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DanLoad 6000 REFERENCE MANUAL __________________________________________

DANIEL MEASUREMENT AND CONTROL, INC. AN EMERSON PROCESS MANAGEMENT COMPANY HOUSTON, TEXAS

Part Number: 3-9000-670 Revision 6.A

Supporting Software Version 6.00

SEPTEMBER 2006

DanLoad 6000 (v6.00) __________________________________________________________

DANIEL DANLOAD 6000 REFERENCE MANUAL NOTICE DANIEL MEASUREMENT AND CONTROL, INC. ("DANIEL") SHALL NOT BE LIABLE FOR TECHNICAL OR EDITORIAL ERRORS IN THIS MANUAL OR OMISSIONS FROM THIS MANUAL. DANIEL M AKES NO W ARRANTIES, EXPRESSED OR IM PLIED, INCLUDING THE IM PLIED WARRANTIES OF M ERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPO SE W ITH RESPECT TO THIS M ANUAL A ND, IN NO EVENT, SHALL DANIEL BE LIABLE FOR ANY INCIDENTAL, PUNITIVE, SPECIAL OR CONSEQUENTIAL DAM AGES INCLUDING, BUT NOT LIM ITED TO, LOSS OF PRODUCTION, LOSS OF PROFITS, LOSS OF REVENUE OR USE AND COSTS INCURRED INCLUDING W ITHOUT LIM ITATION FOR CAPITAL, FUEL AND POW 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 INFORMATIONAL PURPOSES ONLY, AND W HILE EVERY EFFORT HAS BEEN MADE TO ENSURE THEIR ACCURACY, THEY ARE NOT TO BE CONSTRUED AS W ARRANTIES OR GUARANTEES, EXPRESSED OR IMPLIED, REGARDING THE PRODUCTS OR SERVICES DESCRIBED HEREIN OR THEIR USE OR APPLICABILITY. ALL SALES ARE GOVERNED BY DANIEL’S TERMS AND CONDITIONS, W HICH ARE AVAILABLE UPON REQUEST. W E RESERVE THE RIGHT TO MODIFY OR IMPROVE THE DESIGNS OR SPECIFICATIONS OF SUCH PRODUCTS AT ANY TIME. DANIEL DOES NOT ASSUME RESPONSIBILITY FOR THE SELECTION, USE OR MAINTENANCE OF ANY PRODUCT . RESPONSIBILITY FOR PROPER SELECTION, USE AND M AINTENANCE OF ANY DANIEL PRODUCT REMAINS SOLELY W ITH THE PURCHASER AND END-USER. DANIEL AND THE DANIEL LOGO ARE REGISTERED TRADEMARKS OF DANIEL INDUSTRIES, INC. THE EMERSON LOGO IS A TRADEMARK AND SERVICE MARK OF EMERSON 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

_________________________________________________________

DanLoad 6000 (v6.00)

WARRANTY 1. LIM ITED W ARRANTY: Subject to the limitations contained in Section 2 herein and except as otherwise expressly provided herein, Daniel Measurement 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, Daniel 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, THERE 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 OF REM EDY AND LIABILITY: DANIEL SHALL NOT BE LIABLE FOR DAMAGES CAUSED BY DELAY IN PERFORMANCE. THE SOLE AND EXCLUSIVE REMEDY FOR BREACH OF W ARRANTY HEREUNDER SHALL BE LIMITED 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, INFRINGEMENT, NEGLIGENCE, STRICT LIABILITY, OTHER TORT OR OTHERW ISE), SHALL DANIEL'S LIABILITY TO BUYER AND/OR ITS CUSTOMERS EXCEED THE PRICE TO BUYER OF THE SPECIFIC GOODS MANUFACTURED 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 CUSTOMERS EXTEND TO INCLUDE INCIDENTAL, CONSEQUENTIAL OR PUNITIVE DAMAGES. THE TERM "CONSEQUENTIAL DAMAGES" SHALL INCLUDE, BUT NOT BE LIMITED TO, LOSS OF ANTICIPATED PROFITS, REVENUE OR USE, AND COSTS INCURRED INCLUDING W ITHOUT LIMITATION FOR CAPITAL, FUEL AND POW ER, AND CLAIM S OF BUYER’S CUSTOMERS.

Preface

DanLoad 6000 (v6.00) __________________________________________________________

TABLE OF CONTENTS Section 1.0 1.1 1.2 1.3

2.0

Page INTRODUCTION Functional Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6 Hardware Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9 General Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10

INSTALLATION

2.1

DanLoad 6000 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

2.2 2.2.1 2.2.2

Installation Planning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9 Card Cage Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9 DanLoad 6000 Board Description and Jumper Settings . . . . . . . . . . . . . 2-11

2.3

Mechanical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-35

2.4 2.4.1 2.4.2 2.4.2.1 2.4.2.2 2.4.3

Electrical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Selection/Installation of Electrical Wire / Cable . . . . . . . . . . . . . . . . . Input / Output Field Signal Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electrical Grounds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Selection/Installation of Wire Conduit . . . . . . . . . . . . . . . . . . . . . . . . .

2.5 2.5.1 2.5.2 2.5.3 2.5.4

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

3.0

2-38 2-38 2-39 2-41 2-41 2-43

SETUP

3.1

Overview of DanLoad 6000 Capabilities . . . . . . . . . . . . . . . . . . . . . . . . 3-2

3.2 3.2.1

Operator Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 Data Display Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

Table of Contents

iii

_________________________________________________________ 3.2.2

Keypad Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10

3.3 3.3.1

Initial Setup Procedure Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16 Data Entry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16

3.4

Initial Setup Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20

3.5 3.5.1 3.5.2

Process I/O Signal Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24 Physical I/O Signal Assignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25 Inverted Discrete Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27

3.6 3.6.1 3.6.2

Product Delivery and Blending . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-70 Sequential Blending . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-70 In-Line Blending . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-71

3.7 3.7.1

Temperature and Pressure Compensation . . . . . . . . . . . . . . . . . . . . . . 3-78 Temperature Correction to a Non-Standard Reference Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-83

3.8

Mass Loading Using a Mass Flow Meter . . . . . . . . . . . . . . . . . . . . . . . . 3-86

3.9

Mass Loading Using a Volumetric Flow Meter . . . . . . . . . . . . . . . . . . . 3-87

3.10 3.10.1 3.10.2 3.10.3 3.10.4 3.10.5

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

3.11 3.11.1

3.11.6 3.11.7 3.11.8

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

3.12

Compartment Size Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-164

3.13

Cutoff (End of Day Processing) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-165

3.11.2 3.11.3 3.11.4 3.11.5

DanLoad 6000 (v6.00)

Table of Contents

DanLoad 6000 (v6.00) __________________________________________________________ 3.14 3.15

Set Contrast / Backlighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-166 CALMON - Turbine Meter Calibration Monitoring for the DanLoad 6000 Electronic Preset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-167

3.16

Configuration Parameter Groups . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-175

4.0

OPERATION

4.1 4.1.1 4.1.1.1 4.1.1.2 4.1.1.3

Physical Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Displays and Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LED Status Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LCD Alpha-Numeric / Graphic Data Display . . . . . . . . . . . . . . . . . . . . Keypad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.2 4.2.1

Batch Delivery Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9 Controlling the Batch Delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14

4.3

Additive Injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19

4.4 4.4.1

Data Logging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20 Example Data Logs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21

4.5 4.5.1 4.5.2

Alarm Analysis / Correction / Diagnostic Tests . . . . . . . . . . . . . . . . . . 4-30 Alarm Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-31 Diagnostic Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-50

5.0

4-3 4-3 4-3 4-5 4-6

FLOW METER PROVING

5.1 5.1.1

General Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6 Initial Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17

5.2 5.2.1 5.2.2 5.2.3 5.2.4 5.2.5

Tank Prover Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Meter Proof RUN 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Meter Proof RUN 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Meter Proof RUN 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Meter Proof RUN 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Meter Proofs for Component 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-21 5-22 5-23 5-23 5-24 5-24

5.3 5.3.1 5.3.2 5.3.3 5.3.4 5.3.5

Master Meter Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Meter Proof RUN 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Meter Proof RUN 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Meter Proof RUN 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Meter Proof RUN 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Meter Proofs for Component 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-28 5-29 5-30 5-31 5-31 5-31

Table of Contents

_________________________________________________________

6.0

DanLoad 6000 (v6.00)

PROGRAM CODE DESCRIPTIONS

6.1

Program Code Attributes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3

6.2

Program Code Groups . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6

6.3

Security Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12

6.4

Unit Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16

6.5

Valve Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-34

6.6

Meter Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-36

6.7

Component Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-39

6.8

Delivery Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-42

6.9

Digital Valve Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-50

6.10

Pulse Per Unit Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-54

6.11

Additive Delivery Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-58

6.12

Factors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-68

6.13

Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-77

6.14

I/O Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-112

6.15

Additive I/O Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-144

6.16

Component I/O Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-148

6.17

Temperature / Pressure / Density . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-158

6.18

Recipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-180

6.19

Data Communications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-186

6.20 6.20.1

Dynamic Data Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-190 Dynamic Data Display Data Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-195

6.21

Data Logging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-202

Table of Contents

DanLoad 6000 (v6.00) __________________________________________________________ 6.22

Blending . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-208

6.23

Additive Pumps / Block Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-228

6.24

LPG / Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-230

6.25

Transaction Data Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-239

6.26

Transaction Ticket Format . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-248

6.27

Analog Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-254

6.28

CPU Version 2 Analog Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-257

APPENDICES A

Installation Worksheets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

A.1 A.2 A.3 A.4 A.5 A.6 A.7 A.8 A.9 A.10 A.11 A.12 A.13 A.14 A.15 A.16 A.17 A.18 A.19 A.20

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table of Contents

A-1

D-1

vii

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DanLoad 6000 (v6.00)

Field Wiring Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-1

Other Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-1

FIGURES 1-1

Typical Load Rack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

2-1 2-2 2-3 2-4 2-5 2-6 2-7 2-8 2-9 2-10 2-11 2-12 2-13 2-14 2-15 2-16 2-17 2-18 2-19 2-20 2-21

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

3-1 3-2 3-3 3-4 3-5 3-6 3-7 3-8 3-9 3-10 3-11

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

3-12

Transaction Ticket (Typical) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-126

viii

Table of Contents

DanLoad 6000 (v6.00) __________________________________________________________ 3-13 3-14 3-15 3-16

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

4-1 4-2 4-3 4-4 4-5 4-6 4-7 4-8 4-9

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

5-1 5-2 5-3

Prover / Meter Volume Relationship . . . . . . . . . . . . . . . . . . . . . . . . . . Meter Proving Report For Tank Prover Method . . . . . . . . . . . . . . . . . Meter Proving Report For Master Meter Method . . . . . . . . . . . . . . . . Master Meter Meter-Factors Table . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-1 6-2 6-3

Menu Tree . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8 Parameters List Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9 CPU v2 Analog Calibration Set Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-262

Table of Contents

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Table of Contents

Section 1 Introduction

Functional Characteristics Hardware Configuration General Terminology

_________________________________________________________

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

Unique program code.

052 / 055 / 058 / 061 Valve to be controlled

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

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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. # # # #

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. # #

Section 4 - Operation Section 5 - Flow Meter Proving

The individual sections contain the following information. #

Section 1 - Introduction (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.

Section 2 - Installation 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.

Section 3 - Setup 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)

Section 4 - Operation 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.

Section 5 - Flow Meter Proving 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.

Section 6 - Program Code Definitions This section contains reference information for all program codes (parameters) which determine the functional configuration of the DanLoad 6000.

Appendix A - Parameter Configuration 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.

Appendix B - Configuration Record This appendix contains a table that can be copied to provide a place to document the configuration of an installation.

Appendix C - LPG Loading Configuration Checklist This appendix contains instructions and listings that can be copied to provide a place to document LPG loading configurations.

Appendix D - Spare Parts This appendix contains lists of recommended DanLoad 6000 spare parts.

Appendix E - Field Wiring Drawings This appendix contains drawings that are relevant to the set up and operation of the DanLoad 6000 installation in the field.

Appendix F - Other Drawings 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 Standalone 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

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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

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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

A preset, quantity-based product delivery or blended component delivery of a single recipe.

blend stream

Blend stream is the blended product stream and is a mix of both gasoline and ethanol.

blending

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.

component

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.

1 - 10 ____________________________________________________________ Introduction

_________________________________________________________ Term

DanLoad 6000 (v6.00)

Definition

gross quantity

The indicated quantity times the meter factor derived from a meter proving 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

(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.

loading riser

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

(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.

meter factor

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 factor

Meter prover volume corrected to standard conditions ----------------------------------------------------Flow meter indicated vol corrected to std conditions

meter proving

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.)

permissive

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

_________________________________________________________ Term

DanLoad 6000 (v6.00)

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 CTLM (correction factor for the effect of temperature on the liquid in the meter) times CPLM (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

Section 2 Installation

Specifications Installation Planning Mechanical Installation Electrical Installation

_________________________________________________________

DanLoad 6000 (v6.00)

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

Standard

Remote / Secondary

Height

13-inches (330 mm)

Width

14-inches (355 mm)

Depth

14-inches (355 mm)

8-inches (200 mm)

Weight

75-pounds (34 kg)

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

_________________________________________________________ 2.2

DanLoad 6000 (v6.00)

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

NOTE:

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

_________________________________________________________ 2.2.2

DanLoad 6000 (v6.00)

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

Use

+ 5 Vdc

digital logic

+ 5 Vdc unregulated

LCD display unit

+ 15 Vdc / - 15 Vdc

analog inputs

+ 12 to + 15 Vdc

meter pulse transmitter power supply (100 mA dc version)

+ 24 Vdc

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

Function

JO1-1 to JO1-2 JO2-1 to JO2-2

115 Vac power input

JO1-2 to JO2-2

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

Function

E16 to E17

4Mbit EPROM with firmware 3.00 & up

E7 to E8

4Mbit EPROM with firmware 2.00 & up

E2 to E3

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 Analog Inputs Board is board and install JP1 on Analog installed Inputs Board 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. Jumper

RS232

RS485

JP1

1&2 closed

2&3 closed

JP2

1&2 closed

2&3 closed

JP3

1&2 closed

2&3 closed

JP4

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. PC

4-20 mA

RTD

984

LL (low low)

988

LL (low low)

985

LH (low high)

989

LH (low high)

986

HL (high low)

990

HL (high low)

987

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 RS232 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.

Switch SW1 6

Address

Decimal weight 6

128

off

255

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)

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

JP1 JP5

1 to 2 in

meter 1 preamp power = 24 Vdc

JP1 JP5

2 to 3 in

meter 1 preamp power = 8 to 15 Vdc (PS1)

JP1 JP3 JP3 JP5

1-to-2 1-to-2 3-to-4 out

meter 1 input optically isolated and floating, requires external 5 to 24 Vdc supply

JP3 JP3

1 to 2 3-to-4

meter 1 input optically isolated

JP3

2-to-3

meter 1 input direct

JP8

out

meter 1 standard input filtering ( 5 kHz. low pass filter)

meter 1 additional high frequency filtering ( 50 Hz. low pass filter)

JP2 JP4

1-to-2 in

meter 2 preamp power = 24 Vdc

JP2 JP4

2-to-3 in

meter 2 preamp power = 8 to 15 Vdc (PS2)

JP2 JP7 JP7 JP4

1-to-2 1-to-2 3-to-4 out

meter 2 input optically isolated and floating, requires external 5 to 24 Vdc supply

JP7 JP7

1-to-2 3-to-4

meter 2 input optically isolated

JP7

2-to-3

meter 2 input direct

JP6

out

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

Input Signal

3-6000-042

+12 V square wave (nominal)

3-6000-132

+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: Meter 1A, short 2&3 on jumper JP1 Second Meter: 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 Connection

Function

JP4

Enable meter input X

JP13

JP14

JP16

JP6

JP5

1-to-2 3-to-4 out

meter input optically isolated and floating, requires external 5 to 24 Vdc supply

JP11

JP12

JP13

JP14

meter input optically isolated

JP15

JP16

JP6

JP5

1-to-2 3-to-4 in

JP11 JP15

JP12 JP16

JP13 JP6

JP14 JP5

2-to-3 in

meter input direct local ground

JP9

JP10

JP8

JP7

out

meter standard input filtering ( 5 kHz. low pass filter)

meter additional high frequency filtering ( 50 Hz. low pass filter)

JP1

JP2

JP3

JP11

JP12

JP15

local ground

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 For 15 Volts adjustable: Close Jumper JP19, Open JP20

Jumper options:

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: Jumper options:

12.5 VDC 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

Factored pulse outputs

2.00

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

out

Input 2 90-to-240 Vac / Vdc

Input 2 24 Vac / Vdc

out

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

pins 1 to 2

Input 2 is 24 Vac or 24 Vdc

JP2

pins 1 to 2

Input 1 is 24 Vac or 24 Vdc

JP1

pins 2 to 3

Input 2 is 120 Vac

JP2

pins 2 to 3

Input 1 is 120 Vac

JP1

out

Input 2 is 240 Vac

JP2

out

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

Jumper

Internal Power

External Power

1&2

SHORT PINS 1&2, 3&4, 5&6

OPEN NO JUMPERS

3&4

SHORT PINS 1&2, 3&4, 5&6

OPEN NO JUMPERS

5&6

SHORT PINS 1&2, 3&4, 5&6

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

External Power

Input Channel

24 Vdc Internal Power

20 to 30 Vac or Vdc

102 to 140 Vac

204 to 260 Vac

1 and 2

JP9 1 to 2, 3 to 4, 5 to 6 JP8 1 to 2 JP7 1 to 2

JP9 all out JP8 1 to 2 JP7 1 to 2

JP9 all out JP8 2 to 3 JP7 2 to 3

JP9 all out JP8 all out JP7 all out

3 and 4

JP6 1 to 2, 3 to 4, 5 to 6 JP5 1 to 2 JP4 1 to 2

JP6 all out JP5 1 to 2 JP4 1 to 2

JP6 all out JP5 2 to 3 JP4 2 to 3

JP6 all out JP5 all out JP4 all out

5 and 6

JP3 1 to 2, 3 to 4, 5 to 6 JP2 1 to 2 JP1 1 to 2

JP3 all out JP2 1 to 2 JP1 1 to 2

JP3 all out JP2 2 to 3 JP1 2 to 3

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

Connection

Function

W1 2-to-3

Input 6 floating, 24 Vac or 24 Vdc external input

W1 1-to-2 W1 3-to-4

Input 6 internal 24 Vdc power furnished

W2 2-to-3

Input 5 floating, 24 Vac or 24 Vdc external input

W2 1-to-2 W2 3-to-4

Input 5 internal 24 Vdc power furnished

W3 2-to-3

Input 4 floating, 24 Vac or 24 Vdc external input

W3 1-to-2 W3 3-to-4

Input 4 internal 24 Vdc power furnished

W4 2-to-3

Input 3 floating, 24 Vac or 24 Vdc external input

W4 1-to-2 W4 3-to-4

Input 3 internal 24 Vdc power furnished

W5 2-to-3

Input 2 floating, 24 Vac or 24 Vdc external input

W5 1-to-2 W5 3-to-4

Input 2 internal 24 Vdc power furnished

W6 2-to-3

Input 1 floating, 24 Vac or 24 Vdc external input

W6 1-to-2 W6 3-to-4

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 (standard, -40 to 110 oC), -062 (high range, 50 to 200 oC), -063 (low range, -50 to -200 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 0.003850 S/S/oC (DIN 43670) and will be 115.54 S at 40 oC. A common current source 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 (-40 to 110 oC), high range (50 to 200 oC), and a low range (-50 to -200 oC). Be sure to 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 (standard, -40 to 110 oC), -065 (high range, 50 to 200 oC), -066 (low range, -50 to -200 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 0.003850 S/S/oC (DIN 43670) and will be 115.54 S at 40 oC. A common current source 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 (-40 to 110 oC), high range (50 to 200 oC), and a low range (-50 to -200 oC). Be sure to specify the correct part number. Refer to Figure 2-9 for jumper settings.

2 - 34 ______________________________________________________________ Installation

_________________________________________________________ 2.3

DanLoad 6000 (v6.00)

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

_________________________________________________________ 2.4.2.1

DanLoad 6000 (v6.00)

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

_________________________________________________________ 2.4.3

DanLoad 6000 (v6.00)

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.

2.5.2

Interface Board

Function

3-6000-034

Remote display

3-6000-147

Remote start/stop

3-6000-149

Remote start/stop and remote display

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. 3-6000147). The field wiring for both boards is shown in Appendix E.

2 - 44 ______________________________________________________________ Installation

_________________________________________________________ 2.5.3

DanLoad 6000 (v6.00)

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

Section 3 Setup

Operator Interface Initial Setup Procedure Signal Handling

_________________________________________________________

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

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.

<attribute> (not shown)

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

Alarm reset display

Reprint transaction

Reprint transaction display

Setup

Setup menu

Program code attributes

Program code attributes display

Set date and time

Set date and time display

Set contrast/backlighting

Set contrast/backlighting display

Diagnostics

Diagnostics menu _______________________________

Reprint cutoff

Reprint end-of-day processing data

CALMON status

Calibration monitoring

Additive calibration

Additive meter calibration screen

EXIT (ALT+CLEAR)

______________________________________________________

* * *

Diagnostics Menu Firmware versions RAM tests Keypad Display Inputs/Outputs DUART ARCNET Crash analysis Show memory Print configuration Exit (ALT+CLEAR)

* * * * * * * * * * *

Setup Menu 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 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

001 to 024

operation security

Unit parameters

025 to 047

global parameters

Valve parameters

048, 049

flow control valves

Meter parameters

050 to 061

flow meters

Component parameters

065 to 077

liquid components

Delivery parameters

078 to 111

batch deliveries

Digital valve parameters

112 to 127

digital flow control valves

Pulse per unit outputs

128 to 134

quantity pulses to external equipment

Additive delivery parameters

135 to 168

additive injection

Factors

169 to 219

flow meter factors and flow rates

Alarms

220 to 279

actions and limits

I/O parameters

280 to 379

input / output signal assignments

Additive I/O parameters

380 to 399

additive injection signal assignments

Component I/O parameters

400 to 425

component block valve signal assignments

Temperature / pressure / density

426 to 479

standard quantity calculation

Recipes

480 to 661

product / batch deliveries

Data communications

662 to 672

logging / terminal automation system

Dynamic data display

679 to 695

operator data view (programmable)

Data logging

696 to 710

reports to printer

Blending

711 to 799

product blending control

Additive pumps/block valves

800 to 817

additive pump and block valve control

LPG/Pressure

818 to 833

select pressure calculation and control methods

Transaction data storage

834 to 902

allocate memory for transaction data storage

Transaction ticket

920 to 982

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

_________________________________________________________ 3.2

DanLoad 6000 (v6.00)

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.

