.
Safety Circuit Configuration
Assign discrete input to alarm
Response to TRUE input to Safety circuit 1
Configurable message for Safety circuit 1
Default
10
-40.0
110.0
Primary
Primary
0.00
0.00
3
0
10
0
Secondary
<as indicated>
Actual
Setup (Parameter Groups) _____________________________________________________________________ Appendix A - 66
________________________________________________________________________________________ DanLoad 6000 (v6.00)
TABLE A - 28 Alarm Parameters Location: Unit: Date:
Program Code Function
346 Safety circuit 2
251 Circuit 2 alarm action
252 #2 Overspill detector open
Assign discrete input to alarm
Response to TRUE input to Safety circuit 2
Configurable message for Safety circuit 2
347 Safety circuit 3
253 Circuit 3 alarm action
254 #3 Permissive power failure
348 Safety circuit 4
255 Circuit 4 alarm action
256 #1 Additive injection failure
349 Safety circuit 5
Assign discrete input to alarm
Response to TRUE input to Safety circuit 3
Configurable message for Safety circuit 3
Assign discrete input to alarm
Response to TRUE input to Safety circuit 4
Configurable message for Safety circuit 4
Assign discrete input to alarm
257 Circuit 5 alarm action
258 #5 Arm down side 1
265 Circuit 5 type
350 Safety circuit 6
259 Circuit 6 alarm action
260 #6 Arm down side 2
266 Circuit 6 type
351 Safety circuit 7
261 Circuit 7 alarm action
262 #7 Walkway down side 1
Response to TRUE input to Safety circuit 5
Configurable message for Safety circuit 5
Enable / disable / define swing-arm side checking for this circuit.
Assign discrete input to alarm
Response to TRUE input to Safety circuit 6
Configurable message for Safety circuit 6
Enable / disable / define swing-arm side checking for this circuit.
Assign discrete input to alarm
Response to TRUE input to Safety circuit 7
Configurable message for Safety circuit 7
1
0
Secondary
<as indicated>
Secondary
<as indicated>
2
0
Secondary
<as indicated>
Default
0
Primary
<as indicated>
0
Secondary
<as indicated>
0
Secondary
<as indicated>
0
Actual
Setup (Parameter Groups) _____________________________________________________________________ Appendix A - 67
________________________________________________________________________________________ DanLoad 6000 (v6.00)
TABLE A - 28 Alarm Parameters Location: Unit: Date:
Program Code Function
267 Circuit 7 type
352 Safety circuit 8
263 Circuit 8 alarm action
264 #8 Walkway down side 2
268 Circuit 8 type
Enable / disable / define swing-arm side checking for this circuit.
Assign discrete input to alarm
Response to TRUE input to Safety circuit 2
Configurable message for Safety circuit 2
Enable / disable / define swing-arm side checking for this circuit.
Discrete Control Output for Alarms
Enable alarms to output 1 (bit mask).
269 Alarm o/p mask 1
287 Alarm output 1
270 Alarm o/p mask 2
379 Alarm output 2
Assign alarm output 1 to a discrete output.
Enable alarms to output 2 (bit mask).
Assign alarm output 2 to a discrete output.
Default
1
0
Secondary
<as indicated>
2
16777215
4
0
0
Actual
Setup (Parameter Groups) _____________________________________________________________________ Appendix A - 68
________________________________________________________________________________________ DanLoad 6000 (v6.00)
TABLE A - 29 Analog Inputs Location: Unit: Date:
Program Code Function
983 RTD Alpha
984 LLcnt
985 LH cnt
986 HL cnt
987 HH cnt
988 LL cnt
Analog Inputs Configuration
Set the alpha value for temperature calculations
Set A/D value for Low channel Low calibration point for 4-20 mA input
Set A/D value for Low channel High calibration point for 4-20 mA input
Set A/D value for High channel Low calibration point for 4-20 mA input
Set A/D value for High channel High calibration point for 4-20 mA input
Set A/D value for Low channel Low calibration point for RTD input
989 LH cnt
990 HL cnt
991 HH cnt
Set A/D value for Low channel High calibration point for RTD input
Set A/D value for High channel Low calibration point for RTD input
Set A/D value for High channel High calibration point for RTD input
Default
0
0
0
0
0
0
0
3850
0
Actual
Setup (Parameter Groups) _____________________________________________________________________ Appendix A - 69
________________________________________________________________________________________ DanLoad 6000 (v6.00)
This page intentionally left blank.
Setup (Parameter Groups) _____________________________________________________________________ Appendix A - 70
__________________________________________________________ DanLoad 6000 (v6.00)
The table on the following pages is intended to provide an easy method for documenting the current configuration of a DanLoad 6000 Preset. The table contains a numerical sequential list of all program codes. The table can be photocopied and the current value or selection for each parameter can be manually entered.
Manually enter the Location, the Unit ID, and the Date.
Enter the Program Mode and scroll through or select the program codes of interest. Manually enter the indicated value or selection of each program code in the Value / Selection column.
Configuration Record ___________________________________________ Appendix B - 1
DanLoad 6000 (v6.00) __________________________________________________________
Location: Unit ID: Date:
Code Parameter Value / Selection
USER 1
001
002
003
Passcode
User ID
Supervisor privilege
USER 2
004
005
006
Passcode
User ID
Supervisor privilege
USER 3
007
008
009
Passcode
User ID
Supervisor privilege
USER 4
010
011
012
Passcode
User ID
Supervisor privilege
USER 5
013
014
015
Passcode
User ID
Supervisor privilege
USER 6
016
017
018
Passcode
User ID
Supervisor privilege
023
UNIT PARAMETERS <PAGE 1>
"Side" Stream Blending
Appendix B - 2 _____________________________________________ Configuration Record
__________________________________________________________ DanLoad 6000 (v6.00)
025
026
027
028
029
030
031
032
033
034
035
036
037
038
039
040
041
042
043
044
045
046
Code
024
Parameter
“Sequential” proportional
Value / Selection
UNIT PARAMETERS <PAGE 2>
Operating mode
Unit type
Valve type
Language
Product Units
UNIT PARAMETERS <PAGE 3>
Number of data items
#1 Enter data item #1
#2 Enter data item #2
#3 Enter data item #3
#4 Enter data item #4
#5 Enter data item #5
UNIT PARAMETERS <PAGE 4>
Prompt time-out (s)
Check display
Date format
Date separator
Decimal separator
Display data rate
UNIT PARAMETERS <PAGE 5>
Transaction #
Batch #
Additive units
Round method
Density/gravity scale
Configuration Record ___________________________________________ Appendix B - 3
DanLoad 6000 (v6.00) __________________________________________________________
Code
047
Parameter
Batches/transaction
VALVE PARAMETERS
048
049
Number of valves
Initial flow time (s)
Value / Selection
050
051
052
053
054
055
056
057
058
059
060
061
062
063
065
METER PARAMETERS
Number of meters
Meter ID
Valve to be controlled
METER 1 PARAMETERS
"Side" Stream Meter
Meter ID
Valve to be controlled
"Side" Stream Meter
METER 2 PARAMETERS
Meter ID
Valve to be controlled
"Side" Stream Meter
METER 3 PARAMETERS
Meter ID
Valve to be controlled
METER 4 PARAMETERS
"Side" Stream Meter
METER PARAMETERS
Midgrade Primary blend stream meter
COMPONENT PARAMETERS
Number of components
Appendix B - 4 _____________________________________________ Configuration Record
__________________________________________________________ DanLoad 6000 (v6.00)
078
079
080
081
082
083
Code
066
067
068
069
070
071
072
073
074
075
076
077
084
085
086
Parameter Value / Selection
COMPONENT 1
Component ID
Meter
Mass adjustment
COMPONENT 2
Component ID
Meter
Mass adjustment
COMPONENT 3
Component ID
Meter
Mass adjustment
COMPONENT 4
Component ID
Meter
Mass adjustment
Maximum preset qty
DELIVERY PARAMETERS
Minimum preset qty
Preset/delivery type
Delivery display type
Stop key action
Fall back qty
COMP 1 DELIVERY PARAMETERS
Low flow start qty
Low flow restart qty
Low flow stop qty
Configuration Record ___________________________________________ Appendix B - 5
DanLoad 6000 (v6.00) __________________________________________________________
090
091
092
093
094
095
096
097
098
099
100
101
102
103
104
105
106
107
Code
087
088
089
108
109
Parameter
Line pack delay (s)
Pump stop delay (s)
Block valve delay (s)
Value / Selection
COMP 2 DELIVERY PARAMETERS