Header line Data line Data line Data line Data line Data line Data line Message line 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.

Header line ccc name ccc name ccc name ccc name ccc name ccc name Message line

vvvvvvvv vvvvvvvv vvvvvvvv vvvvvvvv vvvvvvvv vvvvvvvv 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

_________________________________________________________ #

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: #

Setup

Message line

DanLoad 6000 (v6.00)

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.

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.

_________________________________________________________________ 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

numeric digits

ALT

used in combination with other keys to modify the function of the other keys, see descriptions in the ALTERNATE FUNCTION column

0 digit

view I/O configuration summary

1 digit

toggle minus sign '-'

3 digit

increase display contrast (darken)

6 digit

decrease display contrast (lighten)

START STOP/PRINT

start batch delivery stop batch delivery/print batch/transaction report

ENTER

accept value or execute option

CLEAR

remove selected value

SELECT

scroll options list

PROGRAM EXIT BACKSPACE

8 7

scroll up

scroll left

9 6

scroll down

scroll right

W&M

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

Setup

(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).

_________________________________________________________________ 3 - 13

DanLoad 6000 (v6.00) __________________________________________________________ Key

Function 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.

ALT

0 thru 9 (Loading Mode) (Program Mode)

Numeric keys used for numeric data entry. Numeric keys used for numeric data entry and selection of alpha character group for data entry.

ALT+0

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

ALT+1

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

Active in Loading Mode and Program Mode. Increases the display contrast (darkens the display).

ALT+6

Active in Loading Mode and Program Mode. Decreases the display contrast (lightens the display).

ENTER (Loading Mode)

(Program Mode)

3 - 14

Accept or bypass data item entry or preset quantity entry and continue. Accept the value or selection highlighted by the box cursor.

_________________________________________________________________ Setup

_________________________________________________________ Key

DanLoad 6000 (v6.00)

Function

PROGRAM (ALT+ENTER) (Loading Mode) Change to Program Mode. (Program Mode)

CLEAR (Loading Mode)

(Program Mode) EXIT (ALT+CLEAR) (Loading Mode) (Program Mode)

SELECT (Loading Mode) (Program Mode)

Ignore any edit made to the current field selected by the box cursor and restore the original value / selection.

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.

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.

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.

(Loading Mode)

Change Dynamic Data Display page.

(Program Mode)

Step to next or previous program code (parameter) display line.

67 (ALT+9 or ALT+8) (Loading Mode) (Program Mode)

Setup

No function. Step to next or previous character entry when editing an alphanumeric string entry.

_________________________________________________________________ 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) __________________________________________________________

number/pound

double quote

dollars

apostrophe

percent

colon

question mark

;

semicolon

exclamation point

(

left parenthesis

ampersand

)

right parenthesis

plus

less than

minus

greater than

asterisk

[

left bracket

slash

]

right bracket

equal

{

left brace

dot

}

right brace

comma

backslash

underline

circumflex

tilde

a acute

I acute

o acute

u acute

n tilde (eñe)

a diaeresis (umlaut)

e diaeresis (umlaut)

I diaeresis (umlaut)

o diaeresis (umlaut)

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.

The flashing square cursor is positioned in the leftward field position. The cursor indicates the current character entry position within the alpha-numeric field.

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.

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.)

The first character of the selected group will now be displayed in the active character position.

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.

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.

DanLoad 6000 CPU-1 firmware v5.30 CPU-2 firmware v5.30 Message EPROM v5.30 Power failure

mm/dd/yy

hh:mm:ss

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.

DanLoad 6000 Running CPU-1 RAM test Passed Running CPU-2 RAM test Passed

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.

Slot 1 AC I/O Slot 2 Empty Slot 3 Empty Slot 4 Empty Slot 5 2-Ch. Meter Slot 6 Empty Slot 7 2-Ch. Analog DUART = 000 Pres ALT+CLEAR to exit 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) __________________________________________________________

Meter inputs 01 Chan 0 2-Ch Meter in J5 02 Chan 1 2-Ch Meter in J5

ALT+SELECT to reconfigure 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

Maximum Number

Meter inputs (shown above)

RTD inputs

4 * (5 for v2 CPU)

4-20 mA inputs

8 * (9 for v2 CPU)

Discrete inputs (can be more than one display page)

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

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 420 mA inputs groups will display the message No points of this type.

3 - 22

_________________________________________________________________ Setup

_________________________________________________________

DanLoad 6000 (v6.00)

Chan #

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.

Meter Pulse

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 8channel 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 the DUART board’s address switch is ignored. 2. 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. 3. 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.

Capacity Input

Output

main processor 2 RS-485 or 1 RS-485 and 1 RS-232

2 DC (dedicated function: swing arm)

N/A

one meter pulse (2-ch or 4-ch)

2 pulse - OR 4 pulse

2 pulse (dedicated function: high resolution meter pulse for 2-ch meter pulse board only) 2 DC control

one AC I/O or one Enhanced I/O

2 AC status

8 AC control

6 DC/AC status

6 AC control

I/O Board

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

Setup

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.)

_________________________________________________________________ 3 - 25

DanLoad 6000 (v6.00) __________________________________________________________ I/O Channel Type Description Analog Input Signal Channel Assignment Analog Board Type Input Type

1 each 2Ch

2 each 2Ch

1 each 8-Ch

2 each 8-Ch

1 each 2-Ch / 1 each 8-Ch

# of RTD inputs

# of 4-20 mA inputs

Discrete inputs

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.

Discrete outputs

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

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.

Chan n

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

<board type>=

3 - 26

Slot number, J1 through J7, where the board is located.

_________________________________________________________________ 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. Discrete input Meaning number 0 Point not configured 1 First discrete input, closed when power applied 2 Second discrete input, closed when power applied . . . . 51 52 . .

Setup

First discrete input, closed when no power applied Second discrete input, closed when no power applied . .

_________________________________________________________________ 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

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_________________________________________________________________ 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.

DanLoad 6000 Unit is not configured Initial setup required Enter passcode _________ 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 Current date is mm/dd/yy Enter new date (mm/dd/yy): Current time is hh:mm:ss Enter new time (hh:mm:ss):

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.

Meter totalizers Meter 1 2 3 4

Gross 0 0 0 0

Std 0 0 0 0

Press any key to continue 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.

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_________________________________________________________________ Setup

_________________________________________________________

Initial setup Is this unit a blender

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.

Initial setup Is this unit a blender Type of blender 065 Number of components

Setup

Yes Seq.(auto) 2

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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

_________________________________________________________

Meter 1 parameters 051 Meter ID 052 Valve to be controlled

DanLoad 6000 (v6.00)

M1 1

0=Space, 1=A, 2=a, 3= 0, 4=#, 5=" 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

051 Meter ID

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

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 Offrack blender, flow meters 2 through 4, as required, are defined at this time.

Setup

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DanLoad 6000 (v6.00) __________________________________________________________

Component 1 066 Component ID 067 Meter 068 Mass adjustment

Component #1 1 0.000000

0=Space, 1=A, 2=a, 3= 0, 4=#, 5=" 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

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

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

_________________________________________________________

Delivery parameters 078 Maximum preset qty 079 Minimum preset qty 080 Preset/delivery type 081 Delivery display type 082 Stop key action 083 Fall back qty

DanLoad 6000 (v6.00)

3000 50 Gross Gross Low flow 1000

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

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

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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

_________________________________________________________

Comp 1 delivery parameters 084 Low flow start qty 085 Low flow restart qty 086 Low flow stop qty 087 Line pack delay (s) 088 Pump stop delay (s) 089 Block valve delay (s)

DanLoad 6000 (v6.00)

50 20 50 2 30 0

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

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

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

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

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DanLoad 6000 (v6.00) __________________________________________________________ 087 Line pack delay (s)

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)

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)

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

_________________________________________________________

Delivery parameters (cont'd) 108 Ramp clicks 109 Maintenance clicks 110 Additive pump stop (s) 111 Primary component

DanLoad 6000 (v6.00)

30 30 10 1

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

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

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)

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

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

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DanLoad 6000 (v6.00) __________________________________________________________

Meter factors 169 Number of factors/component 170 Meter factor method

2 Fixed

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

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

_________________________________________________________

Component 1 factors 171 Nominal K-factor 172 Master meter factor 173 Stop rate

DanLoad 6000 (v6.00)

23.0 1.0000 120

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

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DanLoad 6000 (v6.00) __________________________________________________________

Component 1 factor 1 174 Comp 1 flow rate 1 175 Comp 1 meter factor 1

200 1.0000

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

_________________________________________________________

Component 1 factor 2 176 Comp 1 flow rate 2 177 Comp 1 meter factor 2

DanLoad 6000 (v6.00)

600 1.0000

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

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DanLoad 6000 (v6.00) __________________________________________________________

MF validation 215 Master MF % 216 Adjacent MF % 217 Passcode per transaction 218 Product units mnemonic 219 Use restart qty

2.00 0.25 No Gal No

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.

3 - 44

Components 6

Master Meter Factors 6

172

183

194

205

Comp x meter factor 1

175

186

197

208

Comp x meter factor 2

177

188

199

210

Comp x meter factor 3

179

190

201

212

Comp x meter factor 4

181

192

203

214

_________________________________________________________________ Setup

_________________________________________________________ 216 Adjacent MF %

DanLoad 6000 (v6.00)

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. Components 1

172

183

194

205

175

186

197

208

8 Comp x meter factor 2 9

177

188

199

210

8 Comp x meter factor 3 9

179

190

201

212

181

192

203

214

Master Meter Factors 6 Adjacent Meter Factors 9 Comp x meter factor 1 9

8 Comp x meter factor 4

217 Passcode per transaction

Not implemented.

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

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

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DanLoad 6000 (v6.00) __________________________________________________________

Alarm parameters 220 Secondary alarm reset (s)

300

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

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).

Reset Keypad in Program Mode. Alarm reset discrete input, program code 344 Primary alarm reset (if defined). Terminal automation system.

Alarm data is stored in Alarm Storage Memory. Secondary

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.

Correct cause of alarm Automatically reset after time value in program code 220 Secondary alarm reset (s) 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). 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. Info

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. Off

Disable monitoring of this alarm.

Alarm Action Summary Figure 3 - 9

Setup

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DanLoad 6000 (v6.00) __________________________________________________________

Alarm parameters (cont'd) 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)

Primary 100 10 Primary 660 10

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)

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

_________________________________________________________ 225 Maximum flow rate

DanLoad 6000 (v6.00)

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)

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

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DanLoad 6000 (v6.00) __________________________________________________________

Alarm parameters (cont'd) 227 Overrun limit qty 228 Underflow alarm action 229 Underflow limit qty 230 No flow t-o alarm action 231 No flow t-o (s) 232 Unauthorized flow limit qty

2.0 Off 5.0 Primary 5 10.0

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

_________________________________________________________ 229 Underflow limit qty

DanLoad 6000 (v6.00)

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

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DanLoad 6000 (v6.00) __________________________________________________________

Alarm parameters (cont'd) 233 Error limit (pulses) 234 Reset count (pulses) 235 Data logging alarm action 236 Time-out ch. A (s) 237 Time-out ch. B (s)

0 10000 Info 10 10

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)

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:

3 - 52

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.

_________________________________________________________________ Setup

_________________________________________________________ 235 Data logging alarm action

DanLoad 6000 (v6.00)

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)

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)

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 239 Minimum temperature 240 Maximum temperature 241 Density fail alarm action 242 Minimum density/gravity 243 Maximum density/gravity

Primary -40.0 110.0 Primary 0.0000 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

_________________________________________________________ 241 Density fail alarm action

DanLoad 6000 (v6.00)

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) __________________________________________________________

Alarm parameters (cont'd) 244 Minimum pressure 245 Maximum pressure 246 Additive error limit 247 Additive feedback count 248 Block valve time (s)

0.0 0.0 3 10 10

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

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

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)

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)

Alarm parameters (cont'd) 249 Circuit 1 alarm action Secondary 250 #1 Ground detector open 251 Circuit 2 alarm action Primary 252 #2 Overspill detector open

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) __________________________________________________________

Alarm parameters (cont'd) 253 Circuit 3 alarm action Secondary 254 #3 Permissive power failure 255 Circuit 4 alarm action Secondary 256 #4 Additive injection failure

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)

Alarm parameters (cont'd) 257 Circuit 5 alarm action Secondary 258 #5 Arm down side 1 259 Circuit 6 alarm action Secondary 260 #6 Arm down side 2

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) __________________________________________________________

Alarm parameters (cont'd) 261 Circuit 7 alarm action Secondary 262 #7 Walkway down side 1 263 Circuit 8 alarm action Secondary 264 #8 Walkway down side 2

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

_________________________________________________________

Alarm parameters 265 Circuit 5 type 266 Circuit 6 type 267 Circuit 7 type 268 Circuit 8 type 269 Alarm o/p 1 mask 270 Alarm o/p 2 mask

DanLoad 6000 (v6.00)

(cont'd) 1 2 1 2 8388607 0

The display example above shows program codes related to the method of processing the indicated error conditions.

265 Circuit 5 type

This selection limits checking for an open safety circuit 5.

266 Circuit 6 type

This selection limits checking for an open safety circuit 6.

267 Circuit 7 type

This selection limits checking for an open safety circuit 7.

268 Circuit 8 type

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

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. Program Code 265 to 268 Circuit x type 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

_________________________________________________________

Alarm parameters (cont'd) 271 Unauth additive flow vol 272 Prod/add -% 273 Prod/add +%

DanLoad 6000 (v6.00)

0.0000 0 0

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 -%

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 +%

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) __________________________________________________________

Alarm parameters (cont'd) 276 Ramp down alarm action Primary 277 Ramp down time (s) 4 278 Additive per 1000 error limit 1 279 End time (s) 180

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)

This selection sets the time in seconds allowed for ramp down before the ramp down alarm is raised.

278 Additive per 1000 error limit

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)

180

This selection sets the end time in seconds.

3 - 64

_________________________________________________________________ Setup

_________________________________________________________

Recipes 480 Number of recipes

DanLoad 6000 (v6.00)

Recipe 1 481 Recipe name Recipe #1 482 Comp 1 % 100.00 483 Comp 2 % 0.00 484 Comp 3 % 0.00 485 Comp 4 % or ratio qty 0.00 486 Sequence or low proportion 1 0=Space, 1=A, 2=a, 3=0 4=#,5="

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

Valid

Invalid

482 Comp 1 %

483 Comp 2 %

484 Comp 3 %

485 Comp 4 % or ratio qty

486 Sequence or low proportion

312

320

481 Name

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

Valid

Invalid

482 Comp 1 %

483 Comp 2 %

484 Comp 3 %

485 Comp 4 % or ratio qty

481 Name

486 Sequence or low proportion 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

_________________________________________________________ 480 Number of recipes

DanLoad 6000 (v6.00)

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

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)

Setup complete

Press ALT+CLEAR to exit 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.

Gasoline

Loaded Preset Remaining Transaction total Enter preset qty

mm/dd/yy hh:mm

0% +)))),

0 Gal 0 Gal 0 Gal

* * * * * * * * .))))-

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:

Open block valve - press ENTER after a batch delivery has been configured and the START key is pressed

Prompt:

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.

3 - 72

_________________________________________________________________ Setup

_________________________________________________________ •

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.

•

Setup

(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.

_________________________________________________________________ 3 - 73

DanLoad 6000 (v6.00) __________________________________________________________ #

Delivery Parameters

Define batch loading control program codes.

Define the pump / block valve / flow control valve timing relationship. The program codes indicated below set the timing for each component. open start open BV PUMP FCV | | | | | | | | | | |--------LPD-------| |-----------BVD-------------|

close stop FCV BV PUMP | | | | | | | | |---–PSD---|

where: BV FCV LPD BVD PSD

block valve flow control valve 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.

3 - 74

_________________________________________________________________ Setup

_________________________________________________________ #

Digital Valve Parameters

DanLoad 6000 (v6.00)

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 Device

Closed

Opening

Static Open

Closing

Solenoid 1 (upstream) control output

Off

Upstream pilot valve (cavity fill)

Open

Closed

Open

Solenoid 2 (downstream) control output

Off

Downstream pilot valve (cavity drain)

Closed

Open

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

Valve State

Closed

Opening to Low Flow Start & Low Flow Start

Opening to Full Open & Full Open

Closing to Low Flow Stop & Low Flow Stop

Closed

Solenoid 1 control output

Off

Solenoid 2 control output

Off

Device

Two-Stage Flow Control Valve (without Stem-Switches) Figure 3 - 11

3 - 76

_________________________________________________________________ Setup

_________________________________________________________

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

Valve State Output

Closed/ Closing

Opening

Static Open (“locked”)

Solenoid 1 control output

Off

Solenoid 2 control output

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

Temperature (CTL) and Pressure (CPL) Compensation

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)

CTL / CPL Associations Cross Reference (Table 3 -1) CPL Options CTL Options 9 Off

Const

API 11.2.1

API 11.2.2

API 11.2.1M

API 11.2.2M

Off

Yes

Linear

Yes

API 6A

Yes

No1

No2

No1,2

API 6B

Yes

No1

No2

No1,2

API 6C

Yes

No1

No2

No1,2

API 24A

Yes

No2

No1

No2

No1,2

API 24B

Yes

No2

No1

No2

No1,2

API 54A

Yes

No2

No1,2

Yes

No1

API 54B

Yes

No2

No1,2

Yes

No1

API 54C

Yes

No2

No1,2

Yes

No1

IMP/PEMEX

Yes

No2

No1,2

No2

No1,2

Table 24 (Old)

Yes

No2

Yes

No2

Table 54 (Old)

Yes

No2

Yes

Petrobras

Yes

No2

Yes3

No1,2

TP-16

Yes

No2

Yes

No2

China

Yes

API 6D

Yes

No1

No2

No1,2

API 54D

Yes

No2

No1,2

Yes

No1

4311 1

Yes

No2

Yes

No2

CAN 54B

Yes

No2

No1,2

Yes

No1

Notes: Yes = The density ranges for both CTL and CPL overlap and both compensation methods can be used together. 1 = The density ranges do not overlap. 2 = The density units are not the same for CTL and CPL. 3 = The CTL option enables special processing for the CPL option. Setup

_________________________________________________________________ 3 - 79

DanLoad 6000 (v6.00) __________________________________________________________

Density Range Overlaps (Approximate) for CTL and CPL Options (Table 3 - 2) Option

Density Range

kg/m3

350

400

450

500

550

600

650

700

750

800

850

900

950

1000

1050

1100

CTL Table 24

0.500 to 1.100 60/60o F (. 500 to 1100 kg/m3) TTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTT

Table 54

0.500 to 1.100 kg/l (. 500 to 1100 kg/m3) TTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTT

API 6A

0 to 100 degrees API (6110 to 1.0760 (610 to 1075 kg/m3) TTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTT

API 24A

0.6110 to 1.0760 (610 to 1075 kg/m3) TTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTT

API 54A

610 to 1075 kg/m3 TTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTT

API 6B

0 to 85 degrees API (653 to 1075 kg/m3) TTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTT

API 24B

0.6535 to 1.0760 (653 to 1075 kg/m3) TTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTT

API 54B

653 to 1075 kg/m3 TTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTT

IMP/PEMEX

0.6495 to 1.0730 (. 649 to 1072 kg/m3) TTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTT

Linear (User ")

Unlimited density TTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTT

CP L API 11.2.2

Relative density 0.350 to 0.637 (density 349.7 to 636.4) PPPPPPPPPPPPPPPPPPPPPPPPPPPPPP

API 11.2.2M

350 to 636 kg/m3 PPPPPPPPPPPPPPPPPPPPPPPPPPPPPP

API 11.2.1

0 to 90 degrees API (638 to 1074 kg/m3) PPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPP

API 11.2.1M

638 to 1074 kg/m3 PPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPP

User F-factor

Unlimited density PPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPP

CAN 54B

653 TO 1075 kg/m3 T TTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTT

Notes: Approximate density range for CTL selection (432 Temperature option)

TTT ...

PPP ... Approximate density range for CPL selection (444 Pressure option)

3 - 80

_________________________________________________________________ Setup

_________________________________________________________

DanLoad 6000 (v6.00)

The density at 60 degrees Fahrenheit = specific gravity 60/60oF * 999.012 kg/m3.

Program code 445 F-factor X 1000000000 is the component’s compressibility factor * 109 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.

Setup

046 Density/gravity scale

Format

xxxx.x

xxx.xx

xx.xxx

4 (default)

x.xxxx

_________________________________________________________________ 3 - 81

DanLoad 6000 (v6.00) __________________________________________________________

Density Ranges for CTL Selections (432 Temperature option) (Table 3 -3) CTL Option

Temp Range o

API 6A

0 to 300 F

Density Range

API gravity

0 to 40 degrees API

0 to 250o F

40 to 50 degrees API

0 to 200o F

50 to 100 degrees API

0 to 300o F

API 6B

Density Input / Reference Temperature

API gravity

0 to 250o F

40 to 50 degrees API

0 to 200 F

50 to 85 degrees API

API 6C

0 to 300o F

API 24A

None [inputs are "T and t (" at base temperature and batch temperature)] 430 Reference temperature = 60o F

N/A

Relative density 60/60o F

0.8250 to 1.0760

0 to 250o F

0.7795 to 0.8250

0 to 200 F

0.6110 to 0.7795

0 to 300o F

API 24B

Relative density 60/60o F

0.7795 to 0.8250

0 to 200o F

0.6535 to 0.7795 Density kg/m3

API 54C

610 to 778 kg/m3

-18 to 125 C

778 to 824 kg/m3

-18 to 150o C

824 to 1075 kg/m3

-18 to 95o C

API 54B

0.8250 to 1.0760

0 to 250o F

-18 to 95o C

API 54A

0 to 40 degrees API

Density kg/m3

653 to 778 kg/m3

-18 to 125o C

778 to 824 kg/m3

-18 to 150o C

824 to 1075 kg/m3

N/A

None 430 Reference temperature = 15o C

IMP/PEMEX

Relative density 20/4o C

0.6495 to 1.0730

Table 24 (Old)

Specific gravity 60/60o F

0.500 to 1.100 (full range).

Table 54 (Old)

Density kg/l

0.500 to 1.100 kg/l (full range).

Petrobras

Relative density 20o C/4o C

Any temperature and relative density.

Relative density 60/60o F

0.8250 to 1.0760

0 to 300o F

TP-16

CAN 54B

0 to 250o F

0.7795 to 0.8250

0 to 200o F

0.6110 to 0.7795

-40 to 95 C

Density kg/m3

653 to 778 kg/m3

-40 to 125o C

778 to 824 kg/m3

-40 to 150o C

824 to 1075 kg/m3

Note:

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

_________________________________________________________ 3.7.1

DanLoad 6000 (v6.00)

Temperature Correction to a Non-Standard Reference Temperature

Temperature correction to a non-standard reference temperature (using existing CTL tables) has been 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

Standard ref. temp.

Correction to nonstandard ref. temp.

Off

N/A

Linear

N/A

API 6A

60.0°F

Yes

API 6B

60.0°F

Yes

API 6C

N/A

API 24A

60.0°F

Yes

API 24B

60.0°F

Yes

API 54A

15.0°C

Yes

API 54B

15.0°C

Yes

API 54C

N/A

IMP

20.0°C

Yes

Old 24

60.0°F

Yes

Old 54

15.0°C

Yes

P'Bras

20.0°C

Yes

TP-16

60.0°C

Yes

China

20.0°C

Yes

60.0°F

Yes

54D

15.0°C

Yes

4311 1

60.0°F

Yes

NH3

60.0°F

Yes

CAN 54B

15.0°C

Yes

A "Yes" in the right-hand column indicates that the CTL option has a standard reference temperature and allows temperature correction to a non-standard reference temperature. A "No" in the right-hand column indicates that the CTL option does not have a standard reference temperature.

Setup

_________________________________________________________________ 3 - 83

DanLoad 6000 (v6.00) __________________________________________________________ In program mode/setup, if any component's CTL option (program codes 432, 435, etc.) is modified 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 for that CTL option (per the table above). If any component's CTL option is modified to one that does not have a standard reference temperature then the reference temperature is not modified. Thus, if temperature correction to a non-standard reference temperature using a CTL option that has a standard reference temperature is required, it is necessary to configure each component's CTL option prior to configuring the reference temperature (program code 430). (Note: The temperature units (program code 427) must still be configured manually to the appropriate value for the configured CTL options.) When a CTL factor is computed for a CTL option that has a standard reference temperature, the DanLoad 6000 tests whether the configured reference temperature is equal to the standard reference temperature. If it is equal, the CTL factor is computed in the usual way, i.e. as the CTL for the component's batch average temperature, otherwise the CTL factor is computed as the ratio of the CTL for the component's batch average temperature to the CTL for the configured reference temperature which requires two calls to the CTL option's implementation. It should be noted that the reference temperature (program code 430) can be modified indirectly, i.e. by modifying a component's CTL option, and can affect CTL options. Program code 430 is weights and measures protected by default.

3 - 84

_________________________________________________________________ Setup

_________________________________________________________

DanLoad 6000 (v6.00)

Note the following examples using test data:

API 6B, PC 427 = F Ref. temp.

Observed temp.

Density or gravity

CTL factor

60.0°F

80.9°F

35.10

0.9903

60.0°F

86.0°F

35.10

0.9879

86.0°F

80.9°F

35.10

1.0024

API 24A, PC 427 = F Ref. temp.

Observed temp.

Density or gravity

CTL factor

60.0°F

56.5°F

0.8760

1.00160

60.0°F

66.5°F

0.8760

0.99710

66.5°F

56.5°F

0.8760

1.00451

API 54A, PC 427 = C Ref. temp.

Observed temp.

Density or gravity

CTL factor

15.0°C

22.5°C

740.0

0.9916

15.0°C

20.0°C

740.0

0.9944

20.0°C

22.5°C

740.0

0.9972

IMP, PC 427 = C Ref. temp.

Setup

Observed temp.

Density or gravity

CTL factor

20.0°C

6.0°C

0.7210

1.01743

20.0°C

17.5°C

0.7210

1.00311

17.5°C

6.0°C

0.7210

1.01428

_________________________________________________________________ 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 = (Ei=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 options (program code 444, etc. per component) should be configured since the Ctl and Cpl factors 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.

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 following page, which contains data for an injector that injects 100 cm3 (0.0264 gallons) of additive 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)

Setup

cm3

gallons

Product/additive ratio

100

0.0264

1515

100

0.0264

2992

200

0.0528

1515

119

200

0.0528

2254

120

300

0.0793

1513

159

300

0.0793

2083

160

400

0.1057

1514

_________________________________________________________________ 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:

3 - 92

"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.

_________________________________________________________________ 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 #

Value

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 based on a quantity per pulse, and their internal additive units are cm3. The other two injection 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 "Handshake" injection methods it is the volume per pulse in cm3. For the "Meter" and "Control" 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

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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

_________________________________________________________ 3.10.2

DanLoad 6000 (v6.00)

Additive Injection Configuration (Typical Examples)

Example 1 (Additive injection configuration) Configuration Program Code

Description

Value

026

Unit type

Sequential

065

Number of components

050

Number of meters

482

Comp 1 %

100

139

Control meters

140

Ratio qty

40.0

138

Clean line qty

111

Primary component

Test Results

Setup

Preset Quantity

Additive Ratio computed by DanLoad 6000

Additive injections

400

40.00

_________________________________________________________________ 3 - 99

DanLoad 6000 (v6.00) __________________________________________________________ Example 2 (Additive injection configuration) Configuration Program Code

Description

Value

026

Unit type

Sequential

065

Number of components

050

Number of meters

482

Comp 1 %

100

139

Control meters

140

Ratio qty

40.0

138

Clean line qty

111

Primary component

Test Results Preset Quantity

Additive Ratio computed by DanLoad 6000

Additive injections

400

(400 - 20) ÷ (400 ÷ 40) = 38.00

3 - 100 _________________________________________________________________ Setup

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DanLoad 6000 (v6.00)

Example 3 (Additive injection configuration) Configuration Program Code

Description

Value

026

Unit type

Sequential

065

Number of components

050

Number of meters

524

Comp 1 %

100

139

Control meters

140

Ratio qty

40.0

138

Clean line qty

111

Primary component

Test Results Preset Quantity

Additive Ratio computed by DanLoad 6000

Additive injections

400

(400 - 10) ÷ (400 ÷ 40) = 39.00

Setup _________________________________________________________________ 3 - 101

DanLoad 6000 (v6.00) __________________________________________________________ Example 4 (Additive injection configuration) Configuration Program Code

Description

Value

026

Unit type

Sequential

065

Number of components

050

Number of meters

482

Comp 1 %

100

139

Control meters

140

Ratio qty

40.0

138

Clean line qty

111

Primary component

Test Results Preset Quantity

Additive Ratio computed by DanLoad 6000

Additive injections

400

(400 - 10 - 20) ÷ (400 ÷ 40) = 37.00

3 - 102 _________________________________________________________________ Setup

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DanLoad 6000 (v6.00)

Example 5 (Additive injection configuration) Configuration Program Code

Description

Value

026

Unit type

In line

065

Number of components

050

Number of meters

482 483

Comp 1 % Comp 2 %

067 070

Component 1 meter number Component 2 meter number

1 2

139

Control meters

140

Ratio qty

40.0

138

Clean line qty (additive)

111

Primary component

714

Clean line qty (component)

60.00 40.00

Test Results Preset Quantity

Meter 1 Gross

Meter 2 Gross

Additive Ratio computed by DanLoad 6000

Additive injections

400

240

160

40.00

Setup _________________________________________________________________ 3 - 103

DanLoad 6000 (v6.00) __________________________________________________________ Example 6 (Additive injection configuration) Configuration Program Code

Description

Value

026

Unit type

In line

065

Number of components

050

Number of meters

482 483

Comp 1 % Comp 2 %

067 070

Component 1 meter number Component 2 meter number

1 2

139

Control meters

140

Ratio qty

40.0

138

Clean line qty (additive)

111

Primary component

714

Clean line qty (component)

60.00 40.00

Test Results Preset Quantity

Meter 1 Gross

Meter 2 Gross

Additive Ratio computed by DanLoad 6000

Additive injections

400

240

160

(240 - 60) ÷ (240 ÷ 40) = 30.00

3 - 104 _________________________________________________________________ Setup

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DanLoad 6000 (v6.00)

Example 7 (Additive injection configuration) Configuration Program Code

Description

Value

026

Unit type

In line

065

Number of components

050

Number of meters

482 483

Comp 1 % Comp 2 %

067 070

Component 1 meter number Component 2 meter number

1 2

139

Control meters

140

Ratio qty

40.0

138

Clean line qty (additive)

111

Primary component

714

Clean line qty (component)

60.00 40.00

Test Results Preset Quantity

Meter 1 Gross

Meter 2 Gross

Additive Ratio computed by DanLoad 6000

Additive injections

400

240

160

(240 - 30) ÷ (240 ÷ 40) = 35.00

Setup _________________________________________________________________ 3 - 105

DanLoad 6000 (v6.00) __________________________________________________________ Example 8 (Additive injection configuration) Configuration Program Code

Description

Value

026

Unit type

In line

065

Number of components

050

Number of meters

482 483

Comp 1 % Comp 2 %

067 070

Component 1 meter number Component 2 meter number

1 2

139

Control meters

140

Ratio qty

40.0

138

Clean line qty (additive)

111

Primary component

714

Clean line qty (component)

60.00 40.00

Test Results Preset Quantity

Meter 1 Gross

Meter 2 Gross

Additive Ratio computed by DanLoad 6000

Additive injections

400

240

160

(240 - 60 - 30) ÷ (240 ÷ 40) = 25.00

3 - 106 _________________________________________________________________ Setup

_________________________________________________________

DanLoad 6000 (v6.00)

Example 9 (Additive injection configuration) Configuration Program Code

Description

Value

026

Unit type

In line

065

Number of components

050

Number of meters

482 483

Comp 1 % Comp 2 %

067 070

Component 1 meter number Component 2 meter number

1 2

139

Control meters

140

Ratio qty

40.0

138

Clean line qty (additive)

111

Primary component

714

Clean line qty (component)

60.00 40.00

Test Results Preset Quantity

Meter 1 Gross

Meter 2 Gross

Additive Ratio computed by DanLoad 6000

Additive injections

400

240

160

(240 - 60) ÷ (240 ÷ 40) = 30.00

Setup _________________________________________________________________ 3 - 107

DanLoad 6000 (v6.00) __________________________________________________________ Example 10 (Additive injection configuration) Configuration Program Code

Description

Value

026

Unit type

In line

065

Number of components

050

Number of meters

482 483

Comp 1 % Comp 2 %

067 070

Component 1 meter number Component 2 meter number

1 2

139

Control meters

140

Ratio qty

40.0

138

Clean line qty (additive)

111

Primary component

714

Clean line qty (component)

60.00 40.00

Test Results Preset Quantity

Meter 1 Gross

Meter 2 Gross

Additive Ratio computed by DanLoad 6000

Additive injections

400

240

160

(400 - 60 - 30) ÷ (400 - 40) = 31.00

3 - 108 _________________________________________________________________ Setup

_________________________________________________________ 3.10.3

DanLoad 6000 (v6.00)

Additive Meter Calibration

The DanLoad 6000's additive meter calibration screen provides a simple, step-by-step procedure for computing an additive meter's K-factor using a beaker graduated in cubic centimeters (cm3 or cc). 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 volume in cm3 from the additive meter K-factor

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 as cm3 based on the additive meter's K-factor and the configured product units (program code 29).

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 volume of additive measured in the graduated beaker, in cm3. 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: Knew = (Kold x Volmetered) / Volprover 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.

3 - 116 _________________________________________________________________ Setup

_________________________________________________________

DanLoad 6000 (v6.00)

Setup _________________________________________________________________ 3 - 117

DanLoad 6000 (v6.00) __________________________________________________________

3 - 118 _________________________________________________________________ Setup

_________________________________________________________

3.10.5

DanLoad 6000 (v6.00)

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.

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)

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:

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)

Determine the amount of additive delivered per injection: Vol/pulse = (Total additive injected) / (# of pulses)

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).

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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_________________________________________________________ 3.11

DanLoad 6000 (v6.00)

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 3129, 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.

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.

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

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

two-digit (leading zeros) column number on ticket

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DanLoad 6000 (v6.00)

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.

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.

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

150

Batch record length

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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_________________________________________________________ #

DanLoad 6000 (v6.00)

Compare the value of the transaction record length and the sum of all batch records stored for each normal transaction. 1

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.

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.

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.

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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 3 - 128 _________________________________________________________________ Setup

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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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DanLoad 6000 (v6.00)

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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DanLoad 6000 (v6.00)

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.

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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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DanLoad 6000 (v6.00)

Format 1 - Transaction summary 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 summary 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

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.

Nybble

A nybble is 4 binary bits. A byte contains two nybbles.

Database Terminology (applicable to DanLoad 6000 batch and transaction storage)

Database

All of the static (unchanging) and dynamic (changing) data stored in the DanLoad 6000.

File

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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DanLoad 6000 (v6.00)

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

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.

Record Header [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.

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DanLoad 6000 (v6.00) __________________________________________________________

Transaction and Batch File Organization (Record Header Fields plus User Defined Field) Type of Record 9

Batch Sequence Number

Transaction > Batch >

Transaction Sequence Number

Transaction file key Batch file key

Start Batch Number <yes>

Number of Batches in Transaction

Operating Mode

Status

User Defined

<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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DanLoad 6000 (v6.00)

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

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

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 aabbttTTPPPPcccccccccccccccc PPPP

< OFFSET < good record < bad record

3 - 140 _________________________________________________________________ Setup

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DanLoad 6000 (v6.00)

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

Variable

Storage Length (bytes)

File Pointer + Number of Bytes in Variable

880

Unit address

2 (aa)

1 + 2 bytes (9 start next at byte 3)

881

Batch sequence number

2 (bb)

3 + 2 bytes (9 start next at byte 5)

882

Transaction sequence number

2 (tt)

5 + 2 bytes (9 start next at byte 7)

883

Temperature

2 (TT)

7 + 2 bytes (9 start next at byte 9)

884

Pressure

4 (PPPP)

9 + 4 bytes (9 start next at byte 13)

889

Component gross quantity

4 * number of components defined (cccccccccccccccc)

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) __________________________________________________________

Transaction Data Access Program Codes Program Code

Function

696

Enables printing of the PREDEFINED STANDARD Batch Summary Report on one of up to four selectable printers.

697

Enables printing of the PREDEFINED STANDARD Transaction Summary Report on one of up to four selectable printers.

706

Enables printing of a USER DEFINED Transaction Ticket on a one of up to four selectable printers.

707

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.

3 - 142 _________________________________________________________________ Setup

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DanLoad 6000 (v6.00)

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.

Transaction Storage Codes (TSC) Table 3 - 4 TSC Number and Display

Record Offset Program Code

Ticket Coordinates Program Code

Time Saved

# bytes/format

Reference

1 Addr

840

920

start trns

2/nnn

DUART address

2 Tr seq #

841

921

start trns

2/nnnn

PC 042

3 Recipe #

842

922

start trns

2/nn

internal register

4 Recipe name

843

923

start trns

16/(a16)

PC 481...

5 Side

844

924

start trns

1/n

DC 001

6 Prompt 1

845

925

start trns

32/(a32)

PC 031

7 Prompt 2

846

926

start trns

32/(a32)

PC 032

8 Prompt 3

847

927

start trns

32/(a32)

PC 033

9 Prompt 4

848

928

start trns

32/(a32)

PC 034

10 Prompt 5

849

929

start trns

32/(a32)

PC 035

11 Data item 1

850

930

start trns

4/nnnnnnnn

entry for PC 031

12 Data item 2

851

931

start trns

4/nnnnnnnn

entry for PC 032

13 Data item 3

852

932

start trns

4/nnnnnnnn

entry for PC 033

14 Data item 4

853

933

start trns

4/nnnnnnnn

entry for PC 034

15 Data item 5

854

934

start trns

4/nnnnnnnn

entry for PC 035

16 Start date

855

935

start trns

PC 038, 039

17 End date

856

936

end trns

PC 038, 039

18 Gross

857

937

end trns

4/nnnnnn

19 Std

858

938

end trns

4/nnnnnn

20 Temp

859

939

end trns

2/nnn.n

21 Pres

860

940

end trns

22 Dens *

861

941

end trns

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

Record Offset Program Code

Ticket Coordinates Program Code

Time Saved

# bytes/format

23 Start gross

862

942

start trns

4 * # of meters/ nnnnnnnnn

24 Start std

863

943

start trns

4 * # of meters/ nnnnnnnnn

25 End gross

864

944

end trns

4 * # of meters/ nnnnnnnnn

26 End std

865

945

end trns

4 * # of meters/ nnnnnnnnn

27 Alarm bit map

866

946

end trns

10/(a20)

28 Prim alarm

867

947

end trns

10/(a40)

29 Temp alarm

868

948

end trns

10/(a40)

30 Add 1

869

949

end trns

4/nnnnnnn.nn

31 Add 2

870

950

end trns

4/nnnnnnn.nn

32 Add 3

871

951

end trns

4/nnnnnnn.nn

33 Add 4

872

952

end trns

4/nnnnnnn.nn

34 Add 5

873

953

end trns

4/nnnnnnn.nn

35 Add 6

874

954

end trns

4/nnnnnnn.nn

36 Op mode

875

955

authorize trns

1/n

37 Gross units

876

956

authorize trns

6/nnnnnn

38 Std units

877

957

authorize trns

6/nnnnnn

Reference

PC 025

* The component 1 backup density/gravity is stored/printed. The individual batch densities/gravities are not averaged.

3 - 144 _________________________________________________________________ Setup

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DanLoad 6000 (v6.00)

Batch Storage Codes (BSC) Table 3 - 5 BSC Number and Display

Record Offset Program Code

Ticket Coordinates Program Code

Time Saved

# bytes/format

Reference

1 Addr

880

960

start batch

2/nnn

DUART address

2 Ba seq #

881

961

start batch

2/nnnn

PC 043

3 Tr seq #

882

962

start batch

2/nnnn

PC 042

4 Temp

883

963

end batch

2/nnn.n

DC 132

5 Pres

884

964

end batch

4/nnnn.n

DC 134

6 Dens

885

965

end batch

4/nnnn.n

DC 133

7 Preset

886

966

start batch

4/nnnnnn

DC 102

8 Gross

887

967

end batch

4/nnnnnn

DC 002

9 Std

888

968

end batch

4/nnnnnn

DC 003

10 Comp gross

889

969

end batch

4 * # of comp/ nnnnnn

DC 072, 078, 084, 090

11 Comp std

890

970

end batch

4 * # of comp/ nnnnnn

DC 073, 079, 085, 091

12 Comp temp

891

971

end batch

2 * # of comp/ nnn.n

DC 075, 081, 087, 093

13 Comp dens

892

972

end batch

4 * # of comp/ n.nnnn

DC 107, 109, 111, 113

14 Comp pres

893

973

end batch

4 * # of comp/ nnnn.n

DC 108, 110, 112, 114

15 Comp %

894

974

end batch

2 * # of comp/ nnn.n

DC 122, 123, 124, 125

16 Add 1

895

975

end batch

4/nnnnnnn.nn

DC 115

17 Add 2

896

976

end batch

4/nnnnnnn.nn

DC 116

18 Add 3

897

977

end batch

4/nnnnnnn.nn

DC 177

19 Add 4

898

978

end batch

4/nnnnnnn.nn

DC 118

20 Add 5

899

979

end batch

4/nnnnnnn.nn

DC 119

21 Add 6

900

980

end batch

4/nnnnnnn.nn

DC 120

22 Op mode

901

981

authorize trns

1/n

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. Normal Transaction Sequence Step

State

Action

Authorize transaction [authorize trns]

Select recipe (single recipe setup defaults to recipe # 1) Select additives (if defined)

Start transaction [start trns]

Enter preset quantity for first batch to load (go to Step 4)

Authorize batch [authorize batch]

Enter preset quantity to load (same as Step 2 for first batch load)

Start batch [start batch]

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

Batch in progress

Loading is in progress

End batch [end batch]

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]

End transaction [end trns]

Press STOP/PRINT push-button with no load in progress

3 - 146 _________________________________________________________________ Setup

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DanLoad 6000 (v6.00)

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.

Com mon Storage Codes Batch Storage Code

Transaction Storage Code

Reference

1 Addr

DUART address

3 Tr seq #

2 Tr seq #

PC 042

22 Op mode

36 Op mode

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 (BSC) Relations Batch Storage Code

7 Source Batch Storage Code

4 Temp

Average of BSC 12 Comp temp for all defined com ponents in the batch.

5 Pres

Average of BSC 14 Comp pres for all defined com ponents in the batch.

6 Dens

Average of BSC 13 Comp den for all defined com ponents in the batch.

8 Gross

Sum of BSC 10 Comp gross for all defined com ponents in the batch.

9 Std

Sum of BSC 11 Comp std for all defined com ponents in the batch.

3 - 148 _________________________________________________________________ Setup

_________________________________________________________ 3.11.5

DanLoad 6000 (v6.00)

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

Program code 031 <prompt #1> text for which the operator entered response is 11 Data item 1 during transaction setup.

6 Prompt 2

Program code 032 <prompt #2> text for which the operator entered response is 12 Data item 2 during transaction setup.

7 Prompt 3

Program code 033 <prompt #3> text for which the operator entered response is 13 Data item 3 during transaction setup.

8 Prompt 4

Program code 034 <prompt #4> text for which the operator entered response is 14 Data item 4 during transaction setup.

9 Prompt 5

Program code 035 <prom pt #5> text for which the operator entered response is 15 Data item 5 during transaction setup.

18 Gross

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.)

19 Std

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.)

20 Temp

Average of BSC 4 Temp for all batches in the transaction.

21 Pres

Average of BSC 5 Pres for all batches in the transaction

22 Dens

Program code 454 Component 1 backup density/gravity. The individual densities/gravities are not averaged.

30 Add 1

Sum of BSC 16 Add 1 for all batches in the transaction

31 Add 2

Sum of BSC 17 Add 2 for all batches in the transaction

32 Add 3

Sum of BSC 18 Add 3 for all batches in the transaction

33 Add 4

Sum of BSC 19 Add 4 for all batches in the transaction

34 Add 5

Sum of BSC 20 Add 5 for all batches in the transaction

35 Add 6

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.

Batch Quantity Totals Component1

Component2

Component3

Component4

10 Comp gross

BSC 8 Gross is the sum of all defined BSC 10 Comp gross quantities in the batch.

11 Comp std

BSC 9 Std is the sum of all defined BSC 11 Comp standard quantities in the batch. Transaction Quantity Totals M eter3 (PC-067)

M eter2 (PC-070)

M eter4 PC-073)

M eter1 (PC-076)

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

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.

3 - 150 _________________________________________________________________ Setup

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DanLoad 6000 (v6.00)

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.

3 - 152 _________________________________________________________________ Setup

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DanLoad 6000 (v6.00)

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

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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

hex digits

Description ten 8-bit bytes (two hexadecimal digits per byte)

00000000000000000000 <through 9 > ffffffffffffffffffff

twenty 4-bit hexadecimal digits

0 <through 9 > f

each 4-bit digit (nybble)

the bit weight (hexadecimal) for each 4-bit nybble

3 - 156 _________________________________________________________________ Setup

_________________________________________________________

BitMap Character / Printed Character (1 of 20)

Bit Weight 8

DanLoad 6000 (v6.00)

Bit Weight Translation

Bit Weight 4

Bit Weight 2

Bit Weight 1

0 1

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:

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 Character Position

Bit W eigh t

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

Alarm

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.