Low flow start qty
Low flow restart qty
Low flow stop qty
Line pack delay (s)
Pump stop delay (s)
Block valve delay (s)
COMP 3 DELIVERY PARAMETERS
Low flow start qty
Low flow restart qty
Low flow stop qty
Line pack delay (s)
Pump stop delay (s)
Block valve delay (s)
COMP 4 DELIVERY PARAMETERS
Low flow start qty
Low flow restart qty
Low flow stop qty
Line pack delay (s)
Pump stop delay (s)
Block valve delay (s)
DELIVERY PARAMETERS (continued)
Ramp clicks
Maintenance clicks
Appendix B - 6 _____________________________________________ Configuration Record
__________________________________________________________ DanLoad 6000 (v6.00)
112
113
114
115
116
117
118
119
120
121
122
123
124
125
126
127
Code
110
111
Parameter
Additive pump stop (s)
Primary component
128
129
130
Value / Selection
DIGITAL VALVE 1 PARAMETERS
Low flow % error
High flow % error
Maint click adjustment (s)
Open method
DIGITAL VALVE 2 PARAMETERS
Low flow % error
High flow % error
Maint click adjustment (s)
Open method
DIGITAL VALVE 3 PARAMETERS
Low flow % error
High flow % error
Maint click adjustment (s)
Open method
DIGITAL VALVE 4 PARAMETERS
Low flow % error
High flow % error
Maint click adjustment (s)
Open method
PULSE PER UNIT OUTPUTS
Number of pulse per unit outputs
PULSE PER UNIT OUTPUT 1
Control meters
Factor
Configuration Record ___________________________________________ Appendix B - 7
DanLoad 6000 (v6.00) __________________________________________________________
135
136
137
138
139
140
141
142
143
144
145
146
147
148
149
150
151
152
Code
131
132
133
134
Parameter
Pulse width (ms)
PULSE PER UNIT OUTPUT 2
Value / Selection
Control meters
Factor
Pulse width (ms)
ADDITIVE PARAMETERS
Number of additives
Additive Selection method
Inject percentage
Clean line qty
ADDITIVE 1 PARAMETERS
Control meters
Ratio qty
Injection method
Volume/pulse or K-factor
Additive per 1000
ADDITIVE 2 PARAMETERS
Control meters
Ratio qty
Injection method
Volume/pulse or K-factor
Additive per 1000
ADDITIVE 3 PARAMETERS
Control meters
Ratio qty
Injection method
Volume/pulse or K-factor
Appendix B - 8 _____________________________________________ Configuration Record
__________________________________________________________ DanLoad 6000 (v6.00)
159
160
161
162
163
154
155
156
157
158
Code
153
164
165
166
167
168
169
170
171
172
173
Parameter
Additive per 1000
Value / Selection
ADDITIVE 4 PARAMETERS
Control meters
Ratio qty
Injection method
Volume/pulse or K-factor
Additive per 1000
ADDITIVE 5 PARAMETERS
Control meters
Ratio qty
Injection method
Volume/pulse or K-factor
Additive per 1000
ADDITIVE 6 PARAMETERS
Control meters
Ratio qty
Injection method
Volume/pulse or K-factor
Additive per 1000
METER FACTORS
Number of factors/component
Meter factor method
COMPONENT 1 FACTORS
Nominal K-factor
Master meter factor
Stop rate
Configuration Record ___________________________________________ Appendix B - 9
DanLoad 6000 (v6.00) __________________________________________________________
Code
174
175
176
177
178
179
180
181
182
183
184
185
186
187
188
189
190
191
Flow rate 1
Meter factor 1
Parameter
COMPONENT 1 FACTOR 1
Value / Selection
COMPONENT 1 FACTOR 2
Flow rate 2
Meter factor 2
COMPONENT 1 FACTOR 3
Mlow rate 3
Meter factor 3
COMPONENT 1 FACTOR 4
Flow rate 4
Meter factor 4
COMPONENT 2 FACTORS
Nominal K-factor
Master meter factor
Stop rate
COMPONENT 2 FACTOR 1
Flow rate 1
Meter factor 1
COMPONENT 2 FACTOR 2
Flow rate 2
Meter factor 2
COMPONENT 2 FACTOR 3
Flow rate 3
Meter factor 3
COMPONENT 2 FACTOR 4
Flow rate 4
__________________________________________________________ DanLoad 6000 (v6.00)
Code
192
193
194
195
196
197
198
199
200
201
202
203
204
205
Meter factor 4
Parameter
COMPONENT 3 FACTORS
Value / Selection
Nominal K-factor
Master meter factor
Stop rate
COMPONENT 3 FACTOR 1
Flow rate 1
Meter factor 1
COMPONENT 3 FACTOR 2
Flow rate 2
Meter factor 2
COMPONENT 3 FACTOR 3
Flow rate 3
Meter factor 3
COMPONENT 3 FACTOR 4
Flow rate 4
Meter factor 4
COMPONENT 4 FACTORS
Nominal K-factor
Master meter factor
COMPONENT 4 FACTOR 1
207
208
Flow rate 1
Meter factor 1
209 Flow rate 2
COMPONENT 4 FACTOR 2
Configuration Record ___________________________________________ Appendix B - 11
DanLoad 6000 (v6.00) __________________________________________________________
227
228
229
230
221
222
223
224
225
226
215
216
217
218
219
Code
210
211
212
213
214
220
Meter factor 2
Parameter
COMPONENT 4 FACTOR 3
Value / Selection
Flow rate 3
Meter factor 3
COMPONENT 4 FACTOR 4
Flow rate 4
Meter factor 4
MF VALIDATION
Master MF %
Adjacent MF %
Gross units mnemonic
Std units mnemonic
Use restart qty
ALARM PARAMETERS <PAGE 1>
Secondary alarm reset (s)
ALARM PARAMETERS <PAGE 2>
Low flow alarm action
Minimum flow rate
Low flow time (s)
High flow alarm action
Maximum flow rate
High flow time (s)
ALARM PARAMETERS <PAGE 3>
Overrun limit qty
Underflow alarm action
Underflow limit qty
No flow t-o alarm action
__________________________________________________________ DanLoad 6000 (v6.00)
233
234
235
236
237
249
250
251
252
244
245
246
247
248
238
239
240
241
242
243
Code
231
232
Parameter
No flow t-o time (s)
Unauth flow qty
Value / Selection
ALARM PARAMETERS <PAGE 4>
Error limit (pulses)
Reset count (pulses)
Data logging alarm action
Time-out ch. A (s)
Time-out ch. B (s)
ALARM PARAMETERS <PAGE 5>
Temp fail alarm action
Minimum temperature
Maximum temperature
Density fail alarm action
Minimum density/gravity
Maximum density/gravity
ALARM PARAMETERS <PAGE 6>
Minimum pressure
Maximum pressure
Additive error limit
Additive feedback count
Block valve time (s)
ALARM PARAMETERS <PAGE 7>
Circuit 1 alarm action
#1 Ground detector open
Circuit 2 alarm action
#2 Overspill detector open
ALARM PARAMETERS <PAGE 8>
Configuration Record ___________________________________________ Appendix B - 13
DanLoad 6000 (v6.00) __________________________________________________________
257
258
259
260
261
262
263
264
265
266
267
268
269
270
271
272
273
274
275
Code
253
254
255
256
Parameter
Circuit 3 alarm action
#3 Permissive power failure
Circuit 4 alarm action
#4 Additive injection failure
Value / Selection
ALARM PARAMETERS <PAGE 9>
Circuit 5 alarm action
#5 Arm down side 1
Circuit 6 alarm action
#6 Arm down side 2
ALARM PARAMETERS <PAGE 10>
Circuit 7 alarm action
#7 Walkway down side 1
Circuit 8 alarm action
#8 Walkway down side 2
ALARM PARAMETERS <PAGE 11>
Circuit 5 type
Circuit 6 type
Circuit 7 type
Circuit 8 type
Alarm o/p 1 mask
Alarm o/p 2 mask
ALARM PARAMETERS <PAGE 12>
Unauth additive flow vol
Prod/add -%
Prod/add +%
Storage alarm action
Power fail alarm action
__________________________________________________________ DanLoad 6000 (v6.00)
282
283
284
285
286
Code
276
277
278
279
Parameter
Ramp down alarm action
Ramp down time (s)
Additive per 1000 error limit
End time (s)
280
281
287
288
289
290
291
292
293
294
Value / Selection
I/O PARAMETERS <PAGE 1>
Slot 1 board
Slot 2 board
I/O PARAMETERS <PAGE 2>
Slot 3 board
Slot 4 board
Slot 5 board
Slot 6 board
Slot 7 board
I/O PARAMETERS <PAGE 3>
Alarm output 1
COMPONENT 1 I/O
Pump control output
COMPONENT 2 I/O
Pump control output
COMPONENT 3 I/O
Pump control output
COMPONENT 4 I/O
Pump control output
VALVE 1 I/O
Solenoid 1 (upstream)
Solenoid 2 (downstream)
Stem switch 1 (normally closed)
Configuration Record ___________________________________________ Appendix B - 15
DanLoad 6000 (v6.00) __________________________________________________________
297
298
299
300
301
302
303
304
305
306
307
308
309
310
311
312
313
314
315
316
Code
295
296
Parameter
Stem switch 2 (normally open)
Close input
VALVE 2 I/O
Solenoid 1 (upstream)
Solenoid 2 (downstream)
Stem switch 1 (normally closed)
Stem switch 2 (normally open)
Close input
VALVE 3 I/O
Solenoid 1 (upstream)
Solenoid 2 (downstream)
Stem switch 1 (normally closed)
Stem switch 2 (normally open)
Close input
VALVE 4 I/O
Solenoid 1 (upstream)
Solenoid 2 (downstream)
Stem switch 1 (normally closed)
Stem switch 2 (normally open)
Close input
Value / Selection
Side detect method
I/O PARAMETERS <PAGE 12>
Pulse per unit output 1
Pulse per unit output 2
Trip 1 output
Trip 2 output
__________________________________________________________ DanLoad 6000 (v6.00)
318
319
320
321
322
324
325
326
327
328
330
331
332
333
334
336
337
338
339
340
Code
317
341
Parameter Value / Selection