Setup _________________________________________________________________ 3 - 159

DanLoad 6000 (v6.00) __________________________________________________________

Alarm BitM ap for Positions: 00000000hhhhhh000000 Character Position

Bit W eigh t

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

Alarm

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.

3 - 160 _________________________________________________________________ Setup

_________________________________________________________

DanLoad 6000 (v6.00)

Alarm BitM ap for Positions: 0000hhhh000000000000 Character Position

Bit W eigh t

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

Character positions: hhhh0000000000000000 not used in software version 3.0

17 to 20

Alarm

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

Transaction Record / Ticket Worksheet Unit: _______ Date: _______ Transaction Storage Code

Ticket (PC 920 to 955) Row

Column

PgmCode Row/Col

Record (PC 840 to 875) Length (bytes * #)

Offset 1

PgmCode Offset

Batch Record / Ticket Worksheet Unit: _______ Date: _______ Batch Storage Code

Ticket (PC 960 to 982) Row

Column

PgmCode Row/Col

Record (PC 880 to 902) Length (bytes * #)

Offset 1

PgmCode Offset

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.

Set contrast/backlighting SELECT display Primary 8/9 adjust contrast level n ALT+8/ALT+9 adjust backlight level

Press ALT+CLEAR to exit 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

_________________________________________________________ 3.15

DanLoad 6000 (v6.00)

CALMON - Turbine Meter Calibration Monitoring for the DanLoad 6000 Electronic Preset 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.

"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.

Alarm Flags Bit #

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.

Setup _________________________________________________________________ 3 - 173

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

Probable Causes

Calibration sample could not be acquired.

Unstable or pulsating flow. Worn or dry bearings. Blade count indeterminate. Debris in the liquid line.

Monitoring sample could not be acquired.

Unstable or pulsating flow. Worn or dry bearings. Debris in the liquid line.

Calibration failure.

Bent or broken blade. Worn or dry bearing.

Calibration checksum invalid.

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

Characteristic Values Affected

Bent or broken blades.

Total characteristic deviations, Maximum characteristic deviation, Mean blade deviation.

Machine inaccuracies of blades or blade angles.

Mean blade deviation

Unstable flow

Frequency instability.

Debris in liquid line, possibly trapped upstream.

Frequency instability, Sample instability.

Worn or dry bearings or pulsating flow.

Sample instability.

3 - 174 _________________________________________________________________ Setup

_________________________________________________________ 3.16

DanLoad 6000 (v6.00)

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.

Setup _________________________________________________________________ 3 - 175

DanLoad 6000 (v6.00) __________________________________________________________

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3 - 176 _________________________________________________________________ Setup

Section 4 Operation

Operator Interface Batch Delivery Additive Injection Data Logging Alarm Analysis Diagnostics

__________________________________________________________ DanLoad 6000 (v6.00) 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

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.

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.

4-2

______________________________________________________________ Operation

__________________________________________________________ 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

AUTO/MANUAL (yellow) OFF

Function

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.) 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

ALARM STATUS (red) ON 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).

A primary alarm is active (see Section 4.5 for information on alarm action). All alarms are inactive (normal state).

FLASHING

4-4

A secondary alarm is active (see Section 4.5 for information on alarm action).

______________________________________________________________ Operation

__________________________________________________________ DanLoad 6000 (v6.00) 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.

4-6

______________________________________________________________ Operation

__________________________________________________________ DanLoad 6000 (v6.00)

Key

Function

0 thru 9

numeric digits for data entry

ENTER

accept the manually entered value and continue

CLEAR

reject the manually entered value and continue

SELECT

toggle the Off / On option for each defined additive

scroll down, move the select box to the next item in the Recipes Selection Display or the Additive Selection Display

scroll up, move the select box to the previous item in the Recipes Selection Display or the Additive Selection Display

START

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

access to the Program Mode for modification of non-restricted program codes and system data

W&M

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.

4-8

______________________________________________________________ Operation

__________________________________________________________ DanLoad 6000 (v6.00) 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 Regular Gasoline Premium Gasoline Diesel Kerosene

hh:mm

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.

4 - 10 ______________________________________________________________ Operation

__________________________________________________________ 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.

Premium Gasoline Additive #1 Additive #2 Additive #3

mm/dd/yy

hh:mm

Off Off Off

Use arrow keys and SELECT 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.

Premium Gasoline

Loaded

mm/dd/yy hh:mm

Preset Remaining Transaction total Enter preset volume

0% +)))),

0 Gal 0 Gal 0 Gal

* * * * * * * * .))))-

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.

4 - 12 ______________________________________________________________ Operation

__________________________________________________________ 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.

Operation _______________________________________________________________ 4 - 13

DanLoad 6000 (v6.00) __________________________________________________________ #

4.2.1

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.

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.

4 - 14 ______________________________________________________________ Operation

__________________________________________________________ DanLoad 6000 (v6.00) 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.

4 - 16 ______________________________________________________________ Operation

__________________________________________________________ DanLoad 6000 (v6.00) #

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.

Operation _______________________________________________________________ 4 - 17

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.

4 - 18 ______________________________________________________________ Operation

__________________________________________________________ DanLoad 6000 (v6.00) 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 696 697 698 699 700 701 702 703 704 705 706 707 708 709 710

Log Function 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

Additive #1 Additive #2 Additive #3 Additive #4 Additive #5 Additive #6

XXX <- Additive units per program code 44. 9999999.99 9999999.99 9999999.99 9999999.99 9999999.99 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

Transaction A sequential numeric value, generated internally for identification of each transaction.

Side

The loading island side where the delivery was made.

Recipe ##

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

The unit address obtained from the DIP switch settings on the optional DUART board.

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

The preset quantity obtained from the batch data entry.

Gross

The accumulated gross quantity for the composite batch delivery.

Std

The accumulated standard quantity for the composite batch delivery.

Started

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:

Additive #

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.

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>

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 Unit nnn

mm/dd/yy mm/dd/yy

hh:mm:ss -- User aaaaaaaaaaaaaaaa entered program mode 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>

Date and time of the event.

User

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 Unit nnn

mm/dd/yy mm/dd/yy

hh:mm:ss -- Weights and measures switch opened 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>

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

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>

Date and time of the event.

User

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 XXXXXXXXXXXXXXXX XXXXXXXXXXXXXXXX XXXXXXXXXXXXXXXX

999999999 999999999 999999999 999999999

XXXXXXXXXXXXXXXX XXXXXXXXXXXXXXXX XXXXXXXXXXXXXXXX XXXXXXXXXXXXXXXX XXXXXXXXXXXXXXXX XXXXXXXXXXXXXXXX XXXXXXXXXXXXXXXX XXXXXXXXXXXXXXXX XXXXXXXXXXXXXXXX XXXXXXXXXXXXXXXX XXXXXXXXXXXXXXXX XXXXXXXXXXXXXXXX XXXXXXXXXXXXXXXX XXXXXXXXXXXXXXXX XXXXXXXXXXXXXXXX XXXXXXXXXXXXXXXX XXXXXXXXXXXXXXXX XXXXXXXXXXXXXXXX XXXXXXXXXXXXXXXX XXXXXXXXXXXXXXXX XXXXXXXXXXXXXXXX XXXXXXXXXXXXXXXX XXXXXXXXXXXXXXXX XXXXXXXXXXXXXXXX XXXXXXXXXXXXXXXX XXXXXXXXXXXXXXXX XXXXXXXXXXXXXXXX XXXXXXXXXXXXXXXX XXXXXXXXXXXXXXXX XXXXXXXXXXXXXXXX

999999999 999999999 <- Configured recipe ID and gross and std totalizers. 999999999 999999999 999999999 999999999 999999999 999999999 999999999 999999999 999999999 999999999 999999999 999999999 999999999 999999999 999999999 999999999 999999999 999999999 999999999 999999999 999999999 999999999 999999999 999999999 999999999 999999999 999999999 999999999 999999999 999999999 999999999 999999999 999999999 999999999 999999999 999999999 999999999 999999999 999999999 999999999 999999999 999999999 999999999 999999999 999999999 999999999 999999999 999999999 999999999 999999999 999999999 999999999 999999999 999999999 999999999 999999999 999999999 999999999 <- Depending on configured # recipes (max. 30). XXX <- Configured additive units mnemonic. 99999.9999 <- Language-dependent text and totalizer (format depends on additive units). 99999.9999 99999.9999 99999.9999 99999.9999 99999.9999 <- Depending on configured # additives (max. 6).

Additive #1 Additive #2 Additive #3 Additive #4 Additive #5 Additive #6

999999999 <- Configured component ID and gross and std totalizers. 999999999 999999999 999999999 <- Depending on configured # components (max. 4).

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 XXXXXXXXXXXXXXXX XXXXXXXXXXXXXXXX XXXXXXXXXXXXXXXX

999999999 999999999 999999999 999999999

999999999 <- Configured component ID and gross and std totalizers. 999999999 999999999 999999999 <- Depending on configured # components (max. 4).

999999999 999999999 <- Configured recipe ID and gross and std totalizers. 999999999 999999999 999999999 999999999 999999999 999999999 999999999 999999999 999999999 999999999 999999999 999999999 999999999 999999999 999999999 999999999 999999999 999999999 999999999 999999999 999999999 999999999 999999999 999999999 999999999 999999999 999999999 999999999 999999999 999999999 999999999 999999999 999999999 999999999 999999999 999999999 999999999 999999999 999999999 999999999 999999999 999999999 999999999 999999999 999999999 999999999 999999999 999999999 999999999 999999999 999999999 999999999 999999999 999999999 999999999 999999999 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 #

Default

Range

221 Low flow alarm action

Primary

Off Info Secondary Primary

222 Minimum flow rate

100

0 to 99999

223 Low flow time (secs)

5 to 999

Notes: #

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 #

Default

Range

224 High flow alarm action

Primary

Off Info Primary

225 Maximum flow rate

660

0 to 99999

226 High flow time (secs)

5 to 999

Notes: #

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 #

Default

Range

--- Overrun limit alarm action

Primary

<none>

227 Overrun limit qty

2.0

0.0 to 99.9

Notes: #

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 #

Default

Range

228 Underflow alarm action

Off

Off Primary

229 Underflow limit qty

5.0

0.0 to 99.9

Notes: #

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 #

Default

Range

230 No flow time-out alarm action

Primary

Off Info Secondary Primary

231 No flow time-out (secs)

1 to 99

Notes: #

In the alarm message, # is the actual flow meter number (1, 2, 3, 4).

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 #

Default

Range

--- Unauthorized flow limit alarm action

Primary

<none>

232 Unauthorized flow limit qty

0.0 to 99.9

Notes: #

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 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 #

Default

Range

--- Pulse security alarm action

Primary

<none>

233 Error limit (levels B and C)

0 to 255

234 Reset count (pulses)

10000

0 to 65535

Notes: #

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

Default

Range

235 Data logging alarm action

Info

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

Default

Range

236 Time-out ch. A (s)

0 to 300

237 Time-out ch. B (s)

0 to 300

Note: #

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 #

Default

Range

238 Temperature failure alarm action

Primary

Off Info Primary

239 Minimum temperature

-40.0

-999.9 to 999.9

240 Maximum temperature

110.0

-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 #

Default

Range

241 Density fail alarm action

Primary

Info Primary

242 Minimum density/gravity

9.9999

-9.9999 to 9.9999

243 Maximum density/gravity

9.9999

-9.9999 to 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.

Pressure failure meter #

Default

Range

--- Pressure failure alarm action

Primary

<none>

244 Minimum pressure

0.00

0.0 to 9999.99

245 Maximum pressure

0.00

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 density or temperature input to the CPL option is out of range, a pinch back 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

Default

Range

--- Additive error alarm action

Primary

<none>

246 Additive error limit

1 to 99

247 Additive feedback count

0 to 9999

271 Unauthorized additive flow volume

0.0000

0.0000 to 99999.9999

272 Prod/add -%

0 to 99

273

0 to 99

1 to 99

Prod/add +%

278 Additive per 1000 error limit Notes:

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.

Program code 247 Additive feedback count is 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 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”

Multiple additives authorized in multi-stream injection mode. Feedback input count error for “Mech” or “Handshake” injection method (program codes 246 and 247). “T” Ratio output timer expired for “Handshake” injection method (program code 247). “U” Unauthorized additive flow for “Meter” and “Control” injection methods (program code 271). “L” Low additive (or no additive) based on configured additive per 1000 (program codes 272 and 278). “H” 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

Default

Range

--- Block valve close fail alarm action

Primary

<none>

248 Block valve time (s)

0 to 99

Notes: #

In the alarm message, X is the actual component number (1, 2, 3, 4).

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

Default

Range

249 Circuit 1 alarm action

Secondary

Off Info Secondary Primary

250 #1 Ground detector open

7 message

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

Default

Range

251 Circuit 2 alarm action

Secondary

Off Info Secondary Primary

252 #2 Overspill detector open

7 message

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

Default

Range

253 Circuit 3 alarm action

Secondary

Off Info Secondary Primary

254 #3 Permissive power failure

7 message

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

Default

Range

255 Circuit 4 alarm action

Secondary

Off Info Secondary Primary

256 #4 Additive injection failure

7 message

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

Default

Range

257 Circuit 5 alarm action

Secondary

Off Info Secondary Primary

258 #5 Arm down side 1

7 message

1 to 32 characters

265 Circuit 5 type

0 to 2

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

Default

Range

259 Circuit 6 alarm action

Secondary

Off Info Secondary Primary

260 #6 Arm down side 2

7 message

1 to 32 characters

266 Circuit 6 type

0 to 2

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

Default

Range

261 Circuit 7 alarm action

Secondary

Off Info Secondary Primary

262 #7 Walkway down side 1

7 message

Up to 32 characters

267 Circuit 7 type

0 to 2

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

Default

Range

263 Circuit 8 alarm action

Secondary

Off Info Secondary Primary

264 #8 Walkway down side 2

7 message

Up to 32 characters

268 Circuit 8 type

0 to 2

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.

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

Default

Range

274 Storage alarm action

Off

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

Default

Range

275 Power failure alarm action

Off

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

Default

Range

276 Ramp down alarm action

Primary

Off Primary

277 Ramp down time (secs)

0 to 9999

Notes: #

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

Default

Range

755 Calib fail alarm action

Primary

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

Default

Range

756 FPO

0-2

757 Number of blades

0-50

Notes: 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

Default

Range

--- Display failure alarm action

Primary

<none>

Notes: #

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

Default

Range

--- Maximum number of batches exceeded alarm action

Primary

<none>

Notes: #

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

Default

Range

--- Unauthorized swing arm configuration alarm action

Primary

<none>

Notes: #

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.

Diagnostics Menu Firmware versions RAM tests Keypad Display Inputs/Outputs DUART

Pg 1 of 2

More 9

Diagnostics Menu ARCNET Crash analysis Show memory Print configuration Exit (ALT+CLEAR)

Pg 2 of 2

More 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 Meter input RTD input 4-20 mA input Discrete input Discrete output

__ #pulses = nnnnn __ A/D value = hhhh __ A/D value = hhhh __ state = n __ state = n

Press ALT+CLEAR to exit 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

RX2

TX+ 3

Ch-B (RS-232) TX4

RX 5

CTS 6

TX 7

COM 10

.))))))))3)))))))))* .)))))))))))))))))))-

Loopback Connector Pinout (Reference Drawing CE-12693) baud rates

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.

data formats

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 001 Ch. A Local loopback 256/256 External loopback 203/256 baud rates PPPPPPPF data formats PFP interrupts PPP Press ALT+CLEAR to exit

Ch. B 256/256 52/356 FFFFFFFF PPF P--

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.

ARCNET Address = nnn Diagnostic Status 0xhh Configuration 0xhh

Press ALT+CLEAR to exit 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 Int mask/int mask 1 WSR/tsk pg Error code/task adr

4793/2085 004c/0063 0000/0002 0000/e742

7e9d/821e 0043/00c9 000f/0005 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

Error code/task adr The hexadecimal identifier of the critical error code / the address of the active task.

Print configuration

The Window Select Register / multi-task task number.

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

Section 5 Flow Meter Proving

General Tank Prover Method Master Meter Method

__________________________________________________________ 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

Definition

Gross volume

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 CTLM (correction factor for the effect of temperature on the liquid in the meter) times CPLM (correction factor for the effect of 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

Definition

K-factor

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.

Master meter

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.

Meter factor

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

Definition

Pipe prover

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 Component p meter factor 2 Component p meter factor 3 Component p meter factor 4

Lowest defined flow rate. Next higher flow rate if more than one flow rate is defined. Next higher flow rate if more than two flow rates are defined. 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

= 100 = 0 = 0 = 0 1XXX

Recipe 11: 541 Prove Diesel 542 Component 1 % 543 Component 2 % 544 Component 3 % 545 Component 4 % 546 Sequence to load

= 0 = 100 = 0 = 0 2XXX

(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

103 Mtr 1 grs load 104 Mtr 2 grs load 105 Mtr 3 grs load 106 Mtr 4 grs load

689 ____ ____ ____

Description 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 CPLx) which is rarely used at a load rack installation. To ignore CPLx, enter 1.0000 in the equation. (Note: The handling of CPLx 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 CTLx) and compensation for the effect of pressure on the liquid (factor CPLx) for both the master 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, CTLx and CPLx are ignored and entered as 1.0000 in the equations for both the master meter and the rack meter. (Note: The handling of CTLx and CPLx must be determined 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

Master Meter

Rack Meter

indicated volume

equal to: indicated volume which is equal to: gross volume

equal to: indicated volume which is equal to: registered volume

gross volume

equal to: gross volume which is equal to: indicated volume

indicated volume x meter factor

indicated volume x meter factor which is obtained from: (Mtr m grs load xxxx.xx)

gross volume at standard temperature

gross volume x CTSP x CTLP

gross volume x CTLP

gross volume x CTLM

gross standard volume

gross volume x CTSP x CTLP

gross volume at standard temperature x CPLP

gross volume at standard temperature x CPLM

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

CPSP (Effect of pressure on the steel of the vessel.)

CPLP (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 (CPLx) is usually ignored and considered to be equal to 1.0000 for rack operations.

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.

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 percent error

rack meter volume error --------------------------------rack meter corrected gross volume

where: rack meter percent error

The percentage of error in the corrected volume delivery.

rack meter volume error

The difference in the volume delivered to or measured by the prover and the rack meter corrected gross volume (obtained from calculation 1).

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. adjustment

prover corrected gross volume --------------------------------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

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.

adjustment

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

Value

corrected delivery volume

1000.00 gallons

Mtr m grs load

1000.00 gallons

RACK METER VOLUME ERROR

0 gallons (1000.00 - 1000.00)

RACK METER PERCENT ERROR

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

Value

corrected delivery volume

1010.00 gallons

Mtr m grs load

1000.00 gallons

RACK METER VOLUME ERROR

10 gallons (1010.00 - 1000.00)

RACK METER PERCENT ERROR

0.01 (1 percent over delivery) (10 / 1000.00)

Flow Meter Proving ______________________________________________________ 5 - 15

DanLoad 6000 (v6.00) __________________________________________________________ Parameter

Value

ADJUSTMENT

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

Value

corrected delivery volume

990.00 gallons

Mtr m grs load

1000.00 gallons

RACK METER VOLUME ERROR

-10 gallons (990.00 - 1000.00)

RACK METER PERCENT ERROR

-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 CTSP. 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 CTLP and CTLM.

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

Description

Station Date / Time Meter Tag Meter S/N Meter Mfg Meter Model Meter Size Product API Gravity @ 60 oF From Tank No. To Prover Tank No. Initial Totalizer Reading

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.

3 Tank Temp (Avg) oF

The average temperature of the product in the prover tank, API recommends average of temperature at top, middle, and bottom.

4 CTSP

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.

5 CTLP

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 CCFP

Combined correction factor for the prover tank, obtained by multiplying CTSP times CTLP.

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 CCFP (line 6). 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 CTLM

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: CTLM 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.)

13 Rack Meter Pressure

The pressure of the product close to the upstream or downstream side of the flow meter (usually upstream).

14 CPLM

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 CCFM

Combined correction factor for the flow meter, obtained from multiplying CTLM times CPLM.

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 CCFM. 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

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.)

21 New 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 - 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 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

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.

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

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

Description

Station Date / Time Product API Gravity @ 60 oF From Tank No. To Tank No. Initial Totalizer Reading

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 CTLP. 6 CTLP

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 CPLP. 8 CPLP

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 CCFP

Combined correction factor for the master meter, obtained by multiplying CTLP times CPLP 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 CCFP (line 10). Rack meter Data 12 Mtr m grs load (Final)

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 CTLM

17 Rack Meter Pressure

The pressure of the product close to the upstream or downstream side of the flow meter (usually upstream).

18 CPLM

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 CCFM

Combined correction factor for the rack meter, obtained from multiplying CTLM times CPLM.

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 CCFM. 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

Default Attribute

Options / Values

Default Value

Value to Use During Meter Proof

temporarily set to 1

METER FACTORS 169

Number of factors/component

W&M

1 to 4

170

Meter factor method

W&M

Fixed Linear

Fixed

COMPONENT 1 FACTORS 171

Nominal K-factor

W&M

0.5 to 2000.0

172

Master meter factor

W&M

0.5000 to 2.0000

173

Stop rate

W&M

0 to 99999

23.0

round meter nameplate K-factor to nearest tenth program code 171 / nameplate K-factor

120

set to inline batch end volume

200

set to desired low flow rate

COMPONENT 1 FACTOR 1 174

Comp 1 flow rate 1

W&M

175

Comp 1 meter factor 1

W&M

0 to 99999

see text

COMPONENT 1 FACTOR 2 176

Comp 1 flow rate 2

W&M

177

Comp 1 meter factor 2

W&M

0 to 99999

600

set to desired fall back or high flow rate see text

COMPONENT 1 FACTOR 3 178

Comp 1 flow rate 3

W&M

179

Comp 1 meter factor 3

W&M

0 to 99999

set to desired fall back or high flow rate see text

COMPONENT 1 FACTOR 4 180

Comp 1 flow rate 4

W&M

181

Comp 1 meter factor 4

W&M

0 to 99999

set to desired fall back or high flow rate see text

COMPONENT 2 FACTORS 182

Nominal K-factor

W&M

0.5 to 200.0

round meter nameplate K-factor to nearest tenth

183

Master meter factor

W&M

0.5000 to 2.0000

program code 182 / nameplate K-factor

184

Stop rate

W&M

0 to 99999 Yes

120

set to inline batch end volume

COMPONENT 2 FACTOR 1 185

Comp 2 flow rate 1

W&M

186

Comp 2 meter factor 1

W&M

Code

Parameter

Attribute

0 to 99999

set to desired fall back or high flow rate see text

Options

Default

Meter Proof

COMPONENT 2 FACTOR 2

5 - 36 ______________________________________________________ Flow Meter Proving

__________________________________________________________ DanLoad 6000 (v6.00)

Code

Parameter

Attribute

Options

187

Comp 2 flow rate 2

W&M

0 to 99999

188

Comp 2 meter factor 2

W&M

Default

Meter Proof set to desired fall back or high flow rate see text

COMPONENT 2 FACTOR 3 189

Comp 2 flow rate 3

W&M

190

Comp 2 meter factor 3

W&M

0 to 99999

set to desired fall back or high flow rate see text

COMPONENT 2 FACTOR 4 191

Comp 2 flow rate 4

W&M

192

Comp 2 meter factor 4

W&M

0 to 99999

set to desired fall back or high flow rate see text

COMPONENT 3 FACTORS 193

Nominal K-factor

W&M

0.5 to 200.0

round meter nameplate K-factor to nearest tenth

194

Master meter factor

W&M

0.5000 to 2.0000

program code 193 / nameplate K-factor

195

Stop rate

W&M

0 to 99999

120

set to inline batch end volume

COMPONENT 3 FACTOR 1 196

Comp 3 flow rate 1

W&M

197

Comp 3 meter factor 1

W&M

0 to 99999

set to desired fall back or high flow rate see text

COMPONENT 3 FACTOR 2 198

Comp 3 flow rate 2

W&M

199

Comp 3 meter factor 2

W&M

0 to 99999

set to desired fall back or high flow rate see text

COMPONENT 3 FACTOR 3 200

Comp 3 flow rate 3

W&M

201

Comp 3 meter factor 3

W&M

0 to 99999

set to desired fall back or high flow rate see text

COMPONENT 3 FACTOR 4 202

Comp 3 flow rate 4

W&M

203

Comp 3 meter factor 4

W&M

0 to 99999

set to desired fall back or high flow rate see text

Flow Meter Proving ______________________________________________________ 5 - 37

DanLoad 6000 (v6.00) __________________________________________________________

Code

Parameter

Attribute

Options

Default

Meter Proof

COMPONENT 4 FACTORS 204

Nominal K-factor

W&M

0.5 to 200.0

round meter nameplate K-factor to nearest tenth

205

Master meter factor

W&M

0.5000 to 2.0000

program code 204 / nameplate K-factor

206

Stop rate

W&M

0 to 99999

120

COMPONENT 4 FACTOR 1 207

Comp 4 flow rate 1

W&M

208

Comp 4 meter factor 1

W&M

0 to 99999

set to desired high flow rate see text

COMPONENT 4 FACTOR 2 209

Comp 4 flow rate 2

W&M

210

Comp 4 meter factor 2

W&M

0 to 99999

set to desired high flow rate see text

COMPONENT 4 FACTOR 3 211

Comp 4 flow rate 3

W&M

212

Comp 4 meter factor 3

W&M

0 to 99999

set to desired high flow rate see text

COMPONENT 4 FACTOR 4 213

Comp 4 flow rate 4

W&M

214

Comp 4 meter factor 4

W&M

0 to 99999

set to desired high flow rate see text

5 - 38 ______________________________________________________ Flow Meter Proving

METER PROVING REPORT FOR TANK PROVER METHOD

Report:

S T AT IO N

M E T E R T AG

M E T E R S /N

D AT E

T IM E

M ETER M FG

M ETER M O DEL

M E T E R S IZ E

PRODUCT

A P I G R A V IT Y @ 60O F

F R O M TAN K N O .

T O P R O V E R T AN K N O .

IN IT IAL T O T AL IZ E R R E AD IN G

P R O V E R T AN K V O L U M E D AT A

F L O W R A TE

D E L IV E R Y T O P R O V E R T AN K

P R O V E R T AN K T E M P E R A T U R E

(T AB L E A-1 / A-2)

(T AB L E 6)

TSP

TLP

RUN 1

RUN 2

RUN 3

RUN 4

RUN 1

RUN 2

RUN 3

RUN 4

(AV G ), D E G R E E S F

CCFP

C O M B IN E D C O R R E C T IO N FAC T O R

(L IN E 4 X L IN E 5) 7

C O R R E C TE D D E L IV E R Y V O LU M E

(L IN E 2 X L IN E 6)

R AC K M E TE R D ATA

[DA N LO AD 6000]

MT R M G R S L O AD (F IN A L )

MT R M G R S L O AD (IN IT IA L )

R AC K M E T E R M E AS U R E D G R O S S V O LU M E

(L IN E 8 - L IN E 9) 11

R AC K M E T E R T E M P E R AT U R E , D E G R E E S F

R AC K M E T E R P R E S S U R E , PSIG

C O M B IN E D C O R R E C T IO N FAC T O R

TLM

PLM

(T AB L E 6)

(C H A P 11.2) CCFM

(L IN E 12 X L IN E 14) 16

R AC K M E T E R C O R R E C TE D G R O S S V O LU M E

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)

ADJUSTM ENT

R A C K M E T E R C U R R E N T M E T E R -F AC T O R

N E W M E TE R F AC T O R

(L IN E 10 X L IN E 15)

(L IN E 7 / L IN E 16)

(L IN E 19 X L IN E 20)

S IG N AT U R E

D AT E

E N G IN E E R

W IT N E S S

R E M AR K S

Figure 5 - 2 (Typical)

R E P R E S E N T IN G

METER PROVING REPORT FOR MASTER METER METHOD S T AT IO N :

F R O M TAN K N O :

P RO D U CT:

A P I G R A V IT Y @ 60 F:

T O T AN K N O :

MFG:

MODEL:

S E R IAL N O :

M AS T E R M E TE R V O L U M E D AT A

F L O W R A TE

M AS T E R M E TE R F IN AL R E AD IN G

M AS T E R M E TE R IN IT IAL R E AD IN G

M AS T E R M E T E R IN D IC AT E D V O LU M E

D A TE :

T IM E :

IN IT IAL T O T AL IZ E R R E AD IN G :

M A S T E R M E T E R D A TA

Report:

S IZ E :

K-F AC T O R :

RUN 1

RUN 2

RUN 3

RUN 4

RUN 5

AV E R AG E

RUN 1

RUN 2

RUN 3

RUN 4

RUN 5

AV E R AG E

(L IN E 2 - L IN E 3) 5

M AS T E R M E TE R T E M P E R AT U R E , D E G R E E S F

M AS T E R M E TE R P R E S S U R E , PSIG

TLP

(T A B L E 6)

M A S T E R M E T E R M E T E R -F AC T O R

PLP

(C H A P 11.2)

C O M B IN E D C O R R E C T IO N FAC T O R

CCFP

(L IN E 6 X L IN E 8 X L IN E 9) 11

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 LU M E

(L IN E 4 X L IN E 10)

R AC K M E TE R V O LU M E D ATA

[DA N LO AD 6000]

MT R M G R S L O AD (F IN A L )

MT R M G R S L O AD (IN IT IA L )

R AC K M E T E R M E AS U R E D G R O S S V O LU M E

(L IN E 12 - L IN E 13) 15

R AC K M E T E R T E M P E R AT U R E , D E G R E E S F

R AC K M E T E R P R E S S U R E , PSIG

TLM

PLM

(T A B L E 6)

(C H A P 11.2)

C O M B IN E D C O R R E C T IO N FAC T O R

CCFM

(L IN E 16 X L IN E 18) 20

R AC K M E T E R C O R R E C TE D G R O S S V O LU M E

(L IN E 14 X L IN E 19) 21

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)

ADJUSTM ENT

R A C K M E T E R C U R R E N T M E T E R -F AC T O R

N E W R AC K M E T E R F AC T O R

(L IN E 11 / L IN E 20)

(L IN E 23 X L IN E 24)

S IG N AT U R E

D AT E

E N G IN E E R

W IT N E S S

R E M AR K S

Figure 5 - 3 (Typical)

R E P R E S E N T IN G

__________________________________________________________ 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

Master Meter Meter-Factor

174 Comp 1 flow rate 1

175 Comp 1 meter factor 1

176 Comp 1 flow rate 2

177 Comp 1 meter factor 2

178 Comp 1 flow rate 3

179 Comp 1 meter factor 3

180 Comp 1 flow rate 4

181 Comp 1 meter factor 4

182 Comp 2 flow rate 1

183 Comp 2 meter factor 1

184 Comp 2 flow rate 2

185 Comp 2 meter factor 2

186 Comp 2 flow rate 3

187 Comp 2 meter factor 3

188 Comp 2 flow rate 4

189 Comp 2 meter factor 4

190 Comp 3 flow rate 1

191 Comp 3 meter factor 1

192 Comp 3 flow rate 2

193 Comp 3 meter factor 2

194 Comp 3 flow rate 3

195 Comp 3 meter factor 3

196 Comp 3 flow rate 4

197 Comp 3 meter factor 4

198 Comp 4 flow rate 1

199 Comp 4 meter factor 1

200 Comp 4 flow rate 2

201 Comp 4 meter factor 2

202 Comp 4 flow rate 3

203 Comp 4 meter factor 3

204 Comp 4 flow rate 4

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

Section 6 Program Codes

Program Code Attributes Program Codes

________________________________________________________________________________________ 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).

ccc aaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaa

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.

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 codes are displayed in the following format when the DanLoad 6000 is operating in the setup option of Program Mode.

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

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: #

alpha-numeric string A message consisting of letter and number characters. Example: 066

Component #1

integer # Whole number without a fractional part or decimal separator. Example: 078

Maximum preset volume

selection A predefined option selected from a scrollable short list of options. Example:

3000 028

Component ID

Language

English

real number A number consisting of a whole part, decimal separator, and fractional part. Example: 130

Factor

Section 3 - Setup Contains information on the procedures used to enter data in the various types of data fields mentioned above.

1.0

Program Code Definitions ________________________________________________________________________

Section 6 - 2

________________________________________________________________________________________ DanLoad 6000 (v6.00) 6.1

Program Code Attributes

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:

Select different program code:

# #

# # #

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.

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.

Press the EXIT (ALT+CLEAR) key. Perform steps listed above under Access program code attributes as desired.

Program Code Definitions ________________________________________________________________________

Section 6 - 3

________________________________________________________________________________________ DanLoad 6000 (v6.00) 6.1

Program Code Attributes (continued)

Exit program code attribute modification mode:

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.

# #

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.

No Disable this attribute for this program code.

Yes Enable this attribute for this program code.

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.

Program Code Definitions ________________________________________________________________________

Section 6 - 4

________________________________________________________________________________________ DanLoad 6000 (v6.00) 6.1

Program Code Attributes (continued)

Data logging

Value changed

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.

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 39000-674)

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.

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

Alarm reset display

Reprint transaction

Reprint transaction display

Setup

Setup menu

Program code attributes

Program code attributes display

Set date and time

Set date and time display

Set contrast/backlighting

Set contrast/backlighting display

Diagnostics

Diagnostics menu

Reprint cutoff

Reprint end-of-day processing data

CALMON status

Calibration monitoring

Additive calibration

Additive meter calibration screen

EXIT (ALT+CLEAR)

| | Diagnostics Menu Firmware versions RAM tests Keypad Display Inputs/Outputs DUART ARCNET Crash analysis Show memory Print configuration Exit (ALT+CLEAR)

| | | | | | | | | | Setup Menu 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 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

Security parameters

Operation security

023 to 047

Unit parameters

Global parameters

048, 049 V

Valve parameters

Flow control valves

050 to 061

Meter parameters

Flow meters

065 to 077

Component parameters

Liquid components

078 to 111

Delivery parameters

Batch deliveries

112 to 127

Digital valve parameters

Digital flow control valves

128 to 134

Pulse per unit outputs

Volume pulses to external equipment

135 to 168

Additive delivery parameters Additive injection

169 to 219

Factors

Flow meter factors and flow rates

220 to 279

Alarms

Actions and limits

280 to 379

I/O parameters

Input / output signal assignments

380 to 399

Additive I/O parameters

Additive injection signal assignments

400 to 425

Component I/O parameters

Component block valve signal assignments

426 to 479

Temperature / pressure / density

Standard quantity calculation

480 to 661

Recipes

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

Data communications

Logging / terminal automation system

679 to 695

Dynamic data display

Operator data view (programmable)

696 to 710

Data logging

Reports to printer

711 to 799

Blending

Product blending control

800 to 817

Additive pumps/block valves

Additive pump and block valve control

818 to 833

LPG/pressure

LPG pressure control

834 to 902

Transaction storage

Allocate storage for transaction and batch loading data

920 to 982

Transaction ticket

Format control for user defined transaction tickets

983 to 991

Analog inputs

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

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.

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).

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)

Range <Default> OR Option (* = Default)

001 / 004 / 007 / 010 / 013 / 016 Passcode

0 to 999999999 <6000> (001 only)

002 / 005 / 008 / 011 / 014 / 017 User ID

1 to 16 characters <DanLoad 6000> (002 only)

003 / 006 / 009 / 012 / 015 / 018 Supervisor privilege

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

6000

002

User ID

DanLoad 6000

003

Supervisor privilege

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.

The corresponding user has supervisor privilege disabled and can access only the following menu options:

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.

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

Range <Default> OR Option (* = Default)

023 Side stream Blending

Yes "Side" stream blending enabled No "Side" Stream blending disabled *

024 Sequential proportional

Yes - “Side” stream sequential blending performed using in-line proportional blending logic No - "Side" Stream sequential blending performed using in-line non-proportional logic *

025 Operating mode

0 Auto (* for automation systems) 1 Manual (* for local control systems)

026 Unit type

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

027 Valve type

0 Std digital * 1 Std 2-stage 2 Stem sw.

028 Language

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

Range <Default> OR Option (* = Default)

029 Product units

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.

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:

023 Side stream blending #

Auto

This program code enables or disables the side stream blending. 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.

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.

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:

Off-rack Not used.

Seq. (auto) # Sequential blending is performed. One to four components are loaded sequentially, one at a time. The block valves are controlled automatically.

Dispenser A dispenser inherits most of the characteristics of an inline blender. However, the following differences from an in-line blender should be noted:

Seq. (manual) - The STOP key stops and ends a batch. 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

- 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.

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.

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.

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.

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.

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

# # # # # # # # # # # # # # # #

Spanish German Portuguese Dutch French Norwegian Slovak Polish Macedonian Italian Greek Malay Russian Croatian Vietnamese Slovenian

(See notes following list on message codes.)

(Data logging in English) (Data logging in English) (Data logging in English) (Data logging in English) (Data logging in English) (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

Bbl The product units are barrels.

Dek The product units are dekaliters.

L The product units are liters.

029 Product units

Gal The product units are U.S. gallons.

lbs The product units are pounds.

kgs The product units are kilograms.

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”.

See also: Gross and standard product unit mnemonics (program code 217 and 218).

Off Undetermined units. (Not recommended)

Program Code Definitions (023 to 047 Unit Parameters) ______________________________________________

Section 6 - 23

________________________________________________________________________________________ DanLoad 6000 (v6.00) 6.4

Unit Parameters (continued)

Function

Range <Default> OR Option (* = Default)

030 Number of data items

0 to 5 <0>

031 #1 Prompt for data item #1

32 characters <Enter data item #1>

032 #2 Prompt for data item #2

32 characters <Enter data item #2>

033 #3 Prompt for data item #3

32 characters <Enter data item #3>

034 #4 Prompt for data item #4

32 characters <Enter data item #4>

035 #5 Prompt for data item #5

32 characters <Enter data item #5>

036 Prompt time-out (s)

0 to 9999 <60>

037 Check display

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

032 #2 Prompt for data item #2

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.

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:

034 #4 Prompt for data item #4 031 #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:

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

037 Check display

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:

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.

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.

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

Range <Default> OR Option (* = Default)

038 Date format

0 mm/dd/yy * 1 dd/mm/yy 2 yy/mm/dd

039 Date separator

0 / (slash) * 1 . (dot) 2 - (stroke)

040 Decimal separator

0 . (dot) * 1 , (comma)

041 Display data rate

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

040 Decimal separator

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.

This program code selects the character used to separate the whole part and fractional part of a real number. #

<dot>

mm/dd/yy

<comma>

dd/mm/yy

yy/mm/dd

041 Display data rate

039 Date separator This program code selects the character used to separate the month, day, and year components of the date. #

<slash>

<dot>

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 #

0 to 9999 <9999>

043 Batch #

0 to 9999 <9999>

044 Additive units

0 cc * 1 in3 2 Gal 3 L

045 Round method

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 #

044 Additive units

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.

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.) #

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

0.0 to 99999.9999 liters Internal calculation: Vol(L) = Vol(cc) / 1000

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.

Program Code Definitions (023 to 047 Unit Parameters) ______________________________________________

Section 6 - 31

________________________________________________________________________________________ DanLoad 6000 (v6.00) 6.4

Unit Parameters (continued)

045 Round method

046 Density/gravity scale

This program code selects the method for rounding the displayed and printed meter and component quantities to whole numbers.

This program code defines the number of decimal places to use when displaying and printing density or gravity.

Trunc, i.e. truncate

Value Format

Discard accumulated fractions (tenths) of a quantity.

1 2 3 4

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.

Typical Use

xxxx.x density in kg/m3 xxx.xx API gravity xx.xxx x.xxxx density in g/cm3, relative density or specific 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

Range <Default> OR Option (* = Default)

048 Number of valves

1 to 4 <1>

049 Initial flow time (s)

0 to 9.999 < 0.200>

Valve Parameters select the configuration of the flow control valves.

048 Number of valves

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).

This program code sets the number of flow control valves in the system. A minimum of one flow control valve must be defined.

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)

Range <Default> OR Option (* = Default)

050 Number of meters

1 to 4 <1>

051 / 054 / 057 / 060 Meter ID

5 characters <M1>

052 / 055 / 058 / 061 Valve

1 to “number of valves” <depends on initial setup choices>

053/056/059/062 Side Stream Meter (Ethanol Meter)

0 to 4 < 0 > 0 No Side Stream meter

063 Midgrade Primary blend stream meter (Midgrade Gasoline 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.

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)

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.

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.

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)

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.

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

1 to 4 <1>

066 / 069 / 072 / 075 Component ID

16 characters <Component #1>

067 / 070 / 073 / 076 Meter

0 to number of meters

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.

067 / 070 / 073 / 076 Meter

065 Number of components

068 / 071 / 074 / 077 Mass adjustment

This program code sets the number of liquid components used in the system. A minimum of one component must be defined.

This program code sets the component’s “mass computation adjustment” factor (1) such that:

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.

Mass = Std volume x (Density - Buoyancy) x 1 066 / 069 / 072 / 075 Component ID Warning 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.

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

kg kg kg kg kg

L L L L L

kg/m 3 @T g/cm 3 @T 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

U.S. Gal @60°F

r.d. 60°F/60°F

8.337161 (rounded)

ton

L @T

g/cm 3 @T

0.001000 ** WARNING: DL6000 6000 WILL ROUND TO WHOLE TONS! **, e.g. 5000 L / 4 tons

ton

L @T

kg/m 3 @T

0.000001 ** WARNING: DL6000 6000 WILL ROUND TO WHOLE TONS! **

@T @T @15°C @60°F @60°F

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)

Range <Default> OR Option (* = Default)

078 Maximum preset qty

5 to 999999 <3000>

079 Minimum preset qty

0 to 999999 <50>

080 Preset/delivery type

0 Gross * 1 Std

081 Delivery display type

0 Gross * 1 Std

082 Stop key action

0 Low flow * 1 Immediate

083 Fall back qty

0 to 99999 <1000>

084 / 090 / 096 / 102 Low flow start qty

0 to 99999 <50>

085 / 091 / 097 / 103 Low flow restart qty

0 to 99999 <20>

086 / 092 / 098 / 104 Low flow stop qty

0 to 99999 <50>

087 / 093 / 099 / 105 Line pack delay (s)

0 to 99999 <2>

088 / 094 / 100 / 106 Pump stop delay (s)

0 to 999 <30>

089 / 095 / 101 / 107 Block valve delay (s)

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.

081 Delivery display type

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. #

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.

Gross Delivered quantity based on gross quantity calculation.

Std Delivered quantity based on standard quantity calculation, i.e. net volume or mass.

Program Code Definitions (188 to 111 Delivery Parameters) ___________________________________________ Section 6 - 44

________________________________________________________________________________________ DanLoad 6000 (v6.00) 6.8

Delivery Parameters (continued)

082 Stop key action

083 Fall back qty

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.)

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.

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.

Preset/delivery type: Gross

Preset/delivery type: Standard

Sequential Unit type

Recovery from fall back is by gross quantity

Recovery from fall back is by standard quantity

In-line Unit type

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) 087 / 093 / 099 / 105 Line pack delay (s)

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.

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

Range <Default> OR Option (* = Default)

108 Ramp clicks

0 to 999 <30>

109 Maintenance clicks

0 to 999 <30>

110 Additive pump stop (s)

0 to 9999 <10>

111 Primary component

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

111 Primary component

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.

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)

Range <Default> OR Option (* = Default)

112 / 116 / 120 / 124 Low flow % error

2 to 10 <5>

113 / 117 / 121 / 125 High flow % error

2 to 10 <2>

114 / 118 / 122 / 126 Maint click adjustment

0.000 to 0.500 <0.040>

115 / 119 / 123 / 127 Open method

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) #

Normal

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.

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.)

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 multicomponent blending systems. The purpose is to allow a component with low pumping pressure to start flowing before other components with higher pumping pressure.)

Program Code Definitions (112 to 127 Digital Valve Parameters) ______________________________________

Section 6 - 52

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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

0.1 to 10.0 <1.0>

131 / 134 Pulse width (ms)

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.

129 / 132 Control meters

128 Number of pulse per unit outputs

Flow through this meter is not used for determining the control quantity.

Use the gross quantity through this meter for determining the control quantity.

Use the standard quantity through this meter for determining the control quantity.

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.)

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.

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

=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)

Range <Default> OR Option (* = Default)

135 Number of additives

0 to 6 <0>

136 Selection method

0 External * 1 Prompt 2 Inputs 3 Recipe 4 Multi Rate

137 Inject Percentage

0 to 100 <50>

138 Clean line qty

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

4 characters <GGGG> (only G, S and X are valid)

140 / 145 / 150 / 155 / 160 / 165 Ratio qty

1 to 9999 <40>

141 / 146 / 151 / 156 / 161 / 166 Injection Method

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.

136 Selection method

135 Number of additives

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)

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.

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.

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 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.

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 #

Value

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

138 Clean line qty

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.

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.

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.