Trip 3 output
Meter 1 temp input
I/O PARAMETERS <PAGE 13>
Meter 1 offset (Ohms)
Meter 1 pres input
Meter 1 dens input
Meter 1 flow input
Meter 2 temp input
I/O PARAMETERS <PAGE 14>
Meter 2 offset (Ohms)
Meter 2 pres input
Meter 2 dens input
Meter 2 flow input
Meter 3 temp input
I/O PARAMETERS <PAGE 15>
Meter 3 offset (Ohms)
Meter 3 pres input
Meter 3 dens input
Meter 3 flow input
Meter 4 temp input
I/O PARAMETERS <PAGE 16>
Meter 4 offset (Ohms)
Meter 4 pres input
Meter 4 dens input
Meter 4 flow input
I/O PARAMETERS <PAGE 17>
#cpmt inputs
Configuration Record ___________________________________________ Appendix B - 17
DanLoad 6000 (v6.00) __________________________________________________________
355
356
357
358
359
360
345
346
347
348
349
350
351
352
Code
342
343
344
353
354
361
362
363
Parameter
Start method
Auto/manual change-over
Primary alarm reset
Value / Selection
I/O PARAMETERS <PAGE 18>
Safety circuit 1
Safety circuit 2
Safety circuit 3
Safety circuit 4
I/O PARAMETERS <PAGE 19>
Safety circuit 5
Safety circuit 6
Safety circuit 7
Safety circuit 8
RTD range
Delay after outputs
I/O PARAMETERS <PAGE 20>
Primary LCD type
I/O PARAMETERS <PAGE 21>
Primary LCD minimum light
Primary LCD maximum light
Secondary LCD type
Secondary LCD minimum light
Secondary LCD maximum light
I/O PARAMETERS <PAGE 22>
Recipe 1 input
Recipe 2 input
Recipe 3 input
__________________________________________________________ DanLoad 6000 (v6.00)
367
368
369
370
371
372
377
378
379
374
375
376
Code
364
365
366
373
380
381
382
383
384
Parameter
Recipe 4 input
Recipe 5 input
Recipe 6 input
Value / Selection
I/O PARAMETERS <PAGE 23>
Recipe 1 output
Recipe 2 output
Recipe 3 output
Recipe 4 output
Recipe 5 output
Recipe 6 output
I/O PARAMETERS <PAGE 24>
End output method
I/O PARAMETERS <PAGE 25>
Level input
Hatch input
Swing 1 input
Swing 2 input
Low flow input
Alarm output 2
Ratio/valve output
ADDITIVE 1 I/O PARAMETERS
Feedback/meter input
Selection input
Ratio/valve output
ADDITIVE 2 I/O PARAMETERS
Feedback/meter input
Configuration Record ___________________________________________ Appendix B - 19
DanLoad 6000 (v6.00) __________________________________________________________
Code
385
386
387
388
389
390
391
392
393
394
395
396
397
398
399
Parameter
Selection input
Value / Selection
Ratio/valve output
ADDITIVE 3 I/O PARAMETERS
Feedback/meter input
Selection input
Ratio/valve output
ADDITIVE 4 I/O PARAMETERS
Feedback/meter input
Selection input
Ratio/valve output
ADDITIVE 5 I/O PARAMETERS
Feedback/meter input
Selection input
Ratio/valve output
ADDITIVE 6 I/O PARAMETERS
Feedback/meter input
Selection input
ADDITIVE I/O PARAMETERS
Clean line output
Flush output
400
401
402
403
COMPONENT 1 BLOCK VALVE
Block valve output
Block valve input
COMPONENT 2 BLOCK VALVE
Block valve output
Block valve input
COMPONENT 3 BLOCK VALVE
__________________________________________________________ DanLoad 6000 (v6.00)
Code
404
405
406
407
408
409
410
411
412
413
414
415
416
417
418
419
420
421
422
423
424
Parameter
Block valve output
Block valve input
Value / Selection
COMPONENT 4 BLOCK VALVE
Block valve output
Block valve input
COMPONENT COMBINATIONS <PAGE 5>
Combination 1 (1XXX)
Combination 2 (X2XX)
Combination 3 (12XX)
Combination 4 (XX3X)
Combination 5 (1X3X)
COMPONENT COMBINATIONS <PAGE 6>
Combination 6 (X23X)
Combination 7 (123X)
Combination 8 (XXX4)
Combination 9 (1XX4)
Combination 10 (X2X4)
COMPONENT COMBINATIONS <PAGE 7>
Combination 11 (12X4)
Combination 12 (XX34)
Combination 13 (1X34)
Combination 14 (X234)
Combination 15 (1234)
END <PAGE 8>
End output
End input
Configuration Record ___________________________________________ Appendix B - 21
DanLoad 6000 (v6.00) __________________________________________________________
426
427
428
429
430
431
Code
425 Flush pulses
Parameter
432
433
434
435
436
437
438
439
440
441
442
443
444
445
Value / Selection
Buoyancy
Temperature units
TEMPERATURE PARAMETERS
Density units
Pressure units
Reference temperature
Sample qty
COMP 1 TEMPERATURE PARAMETERS
Temperature option
Alpha
Backup temperature
COMP 2 TEMPERATURE PARAMETERS
Temperature option
Alpha
Backup temperature
COMP 3 TEMPERATURE PARAMETERS
Temperature option
Alpha
Backup temperature
COMP 4 TEMPERATURE PARAMETERS
Temperature option
Alpha
Backup temperature
COMP 1 PRESSURE PARAMETERS
Pressure option
F-factor X 1000000000
__________________________________________________________ DanLoad 6000 (v6.00)
Code
446
447
448
449
450
451
452
453
454
455
Parameter
Backup pressure
Value / Selection
Pressure option
COMP 2 PRESSURE PARAMETERS
F-factor X 1000000000
Backup pressure
Pressure option
COMP 3 PRESSURE PARAMETERS
F-factor X 1000000000
Backup pressure
COMP 4 PRESSURE PARAMETERS
Pressure option
F-factor X 1000000000
Backup pressure
456
457
458
459
460
461
462
463
464
COMP 1 DENSITY/GRAVITY
Density/gravity option
Backup density/gravity
COMP 2 DENSITY/GRAVITY
Density/gravity option
Backup density/gravity
COMP 3 DENSITY/GRAVITY
Density/gravity option
Backup density/gravity
COMP 4 DENSITY/GRAVITY
Density/gravity option
Backup density/gravity
METER 1
Pressure @4 mA
Configuration Record ___________________________________________ Appendix B - 23
DanLoad 6000 (v6.00) __________________________________________________________
Value / Selection Code
465
466
467
Parameter
Pressure @20 mA
Density @4 mA
Density @20 mA
468
469
470
471
Pressure @4 mA
Pressure @20 mA
Density @4 mA
Density @20 mA
METER 2
METER 3
472
473
474
475
Pressure @4 mA
Pressure @20 mA
Density @4 mA
Density @20 mA
METER 4
476
477
478
479
Pressure @4 mA
Pressure @20 mA
Density @4 mA
Density @20 mA
480 Number of recipes
RECIPES
RECIPE 1
481
482
483
484
485
Name
Component 1 %
Component 2 %
Component 3 %
Comp 4 % or ratio qty
__________________________________________________________ DanLoad 6000 (v6.00)
Value / Selection
505
506
507
508
499
500
501
502
503
504
493
494
495
496
497
498
487
488
489
490
491
492
Code
486
Parameter
Sequence or low proportion
Name
Component 1 %
Component 2 %
Component 3 %
Comp 4 % or ratio qty
Sequence or low proportion
RECIPE 2
RECIPE 3
Name
Component 1 %
Component 2 %
Component 3 %
Comp 4 % or ratio qty
Sequence or low proportion
RECIPE 4
Name
Component 1 %
Component 2 %
Component 3 %
Comp 4 % or ratio qty
Sequence or low proportion
RECIPE 5
Name
Component 1 %
Component 2 %
Component 3 %
Configuration Record ___________________________________________ Appendix B - 25
DanLoad 6000 (v6.00) __________________________________________________________
Value / Selection
523
524
525
526
527
528
517
518
519
520
521
522
Code
509
510
Parameter
Comp 4 % or ratio qty
Sequence or low proportion
511
512
513
514
515
516
Name
Component 1 %
Component 2 %
Component 3 %
Comp 4 % or ratio qty
Sequence or low proportion
RECIPE 6
RECIPE 7
Name
Component 1 %
Component 2 %
Component 3 %
Comp 4 % or ratio qty
Sequence or low proportion
RECIPE 8
Name
Component 1 %
Component 2 %
Component 3 %
Comp 4 % or ratio qty
Sequence or low proportion
RECIPE 9
529
530
531
Name
Component 1 %
Component 2 %
__________________________________________________________ DanLoad 6000 (v6.00)
Value / Selection
547
548
549
550
551
552
535
536
537
538
539
540
541
542
543
544
545
546
Code
532
533
534
Parameter
Component 3 %
Comp 4 % or ratio qty
Sequence or low proportion
Name
Component 1 %
Component 2 %
Component 3 %
Comp 4 % or ratio qty
Sequence or low proportion
RECIPE 10
RECIPE 11
Name
Component 1 %
Component 2 %
Component 3 %
Comp 4 % or ratio qty
Sequence or low proportion
RECIPE 12
Name
Component 1 %
Component 2 %
Component 3 %
Comp 4 % or ratio qty
Sequence or low proportion
RECIPE 13
553
554
Name
Component 1 %
Configuration Record ___________________________________________ Appendix B - 27
DanLoad 6000 (v6.00) __________________________________________________________
Value / Selection
571
572
573
574
575
576
565
566
567
568
569
570
559
560
561
562
563
564
Code
555
556
557
558
Parameter
Component 2 %
Component 3 %
Comp 4 % or ratio qty
Sequence or low proportion
Name
Component 1 %
Component 2 %
Component 3 %
Comp 4 % or ratio qty
Sequence or low proportion
RECIPE 14
RECIPE 15
Name
Component 1 %
Component 2 %
Component 3 %
Comp 4 % or ratio qty
Sequence or low proportion
RECIPE 16
Name
Component 1 %
Component 2 %
Component 3 %
Comp 4 % or ratio qty