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

Example:

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).

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

Flow through this meter is not used for determining the control quantity.

Use the gross quantity through this meter for determining the control quantity.

Use the standard quantity through this meter for determining the control quantity.

SXGS

Program Code Definitions (135 to 168 Additive Delivery Parameters) ___________________________________ Section 6 - 63

________________________________________________________________________________________ DanLoad 6000 (v6.00) 6.11

Additive Delivery Parameters (continued) #

Mech

140 / 145 / 150 / 155 / 160 / 165 Ratio qty 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).

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 additive units are cm3. The other two injection methods ("Meter" 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:

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

143 / 148 / 153 / 158 / 163 /168 Additive per 1000

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 the volume per pulse in cm3. For the “Meter” and “Control” 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 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 0.00.

The default value is 0.0000. Conversions: 1)

Additive PPM = Additive per 1000 x 1000

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)

Range <Default> OR Option (* = Default)

169 Number of factors/component

1 to 4 <2>

170 Meter factor method

0 Fixed * 1 Linear

171 / 182 / 193 / 204 Nominal K-factor

0.5 to 2000.0 <23.0>

172 / 183 / 194 / 205 Master meter factor

0.5000 to 2.0000 <1.0000>

173 / 284 / 195 / 206 Stop rate

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 170 Meter factor method [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.

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

173 / 184 / 195 / 206 Stop rate

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.

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.

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.

Program Code Definitions (169 to 219 Meter Factor Parameters) _______________________________________ Section 6 - 71

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Factors (continued) PC # /Function (Four Components)

Range <Default> OR Option (* = Default)

174 / 185 / 196 / 207 Flow rate 1

0 to 99999 <200>

175 / 186 / 197 / 208 Meter factor 1

per PC 215 / PC 216 <1.0000>

176 / 187 / 198 / 209 Flow rate 2

0 to 99999 <600>

177 / 188 / 199 / 210 Meter factor 2

per PC 215 / PC 216 <1.0000>

178 / 189 / 200 / 211 Flow rate 3

0 to 99999 <0>

179 / 190 / 201 / 212 Meter factor 3

per PC 215 / PC 216 <1.0000>

180 / 191 / 202 / 213 Flow rate 4

0 to 99999 <0>

181 / 192 / 203 / 214 Meter factor 4

per PC 215 / PC 216 <1.0000>

215 Master MF %

0.00 to 99.99 <2.00>

216 Adjacent MF %

0.00 to 99.99 <0.25>

217 Gross units mnemonic

6 characters <Gal>

218 Std units mnemonic

6 characters <Gal>

219 Use restart qty

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

176 / 187 / 198 / 209 Flow rate 2

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.

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

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.

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

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.

179 / 190 / 201 / 212 Meter factor 3

181 / 192 / 203 / 214 Meter factor 4

This program code sets the meter factor that is used for the corresponding flow rate indicated in the previous parameter.

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 %

216 Adjustment 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).

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

219 Use restart qty

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”.

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: #

Start up each component by loading its low flow start quantity at its low flow rate.

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”.

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

Description

Reset

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).

Keypad in program Mode.

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).

Correct cause of alarm

Info

A message is displayed on the message line of the display panel for ten seconds.

Automatically reset after ten seconds have elapsed.

Off

Disable monitoring of this alarm.

N/A

Primary

Secondary

Alarm reset discrete input, program code 344 Primary alarm reset (if defined). Terminal automation system.

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.

Program Code Definitions (220 to 279 Alarm Parameters) ___________________________________________

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________________________________________________________________________________________ DanLoad 6000 (v6.00) 6.13

Alarms (continued)

PC # /Function

Range <Default> OR Option (* = Default)

220 Secondary alarm reset (s)

0 to 9999 <300>

221 Low flow alarm action

0 Off 1 Info 2 Secondary 3 Primary *

222 Minimum flow rate

0 to 99999 <100>

223 Low flow time (s)

5 to 999 <10>

224 High flow alarm action

0 Off 1 Info 3 Primary *

225 Maximum flow rate

0 to 99999 <660>

226 High flow time (s)

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.

220 Secondary alarm reset (s)

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.

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.

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

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) ___________________________________________

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________________________________________________________________________________________ DanLoad 6000 (v6.00) 6.13

Alarms (continued)

223 Low flow time (s)

226

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.

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 time (s)

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

Range <Default> OR Option (* = Default)

227 Overrun limit qty

0.0 to 99.9 <2.0>

228 Underflow alarm action

0 Off * 3 Primary

229 Underflow limit qty

0.0 to 99.9 <5.0>

230 No flow t-o alarm action

0 Off 1 Info 2 Secondary 3 Primary *

231 No flow t-o time (s)

1 to 99 <5>

232 Unauthorized flow limit qty

0.0 to 99.9 <10>

Program Code Definitions (220 to 279 Alarm Parameters) ___________________________________________

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Alarms (continued)

227 Overrun limit qty

230 No flow t-o (time out) alarm action

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.

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.

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.

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) ___________________________________________

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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

Range <Default> OR Option (* = Default)

233 Error limit (pulses)

0 to 255 <0>

234 Reset count (pulses)

0 to 65535 <10000>

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.

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) ___________________________________________

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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

MAX # of Meters with Pulse Security

one 2-channel

two 2-channel

one 2-channel and one 4-channel

two 4-channel

233 Error limit (pulses) 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) ___________________________________________

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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)

0 to 300 <10>

237 Time-out ch. B (s)

0 to 300 <10>

Program Code Definitions (220 to 279 Alarm Parameters) ___________________________________________

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________________________________________________________________________________________ DanLoad 6000 (v6.00) 6.13

Alarms (continued)

235 Data logging alarm action

237 Time-out ch. B (s)

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.

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) ___________________________________________

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________________________________________________________________________________________ DanLoad 6000 (v6.00) 6.13

Alarms (continued)

PC # / Function

Range <Default> OR Option (* = Default)

238 Temp fail alarm action

0 Off 1 Info 3 Primary *

239 Minimum temperature

-999.9 to 999.9 <-40.0>

240 Maximum temperature

-999.9 to 999.9 <110.0>

241 Density fail alarm action

1 Info 3 Primary *

242 Minimum density/gravity

-9.9999 to 9.9999 <0.0000>

243 Maximum density/gravity

-9.9999 to 9.9999 <0.0000>

244 Minimum pressure

0.0 to 9999.99 <0.00>

245 Maximum pressure

0.0 to 9999.99 <0.00>

246 Additive error limit

1 to 99 <3>

247 Additive Feedback count

0 to 9999 <0>

248 Block valve time (s)

0 to 99 <10>

Program Code Definitions (220 to 279 Alarm Parameters) ___________________________________________

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________________________________________________________________________________________ DanLoad 6000 (v6.00) 6.13

Alarms (continued)

238 Temp fail alarm action

239 Minimum temperature

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.

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.

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.

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.

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.

Program Code Definitions (220 to 279 Alarm Parameters) ___________________________________________

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Alarms (continued)

241 Density fail alarm action

location in this field is dependent on the setting in program code 046 Density/gravity scale.

This program code selects the response to a process density input out of range condition. The default selection is Primary. 244 Minimum pressure 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.

243 Maximum density/gravity

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.

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) ___________________________________________

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________________________________________________________________________________________ DanLoad 6000 (v6.00) 6.13

Alarms (continued)

246 Additive error limit

248 Block valve time (s)

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.

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) ___________________________________________

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________________________________________________________________________________________ DanLoad 6000 (v6.00) 6.13

Alarms (continued)

PC # / Function

Range <Default> OR Option (* = Default)

249 Circuit 1 alarm action

0 Off 1 Info 2 Secondary * 3 Primary

250 #1 <message>

Up to 32 characters <Ground detector open>

251 Circuit 2 alarm action

0 Off 1 Info 2 Secondary 3 Primary *

252 #2 <message>

Up to 32 characters <Overspill detector open>

253 Circuit 3 alarm action

0 Off 1 Info 2 Secondary * 3 Primary

254 #3 <message>

Up to 32 characters <Permissive power failure>

Program Code Definitions (220 to 279 Alarm Parameters) ___________________________________________

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________________________________________________________________________________________ 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) ___________________________________________

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Alarms (continued)

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.

See program code 249 for options and descriptions. The default value is “Primary”.

Secondary

This program code contains the alarm message assigned to this safety circuit. The default message is indicated above.

Primary

The default is “Secondary”.

252 #2 <Overspill detector open>

253

Circuit 3 alarm action

This program code contains the alarm message assigned to this safety circuit. The default message is indicated above.

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

254

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.

This program code contains the alarm message assigned to this safety circuit, the default message is indicated above.

250 #1 <Ground detector open>

#3 <Permissive power failure>

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

Range <Default> OR Option (* = Default)

255 Circuit 4 alarm action

0 Off 1 Info 2 Secondary * 3 Primary

256 #4 <message>

Up to 32 characters <Additive injection failure>

257 Circuit 5 alarm action

0 Off 1 Info 2 Secondary * 3 Primary

258 #5 <message>

Up to 32 characters <Arm down side 1>

259 Circuit 6 alarm action

0 Off 1 Info 2 Secondary * 3 Primary

260 #6 <message>

Up to 32 characters <Arm down side 2>

Program Code Definitions (220 to 279 Alarm Parameters) ___________________________________________

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Alarms (continued)

255 Circuit 4 alarm action

258 #5 <Arm down side 1>

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”.

This program code contains the alarm message assigned to this safety circuit. The default message is indicated above.

256 #4 <Additive injection failure>

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”.

This program code contains the alarm message assigned to this safety circuit. The default message is indicated above. 260 #6 <Arm down side 2> 257 Circuit 5 alarm action

This program code contains the alarm message assigned to this safety circuit. The default message is indicated above.

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”.

Program Code Definitions (220 to 279 Alarm Parameters) ___________________________________________

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Alarms (continued)

PC # / Function

Range <Default> OR Option (* = Default)

261 Circuit 7 alarm action

0 Off 1 Info 2 Secondary * 3 Primary

262 #7 <message>

Up to 32 characters <Walkway down side 1>

263 Circuit 8 alarm action

0 Off 1 Info 2 Secondary * 3 Primary

264 #8 <message>

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

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 351 Safety circuit 7. See program code 249 for options and descriptions. The default value is “Secondary”.

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>

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)

PC # Function

Range <Default> OR Option (* = Default)

265 Circuit 5 type

0 to 2 <1>

266 Circuit 6 type

0 to 2 <2>

267 Circuit 7 type

0 to 2 <1>

268 Circuit 8 type

0 to 2 <2>

Safety Circuit

Program Code

265

266

267

268

830

831

832

833

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

267 Circuit 7 type

This program code sets the side assignment for safety circuit number 5.

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.

266 Circuit 6 type

268 Circuit 8 type

This program code sets the side assignment for safety circuit number 6.

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.

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.

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Alarms (continued)

PC # / Function

Range <Default> OR Option (* = Default)

269 Alarm o/p 1 mask

0 to 16777215 <16777215>

270 Alarm o/p 2 mask

0 to 16777215 <0>

271 Unauth additive flow vol

0.0000 to 99999.9999 <0.0000>

272 Prod/add - %

0 to 99 <0>

273 Prod/add + %

0 to 99 <0>

274 Storage alarm action

0 Off * 3 Primary

275 Power fail alarm action

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

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 Type Mask Values table.

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.

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.

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.

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________________________________________________________________________________________ DanLoad 6000 (v6.00) 6.13

Alarms (continued) Alarm Type Mask Values Alarm Type

Mask Value

Display failure

Comms failure

Unable to maintain blend

Flow rate to low

Alarm Type Mask Values Alarm Type

Mask Value

12 =

Density failure

4096

13 =

Unable to close block valve

8192

14 =

Additive failure

16384

15 =

Safety circuit

32768

Flow rate too high

16 =

Data logging memory full

65536

Valve closed early

17 =

Memory check failed

131072

Timed out - not flow detected

64 18 =

Storage memory full

262144

Unauthorized flow exceeds limit

128 19 =

Power failure

524288

Pulse security error

256

20 =

Unable to ramp down

1048576

Temperature failure

512

21 =

MPMC failure

2097152

10 =

Pressure failure

1024

22 =

Calibration failure

4194304

11 =

Unable to shut valve

2048

23 =

Intermediate level input

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.

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.

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.

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

276

Alarms (continued)

PC # / Function

Range <Default> OR Option (* = Default)

276 Ramp down alarm action

0 Off 3 Primary *

277 Ramp down time (s)

0 to 9999 <4>

278 Additive per 1000 error limit

1 to 99 <1>

279 End time (s)

0 to 9999 <180>

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

Range <Default> OR Option (* = Default)

280 Slot 1 board

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

281 Slot 2 board

282 Slot 3 board

283 Slot 4 board

284 Slot 5 board

285 Slot 6 board

286 Slot 7 board

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.

NOTE Refer to Section 2.2.2 Input/Output Board Descriptions and Jumper Settings for detailed information about board types, uses, configurations and connections. Appropriate drawings are also referenced in Section 2.2.2 and can be found in Appendix E.

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

No card present.

DC I/O

DC Voltage discrete input / output board.

AC I/O

AC Voltage discrete input / output board.

8-Ch. Analog Input 8-channel analog input board.

2-Ch. Pulse Input

2-channel meter pulse input board.

Enhanced I/O

Enhanced input / output board.

2-Ch. Analog Input 2-channel analog input board.

4-Ch. Pulse Input

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

Range <Default> OR Option (* = Default)

287 Alarm output 1

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)

Range <Default> OR Option (* = Default)

288 / 289 / 290 / 291 Pump control output

0 to number of discrete outputs <see table below>

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: Component

Program Code

Discrete Output

288

289

290

291

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)

Range <Default> OR Option (* = Default)

292 / 297 / 302 / 307 Solenoid 1 (upstream)

0 to number of discrete outputs <1>

293 / 298 / 303 / 308 Solenoid 2 (downstream)

0 to number of discrete outputs <2>

294 / 299 / 304 / 309 Stem switch 1

0 to number of discrete inputs, 51 to (50 + max. discrete input) <0>

295 / 300 / 305 / 310 Stem switch 2

0 to number of discrete inputs, 51 to (50 + max. discrete input) <0>

296 / 301 / 306 / 311 Close input

0 to number of discrete inputs, 51 to (50 + max. discrete input) <0>

Recommended discrete output assignments: Flow Control Valve

Solenoid 1 Program Code

Discrete Output

Solenoid 2 Program Code

Discrete Output

292

293

297

298

302

303

307

308

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) 295 / 300 / 305 / 310 Stem switch 2 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

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

Range <Default> OR Option (* = Default)

312 Side detect method

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.

313 Pulse per unit output 1

0 to number of discrete outputs <0>

314 Pulse per unit output 2

0 to number of discrete outputs <0>

315 Trip 1 output

0 to number of discrete outputs <0>

316 Trip 2 output

0 to number of discrete outputs <0>

317 Trip 3 output

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.)

Swing Arm Switch Status Side Detect M ethod

Side 1

Side 2

Parked

Sgl w/o sw

Enabled

N/A

Sgl 1 sw (SW 2)

SW 2 CLOSED

N/A

SW 2 OPEN

Sgl 1 sw (SW 1)

SW 1 CLOSED

N/A

SW 1 OPEN

Dbl 1 sw (SW 2)

SW 2 CLOSED

SW 2 OPEN

N/A

SW 1 must be OPEN Dbl 1 sw (SW 1)

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.

SW 1 OPEN

N/A

SW 2 must be OPEN Dbl 2 sw

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.

SW 1 CLOSED

SW 2 CLOSED

SW 2 OPEN

SW 1 OPEN

SW 1 CLOSED

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).

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.

Sgl 1 sw. (SW1) Single side with one swing arm switch. SW1 CLOSED = side 1, SW1 OPEN = parked.

Dbl 1 sw. (SW1)

Dbl 1 sw. (SW2)

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.

Double side with one swing arm switch. SW2 CLOSED = side 1, SW2 OPEN = side 2; (SW1 must be OPEN).

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

315 Trip 1 output

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).

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).

316 Trip 2 output 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).

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)

Range <Default> OR Option (* = Default)

318 / 324 / 330 / 336 Meter X temp input

0 to number of RTD inputs

319 / 325 / 331 / 337 Meter X offset (Ohms)

-20.00 to +20.00

320 / 326 / 332 / 338 Meter X pres input

0 to number of 4 to 20 mAdc inputs

321 / 327 / 333 / 339 Meter X dens input

0 to number of 4 to 20 mAdc inputs

322 / 328 / 334 / 340 Meter X flow input

0 to max. discrete input, 51 to (50 + max. discrete input) <0>

318 / 324 / 330 / 336 Meter X temp input

319 / 325 / 331 / 337 Meter X offset (Ohms)

This program code assigns a physical RTD process temperature input, corresponding to a flow meter, to the RTD input logical function.

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

322 / 328 / 334 / 340 Meter X flow input

This program code assigns the physical 4 to 20 mAdc input, corresponding to a flow meter, to the meter pressure logical function.

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.

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.

Program Code Definitions (280 to 379 I/O Parameters) ______________________________________________

Section 6 - 125

________________________________________________________________________________________ DanLoad 6000 (v6.00) 6.14

I/O Parameters (continued)

PC # / Function

Range <Default> OR Option (* = Default)

341 # cpmt inputs

0 to 4 <0>

342 Start method

0 Normal * 1 Immed.

343 Auto/manual change-over

0 to max. discrete input, 51 to (50 + max. discrete input) <0>

344 Primary alarm reset

0 to max. discrete input, 51 to (50 + max. discrete input) <0>

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

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

Compartment Size

Program Code for Physical Discrete Input

Program Code for Alarm Action

Compartment Size Low Limit

Compartment Size High Limit

PC 644 x 100

349

257

PC 645 x 100

350

259

PC 650 x 100

PC 651 x 100

PC 646 x 100

351

261

PC 647 x 100

352

263

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

343 Auto/manual change-over

This program code defines the method by which a batch is started. The default value is "Normal". Select one of the following:

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.

"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).

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

Range <Default> OR Option (* = Default)

345 Safety circuit 1

0 to max. discrete input, 51 to (50 + max. discrete input) <0>

346 Safety circuit 2

0 to max. discrete input, 51 to (50 + max. discrete input) <0>

347 Safety circuit 3

0 to max. discrete input, 51 to (50 + max. discrete input) <0>

348 Safety circuit 4

0 to max. discrete input, 51 to (50 + max. discrete input) <0>

349 Safety circuit 5 or compartment size input 1

0 to max. discrete input, 51 to (50 + max. discrete input) <0>

350 Safety circuit 6 or compartment size input 2

0 to max. discrete input, 51 to (50 + max. discrete input) <0>

351 Safety circuit 7 or compartment size input 3

0 to max. discrete input, 51 to (50 + max. discrete input) <0>

352 Safety circuit 8 or compartment size input 4

0 to max. discrete input, 51 to (50 + max. discrete input) <0>

353 RTD range

0 Std * 1 Hi 2 Low

354 Delay after outputs (msec)

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.

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.

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

351 Safety circuit 7 or compartment size input 3

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).

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).

350 Safety circuit 6 or compartment size input 2 352 Safety circuit 8 or compartment size input 4 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).

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

354

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:

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.

Delay after outputs

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.

Program Code Definitions (280 to 379 I/O Parameters) ______________________________________________

Section 6 - 133

________________________________________________________________________________________ DanLoad 6000 (v6.00) 6.14

I/O Parameters (continued)

PC# / Function

Range <Default> OR Option (* = Default)

355 Primary LCD type

0 Unknown 1 Standish 2 Optrex * 3 Old Optrex

356 Primary LCD min light

0 to 1023 <455>

357 Primary LCD max light

0 to 1023 <405>

358 Secondary LCD type

0 Unknown 1 Standish 2 Optrex * 3 Old Optrex

359 Secondary LCD min light

0 to 1023 <455>

360 Secondary LCD max light

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

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.

Automatic contrast adjustment, automatic backlighting adjustment and display failure alarm disabled.

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

Range <Default> OR Option (* = Default)

361 Recipe 1 input

0 to max. discrete input, 51 to (50 + max. discrete input) <0>

362 Recipe 2 input

0 to max. discrete input, 51 to (50 + max. discrete input) <0>

363 Recipe 3 input

0 to max. discrete input, 51 to (50 + max. discrete input) <0>

364 Recipe 4 input

0 to max. discrete input, 51 to (50 + max. discrete input) <0>

365 Recipe 5 input

0 to max. discrete input, 51 to (50 + max. discrete input) <0>

366 Recipe 6 input

0 to max. discrete input, 51 to (50 + max. discrete input) <0>

367 Recipe 1 output

0 to number of discrete outputs <0>

368 Recipe 2 output

0 to number of discrete outputs <0>

369 Recipe 3 output

0 to number of discrete outputs <0>

370 Recipe 4 output

0 to number of discrete outputs <0>

371 Recipe 5 output

0 to number of discrete outputs <0>

372 Recipe 6 output

0 to number of discrete outputs <0>

373 End output method

0 Ba only * 1 Tr only 2 Both

374 Level input

0 to max. Discrete input, 51 to (50 + max. Discrete input) <0>

375 Hatch input

0 to max. Discrete input, 51 to (50 + max. Discrete input) <0>

376 Swing 1 input

0 to max. discrete input, 51 to (50 + max. discrete input) <0>

377 Swing 2 input

0 to max. discrete input, 51 to (50 + max. discrete input) <0>

378 Low flow input

0 to max. discrete input, 51 to (50 + max. discrete input) <0>

379 Alarm output 2

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

373 End output method

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.

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.

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.

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

379 Alarm output 2

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”.

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)

Range <Default> OR Option (* = Default)

380 / 383 / 386 / 389 / 392 / 395 Ratio/valve output

0 to number discrete outputs <0>

381 / 384 / 387 / 390 / 393 / 396 Feedback/meter input

0 to number discrete inputs <0>

382 / 385 / 388 / 391 / 394/ 397 Selection input

0 to max. discrete input, 51 to (50 + max. discrete input) <0>

398 Clean line output

0 to number discrete outputs <0>

399 Flush output

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

382 / 385 / 388 / 391 / 394 / 397 Selection input

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.

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 398 Additive clean line output 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.

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)

Range <Default> OR Option (* = Default)

400 / 402 / 404 / 406 Block valve output

0 to number discrete outputs

401 / 403 / 405 / 407 Block valve input

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.

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.

The function of the block valve is changed in the following manner for “Side” stream in-line blending. 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

Range <Default> OR Option (* = Default)

408 1 1XXX

0 to number discrete outputs

409 2 X2XX

0 to number discrete outputs

410 3 12XX

0 to number discrete outputs

411 4 XX3X

0 to number discrete outputs

412 5 1X3X

0 to number discrete outputs

413 6 X23X

0 to number discrete outputs

414 7 123X

0 to number discrete outputs

415 8 XXX4

0 to number discrete outputs

416 9 1XX4

0 to number discrete outputs

417 10 X2X4

0 to number discrete outputs

418 11 12X4

0 to number discrete outputs

419 12 XX34

0 to number discrete outputs

420 13 1X34

0 to number discrete outputs

421 14 X234

0 to number discrete outputs

422 15 1234

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

410

3 12XX

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).

408

411

1 1XXX

409

4 XX3X

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

412

Component I/O Parameters (continued)

5 1X3X

414

7 123X

413

415

6 X23X

8 XXX4

Program Code Definitions (400 through 425 Component I/O Parameters) ______________________________ Section 6 - 152

________________________________________________________________________________________ DanLoad 6000 (v6.00) 6.16

416

Component I/O Parameters (continued)

9 1XX4

418

11 12X4

10 X2X4 419

12 XX34

Program Code Definitions (400 through 425 Component I/O Parameters) ______________________________ Section 6 - 153

________________________________________________________________________________________ DanLoad 6000 (v6.00) 6.16

420

Component I/O Parameters (continued)

13 1X34

421

422

15 1234

14 X234

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

Range < Default> OR Option (* = Default)

423 End output

0 to 24 <0>

424 End input

0 to max. discrete input, 51 to (50 + max. discrete input) <0>

425 Flush pulses

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

425 Flush pulses

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.

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.

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.

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)

Range <Default> OR Option (* = Default)

426 Buoyancy

-9.9999 to 9.9999 <0>

427 Temperature units

0 C (Celsius) * 1 F (Fahrenheit)

428 Density units

0 lb/ft3 * 1 kg/m3 2 g/cm3 3 60/60 F 4 15/4 C 5 20/4 C

429 Pressure units

0 psi * 1 Pa 2 in. H2O 3 in. Hg 4 bar 5 mbar 6 kPa 7 kg/cm2

430 Reference temperature

-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)

Range <Default> OR Option (* = Default)

431 Sample qty

0 to 9999 <100>

432 / 435 / 438 / 441 Temperature option

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

433 / 436 / 439 / 442 Alpha

0.0002700 to 0.0016740 <0.0005100>

434 / 437 / 440 / 443 Backup temperature

-99.9 to 999.9 <15.0>

Program Code Definitions (426 to 479 Temperature/Pressure/Density Parameters) ______________________

Section 6 - 159

________________________________________________________________________________________ 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 Ctl (correction for the effect of temperature of the liquid) and Cpl (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

kg/m3 kilograms per cubic meter

g/cm3

grams per cubic centimeter

60/60 F

relative density 60 deg. F / 60 deg. F

427 Temperature units

15/4 C

relative density 15 deg. C / 4 deg. C

This program code selects the temperature units to be used in calculations, displays, and logs. The default value is “C”.

20/4 C

relative density 20 deg. C / 4 deg. C

pounds per cubic foot

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).

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

430 Reference temperature

This program code selects the pressure units mnemonic used in calculations, displays, printing and logs.

(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.)

psi

Pounds per square inch

Pascals

in. H2O

Inches water column

in. Hg Inches mercury

bar

Bar

mbar

Millibar

kPa

KiloPascals

kg/cm2

Kilograms per centimeter square

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)

the DanLoad 6000 calculations produce API gross quantity which is the indicated quantity (meter registration) times the meter factor.

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. For pure MTBE, API recommends either Table 6C with "60 = 789.0 x 10-6/oF or Table 54C with "15 = 1420.2 x 10-6/oC. For ethanol, API recommends Table 6C with "60 = 580.0 x 10-6/oF. #

Off Disable temperature compensation. If the meter pulse input is not temperature compensated at the flow meter,

Linear The following linear equation is used to calculate temperature compensation. CTL

1 - ((t - T) * "T )

where: CTL

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: #

Standard reference temperature: 60 degrees F. Temperature correction to a non-standard reference temperature via program code 430.

API 6A 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 24B 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 24A

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)

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.

API 54B Standard reference temperature: 15 degrees C. Temperature correction to a non-standard reference temperature via program code 430.

API 54C #

Old 24

IMP Instituto Mexicano del Petroleo programa Correccion de Volumen por Temperatura de los Productos Petroliferos Evaluados a 20 grados Celsius

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).

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.

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 Densidade 20oC/4oC e Fator de Correção de Volume para 20oC, July 1988. Only part 3, Cálculo do Fator de Correção de Volume para 20oC, is implemented.

Program Code Definitions (426 to 479 Temperature/Pressure/Density Parameters) ______________________

Section 6 - 165

________________________________________________________________________________________ DanLoad 6000 (v6.00) 6.17

Temperature / Pressure / Density (continued)

GPA TP-16-6 for natural gasoline (relative density 60/60 degrees F = 0.664) give Ctpl factors computed from the CTL factor given by API 24A and the CPL factor given by the API 11.2.2. The DanLoad 6000 computes TP-16-6 by configuring the appropriate temperature and pressure correction options.

TP-16 GPA TP-16 CTPL factors for LPG’s, i.e. TP-16-1 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. propanes and butanes, the Cpl option should be 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 F, and if necessary, two Ctl factors from Old Table 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.

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 ("20) based on component density at 20 degrees C.

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 - 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.

ASTM D 4311 Table 1 for asphalts. Less than or equal to 34.9 degrees API, or greater than or equal to 0.850 specific gravity 60oF/60oF, 0 to 500 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”. #

Note: This table is not functional when the Side stream blending (Program code 023) is set to “YES”.

API 54D API Table 54D for lubes: 800 to 1064 kg/m3, -20 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

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 This program code sets the coefficient of thermal expansion ("T) 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)

Range <Default> OR Option (* = Default)

444 / 447 / 450 / 453 Pressure option

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

445 / 448 / 451 / 454 F-factor X 1000000000

0 to 999999999 <0>

446 / 449 / 452 / 455 Backup pressure

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)

Range <Default> OR Option (* = Default)

456 / 458 / 460 / 462 Density/gravity option

0 Off * 1 DT 2 5A 3 5B 4 23A 5 23B 6 53A 8 53B 9 L1 10 L2

457 / 459 / 461 / 463 Backup density/gravity

-9.9999 to 9.9999 <0> Entry and scale dependent on program code 046 Density/gravity scale: 1 nnnn.n 2 nnn.nn 3 nn.nnn 4 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) pressure compensation.

444 / 447 / 450 / 453 Pressure option Program code 444 / 447 / 450 / 453 Pressure option selects the method of pressure compensation. 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.

1 CP L = [1 - (operating pressure - equilibrium pressure)

where: CPL

Correction for the effect of pressure on a liquid.

operating pressure

The pressure obtained from a pressure transmitter.

equilibrium pressure

The equilibrium vapor pressure obtained from program code 446 / 449 / 452 / 455 Pe pressure.

F-factor

The compressibility factor for the liquid obtained from program code 445 / 448 / 451 / 454 F-factor X 1000000000.

The following selections are available. #

Off Disable pressure compensation.

F-factor]

Const The following linear equation is used to calculate

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 Ffactor X 1000000000 and the operating pressure obtained from a pressure transmitter, ranges for the table are:

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)

API Gravity Temp.(deg.F) Pressure (PSI) 0.350 to 0.637 0 to 90

-20 to +200

-50 to +140

0 to 2200

0 to 1500

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:

11.2.2M

Abs.Dns.(kg/m3)

Temp.(deg.C) Press(kPa)

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:

638 to 1074

-30 to +90

Abs.Dns(kg/m3)

0 to 10300

350 to 637

Temp.(deg.C) Press(kPa) -46 to +60

Program Code Definitions (426 to 479 Temperature/Pressure/Density Parameters) ______________________

0 to 15200

Section 6 - 174

________________________________________________________________________________________ DanLoad 6000 (v6.00) 6.17

Temperature / Pressure / Density (continued) #

P’bras

NH3

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.

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.

P’bras LPG

This option is specific to anhydrous ammonia (NH3), and as such the component density is implicit. The Pe method (program code 819) should be configured as “NH3". The temperature range is 0 to 100 oF (inclusive). Note program 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.

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”.

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

456 / 458 / 460 / 462 Density/gravity option

This program code sets the constant F-factor used in pressure compensation calculations (CPL). The entry value is multiplied by 109 by the DanLoad 6000. 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.

This program code selects the status of using density inputs in the flow calculations.

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 (Pm) or differential pressure (Pd) depending 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.

Off

# # # # # # #

5A 5B 23A 23B 53A 53B L1

Use configured backup density (program codes 457, etc.). Use density from density transmitter input (program codes 321, etc.). Not used Not used Not used Not used Not used Not used From an LNG table, density (lb/ft3) against pressure (45 to 201 psia) for pure methane (Liquified Natural Gas). 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

0.00 to 100.00 API gravity

24A, 24B

0.6110 to 1.0760 relative density

Off, Linear, 54A, 54B, 54C

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)

Range <Default> OR Option (* = Default)

464 / 468 / 472 / 476 Pressure @4 mA

0 to 9999.99 <0.00>

465 / 469 / 473 / 477 Pressure @20 mA

0 to 9999.99 <0.00>

466 / 470 / 474 / 478 Density @4 mA

-9.9999 to 9.9999 <0>

467 / 471 / 475 / 479 Density @20 mA

-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

466 / 470 / 474 / 478 Density @4 mA

Zero scale for pressure input from transmitter. Engineering unit specified by program code 429 Pressure units.

Zero scale for density input from transmitter. The position of the “floating decimal point” depends on the density/gravity scale (program code 46).

465 / 469 / 473 / 477 Pressure @20 mA 467 / 471 / 475 / 479 Density @20 mA Full scale for pressure input from transmitter. Engineering units specified by program code 429 Pressure units.

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)

Range <Default> OR Option (* = Default)

480 Number of recipes

0 to 30 <1>

481 / 487 / 493 / 499 / 505 / 511 / 517 / 523 / 529 / 535 Name

1 to 16 chars <Recipe #1>

482 / 488 / 494 / 500 / 506 / 512 / 518 / 524 / 530 / 536 Comp 1 %

0 to 100 <100>

483 / 489 / 495 / 501 / 507 / 513 / 519 / 525 / 531 / 537 Comp 2 %

0 to 100

484 / 490 / 496 / 502 / 508 / 514 / 520 / 526 / 532 / 538 Comp 3 %

0 to 100

485 / 491 / 497 / 503 / 509 / 515 / 521 / 527 / 533 / 539 Comp 4 % or ratio qty

0 to 300

486 / 492 / 498 / 504 / 510 / 516 / 522 / 528 / 534 / 540 Sequence or low proportion

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)

Range <Default> OR Option (* = Default)

541 / 547 / 553 / 559 / 565 / 571 / 577 / 583 / 589 / 595 Name

1 to 16 chars

542 / 548 / 554 / 560 / 566 / 572 / 578 / 584 / 590 / 596 Comp 1 %

0 to 100

543 / 549 / 555 / 561 / 567 / 573 / 579 / 585 / 591 / 597 Comp 2 %

0 to 100

544 / 550 / 556 / 562 / 568 / 574 / 580 / 586 / 592 / 598 Comp 3 %

0 to 100

545 / 551 / 557 / 563 / 569 / 575 / 581 / 587 / 593 / 599 Comp 4 % or ratio qty

0 to 300

546 / 552 / 558 / 564 / 570 / 576 / 582 / 588 / 594 / 600 Sequence or low proportion

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)

Range <Default> OR Option (* = Default)

601 / 607 / 613 / 619 / 625 / 631 / 637 / 643 / 649 / 655 Name

1 to 16 chars

602 / 608 / 614 / 620 / 626 / 632 / 638 / 644 / 650 / 656 Comp 1 %

0 to 100

603 / 609 / 615 / 621 / 627 / 633 / 639 / 645 / 651 / 657 Comp 2 %

0 to 100

604 / 610 / 616 / 622 / 628 / 634 / 640 / 646 / 652 / 658 Comp 3 %

0 to 100

605 / 611 / 617 / 623 / 629 / 635 / 641 / 647 / 653 / 659 Comp 4 % or ratio qty

0 to 300

606 / 612 / 618 / 624 / 630 / 636 / 642 / 648 / 654 / 660 Sequence or low proportion

nnnn

661 # add calib cycles

1 to 9999 <1>

NOTE:

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 “MultiRate” 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 PC# Ch. A

Ch. B

Function

Range <Default> OR Option (* = Default)

662

Address

0 to 255 <0>

663

668

Mode

0 Not used * 1 Modbus RTU 2 ASCII 3 Data logging (ch. B only)

664

669

Data Rate

0 300 bps 1 600 bps 2 1200 bps 3 2400 bps 4 4800 bps 5 9600 bps 6 19200 bps 7 38400 bps

665

670

Word Size

0 5 bits 1 6 bits 2 7 bits 3 8 bits

666

671

Stop Bits

0 1 bit 1 1-1/2 bits 2 2 bits

667

672

Parity

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.

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. #

This port is not assigned. #

Modbus RTU Modicon Modbus RTU (binary) protocol.

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.

Not used

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

667 / 672 Parity

This program code selects the bits per second data rate used by this port.

This program code selects the parity checking method. #

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.

None Parity checking in not performed.

Odd Odd parity checking is performed.

665 / 670 Word size This program code selects the data word length in bits.

Even Even parity checking is performed.

666 / 671 Stop bits This program code selects of the number of stop bits used in serial data transmission.

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

Range <Default> OR Option (* = Default)

PC# / Function

Range <Default> OR Option (* = Default)

679 Mode

Off Standard * All

688 Line 9 data code

3 digit data display code

689 Line 10 data code

3 digit data display code

690 Line 11 data code

3 digit data display code

691 Line 12 data code

3 digit data display code

692 Line 13 data code

3 digit data display code

693 Line 14 data code

3 digit data display code

694 Line 15 data code

3 digit data display code

695 Line 16 data code

3 digit data display code

680 Line 1 data code

3 digit data display code

681 Line 2 data code

3 digit data display code

682 Line 3 data code

3 digit data display code

683 Line 4 data code

3 digit data display code

684 Line 5 data code

3 digit data display code

685 Line 6 data code

3 digit data display code

686 Line 7 data code

3 digit data display code

687 Line 8 data 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.

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

679 Mode This program code controls how the dynamic data display items are presented. The default value is “Standard”. #

Grs Std Mtr Mtr

batch batch 1 grs 1 std

qty qty total total

150 152 23838017 23839223

5 6 7 8

Mtr Mtr Mtr Mtr

1 1 1 1

grs std grs flw

batch batch unauth rate

150 152 0.0 597

9 10 11 12

Mtr Mtr Mtr Mtr

1 1 1 1

factor 1.0000 grs ld 149.72 pls cnt 3821 max flw rate 602

Off

The dynamic data display is disabled. #

1 2 3 4

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.

Program Code Definitions (679 to 695 Dynamic Data Display Parameters) _____________________________

Section 6 - 191

________________________________________________________________________________________ DanLoad 6000 (v6.00)

6.20

Dynamic Data Display (continued)

13 14 15 16

Mtr Cmp Cmp Arm

1 curr temp 1 ave temp 1 ave vlv cls position

42.6 42.6 230 1

Data codes 1 through <maximum>

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

001Arm 002Grs 003Std 004Mtr

position batch qty batch qty 1 grs total

1 150 152 23838017

005Mtr 006Mtr 007Mtr 008Mtr

1 1 1 1

23839223 150 152 597

etc.

std grs std flw

total batch batch rate

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

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 1 in the Dynamic Data Display.

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. .

685 Line 6 data code

688 Line 9 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.

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

689 Line 10 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.

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

693 Line 14 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.

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

694 Line 15 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.

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.

692 Line 13 data code

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 1 in the Dynamic Data Display.

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

001 002 003

Batch Data Arm position Grs batch qty Std batch qty

swing arm position indicator gross batch quantity standard batch quantity

004 005 006 007 008 009 010 011 012

Flow Meter 1 Data Mtr 1 grs total Mtr 1 std total Mtr 1 grs batch Mtr 1 std batch Mtr 1 flw rate Mtr 1 CCF Mtr 1 max flw rate Mtr 1 factor Mtr 1 pls cnt

gross totalizer quantity std totalizer quantity gross batch quantity std batch quantity instantaneous flow rate combined correction factor maximum flow rate this batch meter factor pulse count total (resets at 65535)

Code 013 014 015 016 017 018 019 020

Display Data Function Mtr 1 pls flrt1 pulse count at low flow rate (for load) Mtr 1 pls flrt2 pulse count at flow rate 2 (for load) Mtr 1 pls flrt3 pulse count at flow rate 3 (for load) Mtr 1 pls flrt4 pulse count at flow rate 4 (for load) Mtr 1 grs unauth unauthorized gross quantity Mtr 1 std unauth unauthorized std quantity Mtr 1 grs start start gross quantity Mtr 1 std start start std quantity

021 022 023 024 025 026 027 028 029 030 031 032 033 034 035 036 037

Flow Meter 2 Data Mtr 2 grs total gross totalizer quantity Mtr 2 std total std totalizer quantity Mtr 2 grs batch gross batch quantity Mtr 2 std batch std batch quantity Mtr 2 flw rate instantaneous flow rate Mtr 2 CCF average flow rate Mtr 2 max flwrate maximum flow rate this batch Mtr 2 factor meter factor Mtr 2 pls cnt pulse count total (resets at 65535) Mtr 2 pls flrt1 pulse count at low flow rate (for load) Mtr 2 pls flrt2 pulse count at flow rate 2 (for load) Mtr 2 pls flrt3 pulse count at flow rate 3 (for load) Mtr 2 pls flrt4 pulse count at flow rate 4 (for load) Mtr 2 grs unauth unauthorized gross quantity Mtr 2 std unauth unauthorized std quantity Mtr 2 grs start start gross quantity 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

Code 038 039 040 041 042 043 044 045 046 047 048 049 050 051 052 053 054

Dynamic Data Display Data Codes (continued)

Function

Code

Display Data

Flow Meter 3 Data Mtr 3 grs total gross totalizer quantity Mtr 3 std total std totalizer quantity Mtr 3 grs batch gross batch quantity Mtr 3 std batch std batch quantity Mtr 3 flw rate instantaneous flow rate Mtr 3 CCF average flow rate Mtr 3 max flw rate maximum flow rate this batch Mtr 3 factor meter factor Mtr 3 pls cnt pulse count total (resets at 65535) Mtr 3 pls flrt1 pulse count - low flow rate (for load) Mtr 3 pls flrt2 pulse count at flow rate 2 (for load) Mtr 3 pls flrt3 pulse count at flow rate 3 (for load) Mtr 3 pls flrt4 pulse count at flow rate 4 (for load) Mtr 3 grs unauth unauthorized gross quantity Mtr 3 std unauth unauthorized std quantity Mtr 3 grs start start gross quantity Mtr 3 std start start std quantity

055 056 057 058 059 060 061 062 063 064 065 066 067 068 069 070 071

Flow Meter 4 Data Mtr 4 grs total gross totalizer quantity Mtr 4 std total std totalizer quantity Mtr 4 grs batch gross batch quantity Mtr 4 std batch std batch quantity Mtr 4 flw rate instantaneous flow rate Mtr 4 CCF average flow rate Mtr 4 max flw rate maximum flow rate this batch Mtr 4 factor meter factor Mtr 4 pls cnt pulse count total (resets at 65535) Mtr 4 pls flrt1 pulse count - low flow rate (for load) Mtr 4 pls flrt2 pulse count at flow rate 2 (for load) Mtr 4 pls flrt3 pulse count at flow rate 3 (for load) Mtr 4 pls flrt4 pulse count at flow rate 4 (for load) Mtr 4 grs unauth unauthorized gross quantity Mtr 4 std unauth unauthorized std quantity Mtr 4 grs start start gross quantity Mtr 4 std start start std quantity

072 073 074 075 076 077

Component 1 Data Cmp 1 grs batch component gross quantity, batch Cmp 1 std batch component std quantity, batch Mtr 1 curr temp component current temperature Cmp 1 ave temp component batch average temp Cmp 1 ave vlv cls comp. average FCV closure time Cmp 1 batch % component # % from recipe

Display Data

Function

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

078 079 080 081 082 083

Component 2 Data Cmp 2 grs batch Cmp 2 std batch Mtr 2 curr temp Cmp 2 ave temp Cmp 2 ave vlv cls Cmp 2 batch %

component gross quantity, batch component std quantity, batch component current temperature component batch average temp comp. average FCV closure time component # % from recipe

084 085 086 087 088 089

Component 3 Data Cmp 3 grs batch Cmp 3 std batch Mtr 3 curr temp Cmp 3 ave temp Cmp 3 ave vlv cls Cmp 3 batch %

component gross quantity, batch component std quantity, batch component current temperature component batch average temp comp. average FCV closure time component # % from recipe

090 091 092 093 094 095

Component 4 Data Cmp 4 grs batch Cmp 4 std batch Mtr 4 curr temp Cmp 4 ave temp Cmp 4 ave vlv cls Cmp 4 batch %

component gross quantity, batch component std quantity, batch component current temperature component batch average temp comp. average FCV closure time component # % from recipe

Code

Display Data

Function

Additive Injection Data

(Batch)

096 097 098 099 100 101

Add 1 total Add 2 total Add 3 total Add 4 total Add 5 total Add 6 total

accumulated additive volume accumulated additive volume accumulated additive volume accumulated additive volume accumulated additive volume accumulated additive volume

102 103 104 105 106

Delivery Quantity Data Preset quantity preset entry Mtr 1 grs load accumulated total Mtr 2 grs load accumulated total Mtr 3 grs load accumulated total Mtr 4 grs load accumulated total

107 108 109 110 111 112 113 114

Pressure and Density Data Cmp 1 ave dens average density, component 1 Cmp 1 ave pres average pressure, component 1 Cmp 2 ave dens average density, component 2 Cmp 2 ave pres average pressure, component 2 Cmp 3 ave dens average density, component 3 Cmp 3 ave pres average pressure, component 3 Cmp 4 ave dens average density, component 4 Cmp 4 ave pres average pressure, component 4

Program Code Definitions (679 to 695 Dynamic Data Display Parameters) _____________________________

(n.nn) (n.nn) (n.nn) (n.nn)

Section 6 - 197

________________________________________________________________________________________ DanLoad 6000 (v6.00) 6.20.1

Dynamic Data Display Data Codes (continued)

Code

Display Data

Function

115 116 117 118 119 120

Additive Data for Batch Add 1 batch additive 1 volume this/last batch Add 2 batch additive 2 volume this/last batch Add 3 batch additive 3 volume this/last batch Add 4 batch additive 4 volume this/last batch Add 5 batch additive 5 volume this/last batch Add 6 batch additive 6 volume this/last batch