Sequence or low proportion
RECIPE 17
577 Name
__________________________________________________________ DanLoad 6000 (v6.00)
Value / Selection
595
596
597
598
599
600
583
584
585
586
587
588
589
590
591
592
593
594
Code
578
579
580
581
582
Parameter
Component 1 %
Component 2 %
Component 3 %
Comp 4 % or ratio qty
Sequence or low proportion
Name
Component 1 %
Component 2 %
Component 3 %
Comp 4 % or ratio qty
Sequence or low proportion
RECIPE 18
RECIPE 19
Name
Component 1 %
Component 2 %
Component 3 %
Comp 4 % or ratio qty
Sequence or low proportion
RECIPE 20
Name
Component 1 %
Component 2 %
Component 3 %
Comp 4 % or ratio qty
Sequence or low proportion
RECIPE 21
Configuration Record ___________________________________________ Appendix B - 29
DanLoad 6000 (v6.00) __________________________________________________________
Value / Selection
619
620
621
622
623
624
613
614
615
616
617
618
607
608
609
610
611
612
Code
601
602
603
604
605
606
Parameter
Name
Component 1 %
Component 2 %
Component 3 %
Comp 4 % or ratio qty
Sequence or low proportion
Name
Component 1 %
Component 2 %
Component 3 %
Comp 4 % or ratio qty
Sequence or low proportion
RECIPE 22
RECIPE 23
Name
Component 1 %
Component 2 %
Component 3 %
Comp 4 % or ratio qty
Sequence or low proportion
RECIPE 24
Name
Component 1 %
Component 2 %
Component 3 %
Comp 4 % or ratio qty
Sequence or low proportion
__________________________________________________________ DanLoad 6000 (v6.00)
Value / Selection
643
644
645
646
647
625
626
627
628
629
630
631
632
633
634
635
636
637
638
639
640
641
642
Code Parameter
RECIPE 25
Name
Component 1 %
Component 2 %
Component 3 %
Comp 4 % or ratio qty
Sequence or low proportion
Name
Component 1 %
Component 2 %
Component 3 %
Comp 4 % or ratio qty
Sequence or low proportion
RECIPE 26
RECIPE 27
Name
Component 1 %
Component 2 %
Component 3 %
Comp 4 % or ratio qty
Sequence or low proportion
RECIPE 28
Name
Component 1 %
Component 2 %
Component 3 %
Comp 4 % or ratio qty
Configuration Record ___________________________________________ Appendix B - 31
DanLoad 6000 (v6.00) __________________________________________________________
649
650
651
652
653
654
655
656
657
658
659
660
663
664
665
666
667
Code
648
661
662
668
Parameter
Sequence or low proportion
RECIPE 29
Name
Component 1 %
Component 2 %
Component 3 %
Comp 4 % or ratio qty
Sequence or low proportion
RECIPE 30
Name
Component 1 %
Component 2 %
Component 3 %
Comp 4 % or ratio qty
Sequence or low proportion
ADDITIVE CALIBRATION
# add calib cycles
DATA COMMUNICATIONS
Address
Value / Selection
Ch. A
Mode
Data rate
Word size
Stop bits
Parity
Ch. B
Mode
__________________________________________________________ DanLoad 6000 (v6.00)
679
680
681
682
683
684
685
686
687
688
689
690
691
692
693
694
695
Code
669
670
671
672
673
Parameter
Data rate
Word size
Stop bits
Parity
Alarm in manual
Value / Selection
DYNAMIC DATA DISPLAY <PAGE 1>
Mode
Line 1 data code
Line 2 data code
Line 3 data code
Line 4 data code
DYNAMIC DATA DISPLAY <PAGE 2>
Line 5 data code
Line 6 data code
Line 7 data code
Line 8 data code
DYNAMIC DATA DISPLAY <PAGE 3>
Line 9 data code
Line 10 data code
Line 11 data code
Line 12 data code
DYNAMIC DATA DISPLAY <PAGE 4>
Line 13 data code
Line 14 data code
Line 15 data code
Line 16 data code
DATA LOGGING <PAGE 1>
Configuration Record ___________________________________________ Appendix B - 33
DanLoad 6000 (v6.00) __________________________________________________________
711
712
713
714
715
702
703
704
705
706
707
Code
696
697
698
699
700
701
708
709
710
Parameter
Batch summary
Transaction summary
Alarm log
Power fail log
Program mode entry/exit
W&M switch opened/closed
DATA LOGGING <PAGE 2>
Program value change log
Configuration summary data log
Value / Selection
Crash memory summary
Totalizers
Transaction ticket
Transaction ticket reprint
DATA LOGGING <PAGE 3>
Thruput
Sequence numbers
Cutoff hour
BLENDING <PAGE 1>
Ramp down %
Rate reduction
Low flow start qty
Clean line qty
Low prop fac
BLENDING <PAGE 2>
716
717
718
Correct after qty
Alarm after qty
Adjustment qty
__________________________________________________________ DanLoad 6000 (v6.00)
740
741
742
743
734
735
736
737
728
729
730
731
722
723
724
725
726
727
Code
719
720
Parameter
Comp % display
Add calib delay (s)
BLENDING <PAGE 3>
Blend error method
Max dev %
Blend tol %
Max dev vol
Blend tol vol
Blend sample qty
Value / Selection
METER 1
Flow adj fac
Ratio adj fac
Ramp %
CALMON analysis method
METER 2
Flow adj fac
Ratio adj fac
Ramp %
CALMON analysis method
METER 3
Flow adj fac
Ratio adj fac
Ramp %
CALMON analysis method
METER 4
746
747
Flow adj fac
Ratio adj fac
Configuration Record ___________________________________________ Appendix B - 35
DanLoad 6000 (v6.00) __________________________________________________________
Value / Selection Code
748
749
Parameter
Ramp %
CALMON analysis method
752
753
754
755
FPO basis
CALMON error limit
CALMON reset count
Calib fail alarm action
MPMC
METER 1
756
757
758
759
760
FPO
Number of blades
Max max char dev
Max tot char devs
Calibration sample
METER 2
761
762
763
764
765
FPO
Number of blades
Max max char dev
Max tot char devs
Calibration sample
766
767
768
769
770
FPO
Number of blades
Max max char dev
Max tot char devs
Calibration sample
METER 3
METER 4
771 FPO
__________________________________________________________ DanLoad 6000 (v6.00)
Value / Selection Code
772
773
774
775
Parameter
Number of blades
Max max char dev
Max tot char devs
Calibration sample
776
777
Low flow rate
High flow rate
778
779
Low flow rate
High flow rate
780
781
Low flow rate
High flow rate
782
783
Low flow rate
High flow rate
784
785
Low flow rate
High flow rate
786
787
Low flow rate
High flow rate
788
789
Low flow rate
High flow rate
790 Low flow rate
RECIPE 1
RECIPE 2
RECIPE 3
RECIPE 4
RECIPE 5
RECIPE 6
RECIPE 7
RECIPE 8
Configuration Record ___________________________________________ Appendix B - 37
DanLoad 6000 (v6.00) __________________________________________________________
Code
791
Parameter
High flow rate
792
793
Low flow rate
High flow rate
RECIPE 9
RECIPE 10
794
795
Low flow rate
High flow rate
RECIPE 11-20
796
797
Low flow rate
High flow rate
RECIPE 21-30
798
799
Low flow rate
High flow rate
ADDITIVE 1
800
801
Pump output
Block valve output
ADDITIVE 2
803
804
Pump output
Block valve output
ADDITIVE 3
806
807
Pump output
Block valve output
ADDITIVE 4
809
810
Pump output
Block valve output
ADDITIVE 5
812 Pump output
Value / Selection
__________________________________________________________ DanLoad 6000 (v6.00)
830
831
832
833
834
835
836
837
818
819
820
821
822
823
824
825
826
827
828
829
Code
813
Parameter
Block valve output
815
816
Value / Selection
ADDITIVE 6
Pump output
Block valve output
LPG/pressure
PT type
Pe method
Pinch back method
Pinch back pressure
Atmospheric pressure
Pinch back qty
T1
Pe1 at T1
T2
Pe2 at T2
T3
Pe at T3
SAFETY CIRCUITS
Circuit 1 type
Circuit 2 type
Circuit 3 type
Circuit 4 type
TRANSACTION / BATCH FILE CONFIGURATION <PAGE 1>
Transaction record length
Start page and # pages
Batch record length
Start page and # pages
Configuration Record ___________________________________________ Appendix B - 39
DanLoad 6000 (v6.00) __________________________________________________________
840
841
842
843
844
845
846
847
848
849
850
851
852
853
854
855
856
857
Code
838
839
Parameter Value / Selection
Tr tk format
Time out tr
TRANSACTION FILE OFFSETS <PAGE 2>
1 Addr
2 Tr seq #
3 Recipe #
4 Recipe name
5 Side
6 Prompt 1
TRANSACTION FILE OFFSETS <PAGE 3>
7 Prompt 2
8 Prompt 3
9 Prompt 4
10 Prompt 5
11 Data item 1
12 Data item 2
TRANSACTION FILE OFFSETS <PAGE 4>
13 Data item 3
14 Data item 4
15 Data item 5
16 Start date
17 End date
18 Gross
TRANSACTION FILE OFFSETS <PAGE 5>
858
859
860
19 Std
20 Temp
21 Pres
__________________________________________________________ DanLoad 6000 (v6.00)
864
865
866
867
868
869
870
871
872
873
874
875
880
881
882
883
884
885
Code
861
862
863
876
877
22 Dens
23 Start gross
24 Start std
Parameter Value / Selection
TRANSACTION FILE OFFSETS <PAGE 6>
25 End gross
26 End std
27 Alarm bit map
28 Prim alarm
29 Temp alarm
30 Add 1
TRANSACTION FILE OFFSETS <PAGE 7>
31 Add 2
32 Add 3
33 Add 4
34 Add 5
35 Add 6
36 Op mode
TR FILE OFFSETS <PAGE 8>
37 Gross units
38 Std units
BATCH FILE OFFSETS <PAGE 9>
1 Addr
2 Ba seq #
3 Tr seq #
4 Temp
5 Pres
6 Dens
Configuration Record ___________________________________________ Appendix B - 41
DanLoad 6000 (v6.00) __________________________________________________________
886
887
888
889
890
891
892
893
894
895
896
897
920
921
922
923
924
925
898
899
900
901
902
Code
7 Preset
8 Gross
9 Std
10 Comp gross
11 Comp std
12 Comp temp
Parameter Value / Selection
BATCH FILE OFFSETS <PAGE 10>
BATCH FILE OFFSETS <PAGE 11>
13 Comp dens
14 Comp pres
15 Comp %
16 Add 1
17 Add 2
18 Add 3
BATCH FILE OFFSETS <PAGE 12>
19 Add 4
20 Add 5
21 Add 6
22 Op mode
23 CCF
TSC PRINT ROW/COLUMN <PAGE 1>
1 Addr
2 Tr seq #
3 Recipe #
4 Recipe name
5 Side
6 Prompt 1
__________________________________________________________ DanLoad 6000 (v6.00)
926
927
928
929
930
931
932
933
934
935
936
937
938
939
940
941
942
943
944
945
946
947
948
Code
7 Prompt 2
8 Prompt 3
9 Prompt 4
10 Prompt 5
11 Data item 1
12 Data item 2
Parameter Value / Selection
TSC PRINT ROW/COLUMN <PAGE 2>
TSC PRINT ROW/COLUMN <PAGE 3>
13 Data item 3
14 Data item 4
15 Data item 5
16 Start date
17 End date
18 Gross
19 Std
20 Temp
21 Pres
22 Dens
23 Start gross
24 Start std
TSC PRINT ROW/COLUMN <PAGE 4>
TSC PRINT ROW/COLUMN <PAGE 5>
25 End gross
26 End std
27 Alarm bit map
28 Prim alarm
29 Temp alarm
Configuration Record ___________________________________________ Appendix B - 43
DanLoad 6000 (v6.00) __________________________________________________________
950
951
952
953
954
955
960
961
962
963
964
965
966
967
968
969
970
971
Code
949
956
957
972
Parameter Value / Selection
30 Add 1
TSC PRINT ROW/COLUMN <PAGE 6>
31 Add 2
32 Add 3
33 Add 4
34 Add 5
35 Add 6
36 Op mode
37 Gross units
TSC PRINT ROW/COLUMN <PAGE 7>
38 Std units
ROW/COLUMN <PAGE 8>
1 Addr
2 Ba seq #
3 Tr seq #
4 Temp
5 Pres
6 Dens
BSC PRINT ROW/COLUMN <PAGE 9>
7 Preset
8 Gross
9 Std
10 Comp gross
11 Comp std
12 Comp temp
BSC PRINT ROW/COLUMN <PAGE 10>
13 Comp dens
__________________________________________________________ DanLoad 6000 (v6.00)
978
979
980
981
982
984
985
986
987
988
989
990
991
Code
973
974
975
976
977
983
14 Comp pres
Parameter
15 Comp %
16 Add 1
17 Add 2
18 Add 3
Value / Selection
BSC PRINT ROW/COLUMN <PAGE 11>
19 Add 4
20 Add 5
21 Add 6
22 Op mode
23 CCF
ANALOG INPUTS (v2 CPU)
RTD Alpha
LL cnt (4-20 mA input)
CPU 4-20 mA (v2 CPU)
LH cnt (4-20 mA input)
HL cnt (4-20 mA input)
HH cnt (4-20 mA input)
CPU RTD (v2 CPU)
LL cnt (RTD input)
LH cnt (RTD input)
HL cnt (RTD input)
HH cnt (RTD input)
Configuration Record ___________________________________________ Appendix B - 45
DanLoad 6000 (v6.00) __________________________________________________________
This page intentionally left blank.
__________________________________________________________ DanLoad 6000 (v6.00)
LPG Loading Procedures and Sub-Procedures
INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-2
CONFIGURATION CHECKLIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-3
1) TEMPERATURE CORRECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-4
2) PRESSURE CORRECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-5
3) PRESSURE CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-6
A) TEMPERATURE INPUTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-7
B) PRESSURE INPUTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-8
C) TEMPERATURE/PRESSURE SAMPLE VOLUME . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-9
D) VAPOR PRESSURE METHOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-10
E) PRESET/DELIVERY TYPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-11
F) DENSITIES/GRAVITIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-12
LPG Loading Configuration Checklist ______________________________ Appendix C - 1
DanLoad 6000 (v6.00) __________________________________________________________
Instructions
This appendix contains three main procedures (1-3) and six sub-procedures (A-F) for configuring the Daniel DanLoad 6000 electronic preset for LPG loading. The three main procedures are:
- 1) Temperature correction,
- 2) Pressure correction, and
- 3) Pressure control.
Start with the page titled "LPG Loading Configuration Checklist" below. Follow the applicable main procedures (following the sub-procedures as directed in the text) and check individual steps "X" when complete or mark "N/A".
NOTE: The best way to configure the dynamic data display is to write down the data codes you require as you encounter them in the procedures and sub-procedures and configure the dynamic data display pages (program code 680, etc.) at the end.
The DanLoad 6000 should not be placed into operation until all applicable procedures have been completed.
NOTE: Although up to four meters, components, etc. can be configured on the
DanLoad 6000, this appendix lists only the program codes and the data code for the first two meters, components, etc. Those for other meters, components, etc. can be found in Section 6.
Appendix C - 2 ______________________________ LPG Loading Configuration Checklist
__________________________________________________________ DanLoad 6000 (v6.00)
LPG Loading Configuration Checklist
Configure K-factors, meter factors, flow rates, delivery parameters, safety circuits, recipes, etc. based on the user's requirements.
+)),
....................................................................................................
.))-
If temperature correction is required, i.e. standard quantity corrected for temperature, perform procedure 1) TEMPERATURE CORRECTION.
+)),
.................................................................................................... .))-
If pressure correction is required, i.e. standard quantity corrected for pressure, perform procedure 2)
PRESSURE CORRECTION.
+)),
....................................................................................................
.))-
If flow control based on pressure is required, i.e. flow control valve "pinch back", perform procedure
3) PRESSURE CONTROL.
+)),
....................................................................................................
.))-
Discuss any outstanding questions concerning local safety practices or use of the equipment with the user.
+)),
....................................................................................................
.))-
Verify field wiring using the DanLoad 6000's "Diagnostics"/"Inputs/Outputs" option in the program mode menu.
+)),
....................................................................................................
.))-
Configure the dynamic data display pages (program code 680, etc.) using the data codes specified in the procedures and sub-procedures that you have followed.
+)),
....................................................................................................
.))-
Verify the DanLoad 6000's valve control, standard quantity computations and dynamic data display values (press the "SELECT" key while in the loading display) by loading "small" batches.
+)),
....................................................................................................
.))-
* * *
LPG Loading Configuration Checklist ______________________________ Appendix C - 3
DanLoad 6000 (v6.00) __________________________________________________________
1) TEMPERATURE CORRECTION
Perform procedure F) DENSITIES/GRAVITIES.
+)),
....................................................................................................
.))-
Perform procedure A) TEMPERATURE INPUTS.
+)),
....................................................................................................
.))-
Configure a temperature correction option per component (program codes 432, 435, etc.). The temperature correction option selected depends on the user's operational requirements. “TP-16" is typically used in the United States.
+)),
....................................................................................................
.))-
When "Linear", "6C" or "54C" is selected, the component's alpha (program codes 433, 436, etc.), which is its coefficient of thermal expansion per the configured temperature units, must be configured.
+)),
....................................................................................................
.))-
Perform procedure C) TEMPERATURE/PRESSURE SAMPLE VOLUME.
+)),
....................................................................................................
.))-
Perform procedure E) PRESET/DELIVERY TYPE.
+)),
....................................................................................................
.))codes 126, 127, etc.) and the combined correction factor per meter (data codes 9, 26, etc.) are displayed. (You may wish simply to write down the data codes you require and configure the dynamic data display pages at the end.)
+)),
....................................................................................................
.))-
* * *
Appendix C - 4 ______________________________ LPG Loading Configuration Checklist
__________________________________________________________ DanLoad 6000 (v6.00)
2) PRESSURE CORRECTION
Perform procedure B) PRESSURE INPUTS.
+)),
....................................................................................................
.))-
If the PT type (program code 818) is "Pm", i.e. static pressure transmitters, perform procedure D)
VAPOR PRESSURE METHOD since P = P - P must be computed for the pressure correction d m e computation.
+)),
....................................................................................................
.))-
Configure a pressure correction option per component (program codes 444, 447, etc.) based on the user's requirement, industry standards or local standards. “11.2.2" is typically used in the United
States.
WARNING: Selection of an incorrect pressure correction option is potentially dangerous.
+)),
....................................................................................................
.))-
When "Const" is selected, the component's F-factor (program codes 445, 448, etc.), which is its compressibility factor in volume units per pressure unit, must be configured.
WARNING: Entry of an incorrect pressure correction option or and incorrectly scaled F-factor is potentially dangerous, especially if batch delivery is by standard quantity (program code 80).
+)),
....................................................................................................
.))-
Perform procedure A) TEMPERATURE INPUTS. (The temperature is required in order to perform pressure correction.)
+)),
....................................................................................................
.))-
Perform procedure F) DENSITIES/GRAVITIES. (The density is required in order to perform pressure correction.)
+)),
....................................................................................................
.))-
Perform procedure C) TEMPERATURE/PRESSURE SAMPLING VOLUME.
+)),
....................................................................................................
.))-
Perform procedure E) PRESET/DELIVERY TYPE.
+)),
....................................................................................................
.))codes 139, 140, etc.) and the combined correction factor per meter (data codes 9, 26, etc.) are displayed. (You may wish simply to write down the data codes you require and configure the dynamic data display pages at the end.)
+)),
....................................................................................................
.))-
* * *
LPG Loading Configuration Checklist ______________________________ Appendix C - 5
DanLoad 6000 (v6.00) __________________________________________________________
3) PRESSURE CONTROL
Determine the pinch back method from the user's requirements. Configure the pinch back method
(program code 820).
+)),
....................................................................................................
.))-
If the pinch back method is "Sw.", i.e. pressure switches are used, configure a close input per flow control valve (program codes 296, 301, etc.).
+)),
....................................................................................................
.))-
Test the pressure switch per valve via inputs/outputs diagnostic.
+)),
....................................................................................................
.))-
If the pinch back method is "Sw.", adjust the pressure switches per valve to be closed when there is sufficient pressure to load and open otherwise.
+)),
....................................................................................................
.))-
If the pinch back method is "Pm" or "Pd" perform procedure B) PRESSURE INPUTS.
+)),
....................................................................................................
.))-
If the pinch back method is "Pm" configure the pinch back pressure (program code 821) to be the static pressure below which pressure control adjustments will be made to the flow control valve.
+)),
....................................................................................................
.))-
If the pinch back method is "Pd" configure the pinch back pressure (program code 821) to be the differential pressure below which pressure control adjustments will be made to the flow control valve.
+)),
....................................................................................................
.))-
If the pinch back method is "Pd", i.e. valve control based on differential pressure, and the PT type
(program code 818) is "Pm", i.e. static pressure transmitters, perform procedure D) VAPOR m e
+)),
....................................................................................................
.))-
If the unit type (program code 26) is "In-line", configure the ramp down percentage (program code
711) to a suitable percentage of the configured high flow rate. (There is one high flow rate per recipe.)
+)),
....................................................................................................
.))-
Configure the unable to ramp down alarm so that a failure of the flow rate to decrease can be detected and acted on (program code 276 and 277).
+)),
....................................................................................................
.))-
NOTE: If you experience “pressure failure” alarms right at the start of a batch, you may want to consider setting the pinch back quantity (program code 823). See
Section 6.
* * *
Appendix C - 6 ______________________________ LPG Loading Configuration Checklist
__________________________________________________________ DanLoad 6000 (v6.00)
A) TEMPERATURE INPUTS
NOTE: This procedure is for 100S RTD inputs ("live" temperatures) or backup temperatures.
Configure an appropriate temperature failure alarm action (program code 238). The default value, i.e. "Primary", is usually acceptable. However, if loading is to continue with backup temperatures
(program codes 434, 437, etc.) when the temperature goes out of range during a batch, set the temperature failure alarm action to "Info" and enter backup temperatures (program code 434, 437, etc.).
+)),
....................................................................................................
.))-
Configure appropriate minimum and maximum temperatures (program codes 239 and 240) for temperature failure alarms, i.e. slightly below and above the temperatures that should be measured during normal operation.
+)),
....................................................................................................
.))-
Configure an RTD input for each meter (program codes 318, 324, etc.). When 3-wire RTD's are being used (not recommended) it may be necessary to compute a "resistance offset" (program code
319, 325, etc.) using a high-spec 100S resistor.
+)),
....................................................................................................
.))-
Configure the dynamic data display (program code 680, etc.) so that the current temperature per meter (data codes 74, 80, etc.) and the average temperature per component (data code 75, 81, etc.) are displayed. (You may wish simply to write down the data codes you require and configure the dynamic data display pages at the end.)
WARNING: Incorrect temperature configuration is potentially dangerous, especially if batch delivery is by standard quantity (program code 80) or vapor pressure computation for differential pressure is required.
+)),
....................................................................................................
.))-
* * *
LPG Loading Configuration Checklist ______________________________ Appendix C - 7
DanLoad 6000 (v6.00) __________________________________________________________
B) PRESSURE INPUTS
Configure appropriate minimum and maximum pressures (program codes 244 and 245, using pressure units appropriate to the pressure correction option being used) for pressure failure alarms, i.e. slightly below and above the pressures that should be measured even when there is no batch in
progress.
+)),
....................................................................................................
.))-
Configure a pressure input for each meter (program codes 320, 326, etc.).
+)),
....................................................................................................
.))-
Configure the pressure transmitter type, i.e. static or differential pressure (program code 818).
+)),
....................................................................................................
.))-
Calibrate the pressure inputs by configuring the pressures corresponding to 4 mA and 20 mA per meter (program codes 464 and 465, 468 and 469, etc. using pressure units appropriate to the pressure correction option being used) using the information marked on the pressure transmitter.
WARNING: Incorrect pressure transmitter calibration is potentially dangerous due to product "flashing" and overruns if batch delivery is by standard quantity
(program code 80).
+)),
....................................................................................................
.))-
Configure the dynamic data display (program code 680, etc.) so that the current pressure per meter
(data codes 135, 136, etc.) and the average pressure per component (data code 108, 110, etc.) are displayed. (You may wish simply to write down the data codes you require and configure the dynamic data display pages at the end.)
+)),
....................................................................................................
.))-
* * *
Appendix C - 8 ______________________________ LPG Loading Configuration Checklist
__________________________________________________________ DanLoad 6000 (v6.00)
C) TEMPERATURE/PRESSURE SAMPLE QUANTITY
Configure a suitable sample quantity (program code 431) for temperature and/or pressure correction, i.e. standard quantity computation. This should be sufficiently small to allow good average temperatures and pressures to be computed, but should not be less than the quantity which flows in one second of any component at its highest flow rate. This quantity does not affect temperature and pressure sampling for alarm and "pressure maintenance" purposes.
WARNING: If the sample quantity (program code 431) is too large the standard quanties computed by the DanLoad 6000 will not be correct.
+)),
....................................................................................................
.))-
* * *
LPG Loading Configuration Checklist ______________________________ Appendix C - 9
DanLoad 6000 (v6.00) __________________________________________________________
D) VAPOR PRESSURE METHOD
Configure the vapor pressure (P ) method (program code 819) based on the user's requirements, e industry standards or local standards. “TP-15" is typically used in the United States. The vapor e correction (computation of standard quantity) and (optionally) for valve control (program code 820).
+)),
....................................................................................................
.))-
If the vapor pressure method is "Const Pe" enter the fixed vapor pressure per component (program codes 446, 449, etc.).
+)),
....................................................................................................
.))-
If the vapor pressure method is "2 point" enter two known temperature and vapor pressure pairs
(program codes 824 through 827).
+)),
....................................................................................................
.))-
If the vapor pressure method is "3 point" enter three known temperature and vapor pressure pairs
(program codes 824 through 829).
+)),
....................................................................................................
.))-
If the vapor pressure method is "Hillburn" enter the known vapor pressure at 100°F per component
(program codes 446, 449, etc.).
+)),
....................................................................................................
.))-
If the vapor pressure method is "TP-15" perform procedure F) DENSITIES/GRAVITIES. (The density scale (program code 46) should be 4 and relative densities 60°F/60°F and temperatures in
°F are required.)
+)),
....................................................................................................
.))-
Configure the atmospheric pressure (program code 822). The "standard" atmospheric pressure for the printed TP-16 tables is 14.7 psia. The actual atmospheric pressure allows the component's vapor pressures to be computed most accurately.
e valve pressure control. Incorrect configuration is potentially dangerous.
+)),
....................................................................................................
.))-
* * *
Appendix C - 10 ______________________________ LPG Loading Configuration Checklist
__________________________________________________________ DanLoad 6000 (v6.00)
E) PRESET/DELIVERY TYPE
Configure the preset/delivery type (program code 80) to be "Gross" or "Std" based on the user's requirements.
WARNING: The gross quantity of LPG's changes depending on temperature and pressure, more so than with gasolines. Users may wish to deliver standard quantity or may have a policy of delivering gross quantities that take maximum expansion into account.
WARNING: The gross quantity the volume actually occupied by the product at the
(average) measured temperature. The standard quantity, i.e. the temperature and pressure corrected quantity, is "equivalent" to mass (weight), i.e. weight in pounds
= net volume in gallons x density in pounds per gallon.
+)),
....................................................................................................
.))-
Configure the delivery display type (program code 81) to be "Gross" or "Std" based on the user's requirements. (The determines whether the gross loaded quantity or the standard loaded quantity is displayed during a batch.)
+)),
....................................................................................................
.))-
* * *
LPG Loading Configuration Checklist ______________________________ Appendix C - 11
DanLoad 6000 (v6.00) __________________________________________________________
F) DENSITIES/GRAVITIES
Configure the density/gravity scale (program code 46) to allow densities/gravities to be formatted
999.99), 4 for kg/L or relative density (format 9.9999).
+)),
....................................................................................................
.))-
If 4-20 mA density transmitters are to be used (not necessary if the density at standard conditions is a constant), set the density/gravity option per component (program codes 456, 458, etc.) to "On"
(DanLoad 6000 v4.00 and below) or "DT" (DanLoad 6000 v4.06 and above), configure appropriate minimum and maximum densities/gravities (program codes 242 and 243) for density failure alarms, i.e. slightly below and above the densities that should be measured during normal operation, configure the densities corresponding to 4 mA and 20 mA per meter (program codes 466 and 467,
470 and 471, etc.), and configure a density input per meter (program codes 321, 327, etc.)
NOTE: The DanLoad 6000 is not capable of correcting densities/gravities at ambient conditions to densities/gravities at standard/reference conditions. Density transmitters should be used only if the densitometer can perform the correction external to the DanLoad 6000.
+)),
....................................................................................................
.))-
If density transmitters are not to be used (or if a backup density is required for any other reason) configure the backup density/gravity per component (program codes 457, 458, etc.). The density/gravity at "standard conditions" for the required temperature and pressure correction options should be entered, e.g. relative density 60°F/60°F for GPA TP-16 and API Table 11.2.2.
+)),
....................................................................................................
.))-
Configure the dynamic data display (program code 680, etc.) so that the current density/gravity per meter (data codes 143, 144, etc.) and the average density/gravity per component (data code 107, 109, etc.) are displayed. (You may wish simply to write down the data codes you require and configure the dynamic data display pages at the end.)
+)),
....................................................................................................
.))-
* * *
Appendix C - 12 ______________________________ LPG Loading Configuration Checklist
21
22
23
24
25
16
17
18
19
20
12
13
14
15
7
8
5
6
3
4
1
2
Spare Parts - DanLoad 6000
Item Quantity Model No.
6000-(--------)
Part No.
Description
Model number from unit tag
1
1
1
1
1
1
1
1
Spare Printed Circuit Board Assemblies
(---1----) 3-6000-002 2-Ch. Meter Pulse Board CE-12604
(---2----) 3-6000-042 4-Ch. Meter Pulse Board
(----1---)
(-----1--)
(-------2)
(-------1)
(----2---)
3-6000-005
3-6000-006
3-6000-020
AC I/O Board CE-12613
DC I/O Board CE-12616
DUART (2) RS-485 Ports CE-12625-2
3-6000-009 DUART (1) RS-232 / (1) RS-485 Port
CE-12625-1
3-6000-010 Additive Injection Board CE-12628
9
10
11
1
1
1
(------2-)
(------1-)
3-6000-048 Enhanced I/O Board (3 HIGH & 3 LOW status points)
3-6000-049 Enhanced I/O Board (All HIGH status points)
3-6000-007 A/D 8-Channel Board CE-12619-2
1
1
1
1
1
1
1
1
1
(--1-----)
(--2-----)
(-1------)
(-3------)
(-2------)
All
All
All
All
3-6000-026 A/D 2 Channel Board CE-12725
3-6000-027 115 Vac Power Supply CE-12575-1
3-6000-031 230 Vac Power Supply CE-12575-2
3-6000-052
3-6000-054
Keypad Assembly [English] CE-12680
Keypad Assembly [French] CE-12680
3-6000-055 Keypad Assembly [Spanish] CE-12680
3-6000-038 Display CE-12578
3-6000-029
3-6000-030
3-6000-032
CPU Board CE-12581
Keyboard CE-12584
Motherboard CE-12590
Optional Assemblies
1
1
1
1
1
3-6000-017 I/O Card Extender BE-12647-1
3-6000-047 Power Supply Card Extender BE-12647-2
3-6000-050 Battery (CPU) Module 3.0V BE-11887
3-6000-070 Rib/Cable Key-Display BE-12685
3-6000-071 Rib/Cable Display-CPU BE-12683
34
35
36
Item Quantity Model No.
26 1
27 1
Spare Parts - DanLoad 6000
Part No.
Description
3-6000-073 Rib/Cable P/S-Display BE-12689
3-6000-013 P/S Board Meter Pulse Board AE-12637
[Included in part number 3-6000-002 (see above)]
28
29
30
31
32
33
5
4
2
1
1
0
Optional Mechanical Parts
4-9213-510 Enclosure lid mounting bolts socket head M10-1.5 X 50MM
4-9213-511 Enclosure mounting bolts socket head M10-1.5 X 15MM
4-9213-512 Enclosure lid security mounting bolts socket head M10-1.5 X 60MM w/hole
4-9200-013 Keypad wire seal screw
Manuals
3-9000-670 DanLoad 6000 Reference Manual
1
0
1
3-9000-674 DanLoad 6000 Communications
Specification
Optional Auxillary Equipment
1-6000-006 RAM Copy Eraser
1-6000-005 DanLoad 6000 Simulator
3-6000-123 2-Channel Pulse Simulator
Field Wiring, Power Supply
Field Wiring, CPU & DUART Board
Field Wiring, Meter Pulse Bd (2-Ch)
Field Wiring, AC I/O Board
Field Wiring, DC I/O Board
Field Wiring, Additive Injector Bd
Field Wiring, 8-Chan. ADC Board
Field Wiring, 2-Chan. ADC Board
Field Wiring, Remote Display
Field Wiring, P/S 6000R
Field Wiring, Meter Pulse Bd (4-Ch)
Field Wiring, Enhanced I/O Bd
Field Wiring, CPU Version 2
Field Wiring, Remote Start/Stop
Field Wiring, Remote Start/Stop & Display
Field Wiring, RS-485 2-Wire, Model 6000
CE-12692
CE-12693
CE-12694
CE-12695
CE-12696
CE-12697
CE-12698
BE-12707
BE-12711
BE-12714
CE-15532
CE-19027
BE-19712
AE-19713
BE-19714
BE-19862
Print Sharer Wiring (Dresselhaus)
Wiring for Model 1815 Valve
Outline and Dimension XP enclosure
Overview and Board Layout
Suggested Permissive Wiring
Suggested Permissive Wiring Swing Arm Apps
Program Code to Device Assignments
Device Linkages
Typical DanLoad 6000 Wiring Diagram
Surge Protect, V. 1 DUART, RS-485 Multipt
Surge Protect, V. 2 DUART, (2) RS-485
Surge Protect, V. 2 DUART, RS-485 Multipt
Surge Protect, V. 2 DUART, RS-485 & RS-232
Control Valve Seal Placement
Turbine Meter Seal Placement
DanLoad 6000 Preset Seal Placement
Typical Swing Arm / Ground Wiring
BE-12462
AE-12496
DE-12535
CE-12691
BE-12722
BE-12789
DE-18201
BE-18204
DE-19253
CE-19391
CE-19392
CE-19393
CE-19394
AK-31030
AK-31031
AK-31032
AK-31033
Use the following procedure for returning equipment to the Daniel factory in the United States.
Obtaining a RMA Number
A Return Material Authorization (RMA) number must be obtained prior to returning any equipment for any reason.
To obtain a RMA number, call the Customer Service Department at 713-827-5033 between 8:00 a.m. and 5:00 p.m. (Central Standard Time), Monday through Friday, except holidays or email [email protected].
No product returns will be accepted without a RMA number and will be returned at the customer’s expense.
For warranty consideration, the product must be returned to Daniel within twelve (12) months of the date of original shipment or within eighteen (18) months of the date of original shipment of the product to destinations outside the United States. The Purchaser must prepay any shipping charges.
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•
In addition, the Purchaser is responsible for insuring any product shipped for return, and assumes the risk of loss of the product during shipment.
•
•
•
•
•
•
•
•
•
The following information is required at the time the RMA is issued:
Customer name
Contact name
Billing address
Contact Phone # and email address
Daniel SO #, PO #, or Invoice #
Item(s) to be returned
Reason for return
End user and final destination address
Consignee’s complete name, address, contact name and phone number
A RMA number is required for each original order. (Example: Two fittings purchased on two separate orders now being returned require two RMA numbers.)
For product returns from locations outside the United States, Daniel Customer Service personnel will provide additional shipping requirements.
Cleaning and Decontamination
Prior to shipment, thoroughly clean and decontaminate all equipment removing all foreign substances. This includes all substances used for cleaning the equipment. The cleaning and decontamination requirement applies to any part exposed to process fluids or cleaning substances.
Shipping equipment that has not been decontaminated may be in violation of U.S. Department of
Transportation (DOT) regulations. For your reference, the requirements for packaging and labeling hazardous substances are listed in DOT regulations 49 CFR 172, 178, and 179.
If you suspect that a part has been contaminated, the part must be completely drained and flushed to remove contaminants.
MAY CAUSE DEATH OR SERIOUS INJURY TO PERSONNEL
Contents may be under pressure or materials may be hazardous
Follow appropriate handling instructions for accessing pressurized equipment. Avoid contact with hazardous materials or contaminated units and parts. Failure to do so may result in death or serious injury.
•
•
Decontamination/Cleaning Statement
A blank Decontamination/Cleaning Statement is provided on the “Returned Material Authorization
Repair Form for Used Equipment”.
A Decontamination/Cleaning Statement is required for each returned part.
Fully complete each form and include a signature. If the decontamination statement is incomplete, the customer may be charged for decontamination and cleaning.
If the equipment has been exposed to a known hazardous substance with any characteristic that can be identified in the Code of Federal Regulations, 40 CFR 261.20 through 261.24, the chemical abstracts number and hazardous waste number/hazard code must be stated in the space provided on the form.
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•
Two (2) copies of each Decontamination/Cleaning Statement must be provided:
One (1) copy must be attached to the outside of the package.
One (1) copy must be included inside the package.
Material Safety Data Sheets (MSDS)
Provide a Material Safety Data Sheet (MSDS) with the returned equipment for each substance that has come in contact with the equipment being returned, including substances used for decontamination and cleaning.
A MSDS sheet is required by law to be available to people exposed to specific hazardous
substances, with one exception: if the equipment has only been exposed to food-grade substances or potable water, or other substances for which an MSDS is not applicable, the
Decontamination/Cleaning Statement form alone is acceptable.
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•
Two (2) copies of each MSDS must be provided:
One (1) copy must be attached to the outside of the package.
One (1) copy must be provided inside the package.
Packaging
Shipping a Device With Possible Contamination
To meet DOT requirements for identifying hazardous substances, ship only one device per package.
Shipping a Device Without Any Potential Contamination
Devices being returned may be shipped together in one package, if there is no potential of foreign substance contamination.
Shipping
•
•
•
•
•
Before returning used equipment:
Mark each package clearly with a RMA number.
Include a Decontamination/Cleaning Statement inside the package.
Attach a duplicate Decontamination/Cleaning statement to the outside of the package.
Include a MSDS for each substance that has come in contact with the equipment inside the package.
Attach a duplicate MSDS to the outside of the package.
No product returns will be accepted without a RMA number and will be returned at the customer’s expense.
For warranty consideration, the product must be returned to Daniel within twelve (12) months of the date of original shipment or within eighteen (18) months of the date of original shipment of the product to destinations outside the United States. The Purchaser must prepay any shipping charges.
Ship all * mechanical equipment to the following address:
Daniel Measurement and Control, Inc.
Attn: Service Dept.
5650 Brittmoore Rd.
Houston, TX 77041
Ref: RMA#____________________
*Mechanical equipment includes: Orifice Fittings, Parts, Plates, Seal Rings, Turbine Meters,
Control Valves, Provers, Strainers, Meter Tubes, Ultrasonic Meters, Flow Conditioners, etc.
Ship all * electronic equipment to the following address:
Daniel Measurement and Control, Inc.
Attn: Service Dept.
11100 Brittmoore Park Drive
Houston, TX 77041
Ref: RMA#____________________
*Electronic equipment includes: Gas Chromatographs, Petrocount Presets, Danload Preset,
Ultrasonic Meter Electronics (CPU boards, transducers, etc.), 2403 Totalizer, MRT 97 Indicator,
Preamps, Pick Up Coils, Prover Interface Boards, and the following Flow Computer Models: 2230,
2239, 2270, 2460, 2470, S100, 2100, and 3000.
Repair Form for Used Equipment
Including Decontamination/Cleaning Statement
1. Return Material Authorization (RMA) Number ____________________________________
2. Equipment to be returned:
Model Number _________________________ Serial Number _______________________
3. Reason for return: ___________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
Decontamination/Cleaning Fluids Process
A.
List each substance in which the equipment was exposed. Attach additional documents if necessary.
Common
Name
CAS# if available
Used for Hazardous
Waste (20 CFR 261)
[ ] Yes [ ] No
EPA Waste Code if used for hazardous waste
[ ] Yes [ ] No
[ ] Yes [ ] No
[ ] Yes [ ] No
[ ] Yes [ ] No
[ ] Yes [ ] No
B.
Circle any hazards and/or process fluid types that apply:
Infectious Radioactive Explosive Pyrophoric Poison Gas
Cyanides Sulfides Corrosive Oxidizer Flammable Poison
Carcinogen Peroxide Reactive-Air Reactive-Water Reactive-Other
(list)
Other hazard category (list)
:
C.
Describe decontamination/cleaning process. Include MSDS description for substances used in decontamination and cleaning processes. Attach additional documents if necessary.
Failure to comply with this procedure will result in the shipment being refused.
4. Write the RMA number on the shipping package.
5. Inside the package include one copy of this document and all required Material Safety Data
Sheets (MSDS)
6. Outside of the package attach one copy of this document and all required Material Safety Data
Sheets (MSDS).
THIS EQUIPMENT, BEING RETURNED “FOR REPAIR,” HAS BEEN COMPLETELY
DECONTAMINATED AND CLEANED. ALL FOREIGN SUBSTANCES HAVE BEEN
DOCUMENTED ABOVE AND MSDS SHEETS ARE ATTACHED.
By:
(Signature) (Print name)
Date: Title:
Company:
Phone: Fax:
The sales and service offices of Daniel Measurement and Control are located throughout the United States and in major countries overseas.
Please contact Daniel Measurement Services at
11100 Brittmoore Park Drive, Houston, Texas 77041, or phone (713) 827-6314 for the location of the sales or service office nearest you.
Daniel Measurement Services offers both on-call and contract maintenance service designed to provide single-source responsibility for all Daniel products.
Daniel Measurement and Control, Inc., and Daniel Measurement Services, Inc.
Divisions of Emerson Process Management reserves the right to make changes to any of its products or services at any time without prior notification in order to improve that product or service and to supply the best product or service possible.
www.emersonprocess.com/daniel
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Easy-to-use interface makes it quick and easy to configure and manage your flow computers.
Comprehensive set of features gives you the flexibility to configure your flow computers to meet your specific needs.
Powerful reporting capabilities allow you to track and analyze your flow data to improve efficiency and productivity.
DanLoad 6000 requires a PC running Windows XP or later.
To install DanLoad 6000, insert the DanLoad 6000 CD-ROM into your computer's CD-ROM drive and follow the on-screen instructions.
To connect DanLoad 6000 to your flow computer, use a standard USB cable to connect the computer to the flow computer's USB port.
How are the jumper settings configured for CPU Board and Analog Inputs Board combinations?
If no Analog Inputs Board is installed, E12 to E13 on the CPU Board should be closed. If an Analog Inputs Board is installed, remove E12 to E13 on the CPU board and install JP1 on the Analog Inputs Board.
How does the DanLoad 6000 preserve configuration and data?
The device retains its setup configuration and data in non-volatile memory, which is maintained by an on-board battery for up to ten years. The configuration and totalizer data can also be preserved by moving the configured battery-backed RAM module to another main processor board.
What defines the system parameters (Program Codes) of the DanLoad 6000?
Parameters refer to the Program Codes. Each code has four main parts: an Identification Number, a Name describing its function, a Selection or Value, and Attributes (e.g., Read only, Data logging). These codes are organized into twenty-five functional groups, accessible in Program Mode.
How is the DanLoad 6000 configured to read temperature using an RTD?
To read temperature, ensure a 2-Channel or 8-Channel Analog Input Board is installed and connected to a platinum RTD sensor (100 Ohm base resistance). After a cold start, calibration values must be entered using program codes (PC 988, PC 989, PC 990, PC 991).
What are the required specifications for RTD inputs?
RTD inputs must be 4-wire platinum RTDs, with 100 Ohm base resistance at 32 degrees Fahrenheit (0 degrees Celsius). The RTD alpha is 0.003850 S/S/oC (DIN 43670).
What calibration procedures or functionalities are available on the DanLoad 6000?
The DanLoad 6000 supports several calibration processes, including Meter Proving (determining a meter factor to adjust flow calculations), preliminary Calibration Monitoring (CALMON) for turbine meters, Additive Meter Calibration, and analog calibration for CPU Version 2 inputs (4-20 mA and RTD).
How can one verify the correct temperature reading from the RTD sensor on the DanLoad 6000?
Verification involves three steps: checking that the RTD wiring is correct (refer to wiring diagrams), verifying board and CPU jumpers/settings, and ensuring that the analog input calibration values are correct.
How does the DanLoad 6000 communicate with a PC?
The DanLoad 6000 features bi-directional communication and can function as a slave processor for a host computer.
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