121

Total Flow Rate Flow rate

122 123 124 125

Component Blend Ratio Cmp 1 adjust % comp 1 % for blend ratio adj Cmp 2 adjust % comp 2 % for blend ratio adj Cmp 3 adjust % comp 3 % for blend ratio adj Cmp 4 adjust % comp 4 % for blend ratio adj

126 127 128 129

Quantity Correction Factor for Load Mtr 1 CTL meter 1 Mtr 2 CTL meter 2 Mtr 3 CTL meter 3 Mtr 4 CTL meter 4

130 131 132 133 134

load flow rate

Batch Data Power fail grs bch gross delivered vol. at power fail time Power fail std bch std delivered qty at power fail time Batch temperature average temperature during load Batch density average density during load Batch pressure average pressure during load

Code

Display Data

Function

135 136 137 138

Current Meter Pressure Mtr 1 curr pres meter 1 Mtr 2 curr pres meter 2 Mtr 3 curr pres meter 3 Mtr 4 curr pres meter 4

139 140 141 142

Pressure Correction Factor for Load Mtr 1 CPL meter 1 Mtr 2 CPL meter 2 Mtr 3 CPL meter 3 Mtr 4 CPL meter 4

143 144 145 146

Current Meter Density Mtr 1 curr dens meter 1 Mtr 2 curr dens meter 2 Mtr 3 curr dens meter 3 Mtr 4 curr dens meter 4 Delivery Volume Data

147 148 149 150

Mtr 1 std ld Mtr 2 std ld Mtr 3 std ld Mtr 4 std ld

accumulated total (n.nn) accumulated total (n.nn) accumulated total (n.nn) 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

151 152 153 154 155 156 157 158

Component Quantity Totals Cmp 1 grs total component 1 gross quantity, total Cmp 1 std total component 1 std quantity, total Cmp 2 grs total component 2 gross quantity, total Cmp 2 std total component 2 std quantity, total Cmp 3 grs total component 3 gross quantity, total Cmp 3 std total component 3 std quantity, total Cmp 4 grs total component 4 gross quantity, total Cmp 4 std total component 4 std quantity, total

159 160 161 162 163 164 165 166 167 168 169 170 171 172 173 174 175 176 177 178 179 180

Recipe Quantity Totals Rec 1 grs tot Recipe 1 gross quantity, total Rec 1 std tot Recipe 1 std quantity, total Rec 2 grs tot Recipe 2 gross quantity, total Rec 2 std tot Recipe 2 std quantity, total Rec 3 grs tot Recipe 3 gross quantity, total Rec 3 std tot Recipe 3 std quantity, total Rec 4 grs tot Recipe 4 gross quantity, total Rec 4 std tot Recipe 4 std quantity, total Rec 5 grs tot Recipe 5 gross quantity, total Rec 5 std tot Recipe 5 std quantity, total Rec 6 grs tot Recipe 6 gross quantity, total Rec 6 std tot Recipe 6 std quantity, total Rec 7 grs tot Recipe 7 gross quantity, total Rec 7 std tot Recipe 7 std quantity, total Rec 8 grs tot Recipe 8 gross quantity, total Rec 8 std tot Recipe 8 std quantity, total Rec 9 grs tot Recipe 9 gross quantity, total Rec 9 std tot Recipe 9 std quantity, total Rec 10 grs tot Recipe 10 gross quantity, total Rec 10 std tot Recipe 10 std quantity, total Rec 11 grs tot Recipe 11 gross quantity, total Rec 11 std tot Recipe 11 std quantity, total

Code

Display Data

Function

181 182 183 184 185 186 187 188 189 190 191 192 193 194 195 196 197 198 199 200 201 202 203 204 205 206 207 208 209 210 211 212

Rec 12 grs tot Rec 12 std tot Rec 13 grs tot Rec 13 std tot Rec 14 grs tot Rec 14 std tot Rec 15 grs tot Rec 15 std tot Rec 16 grs tot Rec 16 std tot Rec 17 grs tot Rec 17 std tot Rec 18 grs tot Rec 18 std tot Rec 19 grs tot Rec 19 std tot Rec 20 grs tot Rec 20 std tot Rec 21 grs tot Rec 21 std tot Rec 22 grs tot Rec 22 std tot Rec 23 grs tot Rec 23 std tot Rec 24 grs tot Rec 24 std tot Rec 25 grs tot Rec 25 std tot Rec 26 grs tot Rec 26 std tot Rec 27 grs tot Rec 27 std tot

Recipe 12 gross quantity, total Recipe 12 std quantity, total Recipe 13 gross quantity, total Recipe 13 std quantity, total Recipe 14 gross quantity, total Recipe 14 std quantity, total Recipe 15 gross quantity, total Recipe 15 std quantity, total Recipe 16 gross quantity, total Recipe 16 std quantity, total Recipe 17 gross quantity, total Recipe 17 std quantity, total Recipe 18 gross quantity, total Recipe 18 std quantity, total Recipe 19 gross quantity, total Recipe 19 std quantity, total Recipe 20 gross quantity, total Recipe 20 std quantity, total Recipe 21 gross quantity, total Recipe 21 std quantity, total Recipe 22 gross quantity, total Recipe 22 std quantity, total Recipe 23 gross quantity, total Recipe 23 std quantity, total Recipe 24 gross quantity, total Recipe 24 std quantity, total Recipe 25 gross quantity, total Recipe 25 std quantity, total Recipe 26 gross quantity, total Recipe 26 std quantity, total Recipe 27 gross quantity, total 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

213 214 215 216 217 218

Rec 28 grs tot Rec 28 std tot Rec 29 grs tot Rec 29 std tot Rec 30 grs tot Rec 30 std tot

Recipe 28 gross quantity, total Recipe 28 std quantity, total Recipe 29 gross quantity, total Recipe 29 std quantity, total Recipe 30 gross quantity, total Recipe 30 std quantity, total

219 220 221 222 223

Meter Calibration Status Mtr 1 calib stat meter 1 Mtr 2 calib stat meter 2 Mtr 3 calib stat meter 3 Mtr 4 calib stat meter 4 Flush pls cnt Multi-Stream Additive Injection Flush pulse count

224 225 226 227 228 229 230 231 232 233 234 235 236 237 238 239 240 241 242 243 244 245 246

Current safety circuit state Safety 1 State of safety circuit 1 Safety 2 State of safety circuit 2 Safety 3 State of safety circuit 3 Safety 4 State of safety circuit 4 Safety 5 State of safety circuit 5 Safety 6 State of safety circuit 6 Safety 7 State of safety circuit 7 Safety 8 State of safety circuit 8 Cpmt qty Compartment quantity based on compartment size inputs Add 1 fail code Additive 1 failure reason code Add 2 fail code Additive 2 failure reason code Add 3 fail code Additive 3 failure reason code Add 4 fail code Additive 4 failure reason code Add 5 fail code Additive 5 failure reason code Add 6 fail code Additive 6 failure reason code Add 1% Additive #1 % of required additive Add 2% Additive #2 % of required additive Add 3% Additive #3 % of required additive Add 4% Additive #4 % of required additive Add 5% Additive #5 % of required additive Add 6% Additive #6 % of required additive Power fail preset Power fail preset quantity 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

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

703 Configuration summary 704 Crash memory summary 705 Totalizers 706 Transaction ticket 707 Transaction ticket reprint 708 Throughput 709 Sequence Numbers

0 Off * 1 On

710 Cutoff hour

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.

698 Alarm log This program code controls spooling and printing of single line alarm logs. 699 Power fail log

Data logging program codes with common option selections.

This program code controls spooling and printing of single line power fail logs.

696 Batch summary

700 Program mode entry/exit

This program code controls spooling and printing of the fixed format batch summary report.

This program code controls spooling and printing of single line program mode change logs.

697 Transaction summary

701 W&M switch opened/closed

This program code controls spooling and printing of the fixed format transaction summary report.

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

Operated Switch) and form feed control can be configured.

This program code controls spooling and printing of program code value change logs.

706 Transaction ticket

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.

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 the Crash memory summary.

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.

705 Totalizers

708 Recipe throughput

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

This program code controls spooling and printing of the Recipe Throughput report every 24-hours.

704 Crash memory summary

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.

PR1 Enable spooling for this report and direct this report to printer number 1 via control code to code operated switch.

Off #

PR1FF

Disable spooling and printing for this data log. #

PR Enable spooling and printing for this data log. (No code operated switch)

Same as PR1 above, except send form-feed control to printer at end of report. #

Enable spooling for this report and direct this report to printer number 2 via control code to code operated switch.

PRFF Same as PR above, except send form feed control to printer at end of report.

PR2

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

709 Sequence numbers

Enable spooling for this report and direct this report to printer number 3 via control code to code operated switch.

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.

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.

# #

Off (default)

PR4FF Enable printing of report sequence numbers on each report.

Same as PR4 above, except send form-feed control to printer at end of 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

Range <Default> OR Option (* = Default)

711 Ramp down %

0 to 100 <50>

712 Rate reduction

0 to 9999 <100>

713 Low flow start qty

0 to 99999 <50>

714 Clean line qty

0 to 9999 <0>

715 Low prop fac

1 to 4 <1>

716 Correct after qty

0 to 9999 <100>

717 Alarm after qty

0 to 9999 <200>

718 Adjustment qty

0 to 9999 <50>

719 Comp % display

0 Gross * 1 Std

720 Add calib delay (s)

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.

713 Low flow start qty

711 Ramp down %

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.

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.

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

715 Low prop fac 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.

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

719 Comp % display

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.

This program code defines the display form for the quantities of the blend components, defined by the active recipe. The default is “Gross”.

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.

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

Range <Default> OR Option (* = Default)

722 Blend error method

0 Grspctbatch * 1 Stdpctbatch 2 Grsqtydiff 3 Stdqtydiff 4 Grspctsmpl 5 Stdpctsmpl 6 Flrtsmpl

723 Max dev %

0 to 999 <2>

724 Blend tol %

0 to 999 <5>

725 Max dev qty

0 to 9999 <20>

726 Blend tol qty

0 to 9999 <40>

727 Blend sample qty

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.

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.

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.

Flrtsmpl

Grsqtydiff

Gross quantity difference between each blend 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. #

Grspctsmpl

The sampled flow rates of 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.

Program Code Definitions (711 to 799 Blending Parameters) __________________________________________ Section 6 - 213

________________________________________________________________________________________ DanLoad 6000 (v6.00) 6.22

Blending (continued)

723 Max dev %

726 Blend tol qty

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.

This program code defines the maximum quantity tolerance allowed for the blend before generating an Unable to maintain blend alarm.

727 Blend sample quantity 724 Blend tol % This program code defines the maximum percentage tolerance allowed for the blend before generating an Unable to maintain blend alarm.

This program code defines the blend quantity to deliver between calculations of blend ratio by percentage methods ('Grspctsmpl' and 'Stdpctsmpl').

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.

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)

Range <Default> OR Option (* = Default)

728 / 734 / 740 / 746 Flow adj fac

0.00 to 9.99 <1.00>

729 / 735 / 741 / 747 Ratio adj fac

1.00 to 9.99 <1.00>

730 / 736 / 742 / 748 Ramp %

0 to 110 <85>

731 / 737 / 743 / 749 CALMON analysis method

Fuzzy * Heuristic

PC# / Function MPMC

Range <Default> OR Option (* = Default)

752 FPO basis

Raw * Gross Net

753 CALMON error limit

0 to 255 <25>

754 CALMON reset count

0 to 9999 <50>

755 Calib fail alarm action

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)

Range <Default> OR Option (* = Default)

756 / 761 / 766 / 771 FPO

0 to 2 <0>

757 / 762 / 767 / 772 Number of blades

0 to 50 <0>

758 / 763 / 768 / 773 Max max char dev

0 to 65535 <100>

759 / 764 / 769 / 774 Max tot char devs

0 to 65535 <400>

760 / 765 / 770 / 775 Calibration sample

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

731 / 737 / 743 / 749 CALMON analysis method

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.

This program code selects the “logic” used to perform a “calibration monitoring analysis” with a MPMC board installed. The default value is “Fuzzy”. #

Calibration monitoring analysis incorporates “Fuzzy” logic with four inputs and one output. This is the recommended setting.

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.

Fuzzy

Heuristic Analysis operation using the Heuristic method.

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.

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

754 CALMON reset count

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:

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.

"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.

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

759 / 764 / 769 / 774 Max tot char devs

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.

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%.

757 / 762 / 767 / 772 Number of blades 760 / 765 / 770 / 775 Calibration sample 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.

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.

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%.

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)]

Range <Default> OR Option (* = Default)

776 / 778 / 780 / 782 / 784 / 786 / 788 / 790 / 792 / 794 / 796 / 798 Low flow rate

0 to 99999 <200>

777 / 779 / 781 / 783 / 785 / 787 / 789 / 791 / 793 / 795 / 797 / 799 High flow rate

0 to 99999 <600>

776 / ... / 798 Low flow rate

777 / ... / 799 High 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.

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)

Range <Default> OR Option (* = Default)

800 / 803 / 806 / 809 / 812 / 815 Pump output

0 to number of discrete outputs <0>

801 / 804 / 807 / 810 / 813 / 816 Block valve output

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. BPMIN

(2 * DPWATER) + (1.25 * AVPTMAX)

BPMIN

Minimum back pressure required

DPWATER

pressure drop flowing water at maximum flow rate (. 4 PSIG for turbine meters)

AVPTMAX

absolute vapor pressure of the liquid at maximum temperature

Refer to Appendix C for an example of a “LPG Loading Configuration Checklist”.

where:

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

Range <Default> OR Option (* = Default)

818 PT type

0 Pm - Static pressure inputs * 1 Pd - Differential pressure inputs

819 Pe method

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 *

820 Pinch back method

0 Off - Disable pressure control 1 Sw 2 Pm 3 Pd

821 Pinch back pressure

0 to 9999.99

822 Atmospheric pressure

0 to 9999.99

823 Pinch back qty

0 to 999999 <0>

824 T1

-999.9 to +999.9 <0.0>

825 Pe at T1

0.0 to 9999.99 <0.0>

826 T2

-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

Range <Default> OR Option (* = Default)

827 Pe at T2

0.0 to 9999.99 <0.0>

828 T3

-999.9 to +999.9 <0.0>

829 Pe at T3

0.0 to 9999.99 <0.0>

830 Circuit 1 type

0 to 2 <0>

831 Circuit 2 type

0 to 2 <0>

832 Circuit 3 type

0 to 2 <0>

833 Circuit 4 type

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.

819 Pe method This program code defines the method of back-pressure calculation. #

Const Pe

Program code 825 is the vapor pressure. 818 PT type #

2 point

This program code defines the type of pressure transmitter inputs. Vapor pressure is determined via program codes 824 to 827. #

Pm #

The pressure inputs are static pressure. The DanLoad 6000 calculates Pd = Pm - Pe for pressure correction and valve control. #

3 point

Vapor pressure is determined via program codes 824 to 829.

The pressure inputs are pressure differential (Pm - Pe).

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.

Disable pressure control #

Off

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.

Pressure switch inputs, assigned by program codes 296 / 301 / 306 / 311 Close input, control the OPEN / CLOSE state of the flow control valves.

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.

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. #

With pressure control enabled, response to a low pressure condition also depends on: 026 Unit type 027 Valve type

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

825 Pe at T1

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.

Pe at temperature T1. The default value is 0.0.

826 T2 Temperature 2, i.e. T2. The default value is 0.0.

* 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.

827 Pe at T2 Pe at temperature T2. The default value is 0.0.

828 T3 Temperature 3, i.e. T3. The default value is 0.0.

824 T1

829 Pe at T3

Temperature 1, i.e. T1. The default value is 0.0.

Pe at temperature T3. The default value is 0.0.

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

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

0 to 250 bytes <0>

837 Start page and # pages

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.

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 divisor of 10,000. 835 Start page and # pages 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

838 Tr tk format

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.

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.

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.

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

839 Time out tr

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.

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)

Range <Default> OR Option (* = Default)

840 1 Addr

0 to 250 bytes <0>

841 2 Tr seq #

0 to 250 bytes <0>

842 3 Recipe #

0 to 250 bytes <0>

843 4 Recipe name

0 to 250 bytes <0>

844 5 Side

0 to 250 bytes <0>

845 6 Prompt 1

0 to 250 bytes <0>

846 7 Prompt 2

0 to 250 bytes <0>

847 8 Prompt 3

0 to 250 bytes <0>

848 9 Prompt 4

0 to 250 bytes <0>

849 10 Prompt 5

0 to 250 bytes <0>

850 11 Data item 1

0 to 250 bytes <0>

851 12 Data item 2

0 to 250 bytes <0>

852 13 Data item 3

0 to 250 bytes <0>

853 14 Data item 4

0 to 250 bytes <0>

854 15 Data item 5

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)

Range <Default> OR Option (* = Default)

855 16 Start date

0 to 250 bytes <0>

856 17 End date

0 to 250 bytes <0>

857 18 Gross

0 to 250 bytes <0>

858 19 Std

0 to 250 bytes <0>

859 20 Temp

0 to 250 bytes <0>

860 21 Pres

0 to 250 bytes <0>

861 22 Dens (Comp 1 backup density/gravity)

0 to 250 bytes <0>

862 23 Start gross

0 to 250 bytes <0>

863 24 Start std

0 to 250 bytes <0>

864 25 End gross

0 to 250 bytes <0>

865 26 End std

0 to 250 bytes <0>

866 27 Alarm bit map

0 to 250 bytes <0>

867 28 Prim alarm

0 to 250 bytes <0>

868 29 Temp alarm

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)

Range <Default> OR Option (* = Default)

869 30 Add 1

0 to 250 bytes <0>

870 31 Add 2

0 to 250 bytes <0>

871 32 Add 3

0 to 250 bytes <0>

872 33 Add 4

0 to 250 bytes <0>

873 34 Add 5

0 to 250 bytes <0>

874 35 Add 6

0 to 250 bytes <0>

875 36 Op mode

0 to 250 bytes <0>

876 37 Gross units

0 to 250 bytes <0>

877 38 Std units

0 to 250 bytes <0>

840 to 874 <name>

875 to 877 <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.

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)

Range <Default> OR Option (* = Default)

880 1 Addr

0 to 250 bytes <0>

881 2 Ba seq #

0 to 250 bytes <0>

882 3 Tr seq #

0 to 250 bytes <0>

883 4 Temp

0 to 250 bytes <0>

884 5 Pres

0 to 250 bytes <0>

885 6 Dens

0 to 250 bytes <0>

886 7 Preset

0 to 250 bytes <0>

887 8 Gross

0 to 250 bytes <0>

888 9 Std

0 to 250 bytes <0>

889 10 Comp gross

0 to 250 bytes <0>

890 11 Comp std

0 to 250 bytes <0>

891 12 Comp temp

0 to 250 bytes <0>

892 13 Comp dens

0 to 250 bytes <0>

893 14 Comp pres

0 to 250 bytes <0>

894 15 Comp %

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)

Range <Default> OR Option (* = Default)

895 16 Add 1

0 to 250 bytes <0>

896 17 Add 2

0 to 250 bytes <0>

897 18 Add 3

0 to 250 bytes <0>

898 19 Add 4

0 to 250 bytes <0>

899 20 Add 5

0 to 250 bytes <0>

900 21 Add 6

0 to 250 bytes <0>

901 22 Op mode

0 to 250 bytes <0>

902 23 CCF

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)

Range <Default> OR Option (* = Default)

920 1 Addr

rrrcc <0>

921 2 Tr seq #

rrrcc <0>

922 3 Recipe #

rrrcc <0>

923 4 Recipe name

rrrcc <0>

924 5 Side

rrrcc <0>

925 6 Prompt 1

rrrcc <0>

926 7 Prompt 2

rrrcc <0>

927 8 Prompt 3

rrrcc <0>

928 9 Prompt 4

rrrcc <0>

929 10 Prompt 5

rrrcc <0>

930 11 Data item 1

rrrcc <0>

931 12 Data item 2

rrrcc <0>

932 13 Data item 3

rrrcc <0>

933 14 Data item 4

rrrcc <0>

934 15 Data item 5

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)

Range <Default> OR Option (* = Default)

935 16 Start date

rrrcc <0>

936 17 End date

rrrcc <0>

937 18 Gross

rrrcc <0>

938 19 Std

rrrcc <0>

939 20 Temp

rrrcc <0>

940 21 Pres

rrrcc <0>

941 22 Dens (Comp 1 backup density/gravity)

rrrcc <0>

942 23 Start gross

rrrcc <0>

943 24 Start std

rrrcc <0>

944 25 End gross

rrrcc <0>

945 26 End std

rrrcc <0>

946 27 Alarm bit map

rrrcc <0>

947 28 Prim alarm

rrrcc <0>

948 29 Temp

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)

Range <Default> OR Option (* = Default)

949 30 Add 1

rrrcc <0>

950 31 Add 2

rrrcc <0>

951 32 Add 3

rrrcc <0>

952 33 Add 4

rrrcc <0>

953 34 Add 5

rrrcc <0>

954 35 Add 6

rrrcc <0>

955 36 Op mode

rrrcc <0>

956 37 Gross units

rrrcc <0>

957 36 Std units

rrrcc <0>

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.

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)

Range <Default> OR Option (* = Default)

960 1 Addr

rrrcc <0>

961 2 Ba seq #

rrrcc <0>

962 3 Tr seq #

rrrcc <0>

963 4 Temp

rrrcc <0>

964 5 Pres

rrrcc <0>

965 6 Dens

rrrcc <0>

966 7 Preset

rrrcc <0>

967 8 Gross

rrrcc <0>

968 9 Std

rrrcc <0>

969 10 Comp gross

rrrcc <0>

970 11 Comp std

rrrcc <0>

971 12 Comp temp

rrrcc <0>

972 13 Comp dens

rrrcc <0>

973 14 Comp pres

rrrcc <0>

974 15 Comp %

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)

Program Code (Batch Storage Code)

Range <Default> OR Option (* = Default)

975 16 Add 1

rrrcc <0>

976 17 Add 2

rrrcc <0>

977 18 Add 3

rrrcc <0>

978 19 Add 4

rrrcc <0>

979 20 Add 5

rrrcc <0>

980 21 Add 6

rrrcc <0>

981 22 Op mode

rrrcc <0>

982 23 CCF

rrrcc <0>

982 CCF 960 to 981 <name> 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.

Combined correction factor for temperature and presssure compensation of the liquid components. CTL times CPL

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)

Range <Default> OR Option (* = Default)

983 RTD Alpha

0 3850 * 1 3902

984 LL cnt (4-20 mA input)

0 to 9999 <0>

985 LH cnt (4-20 mA input)

0 to 9999 <0>

986 HL cnt (4-20 mA input)

0 to 9999 <0>

987 HH cnt (4-20 mA input)

0 to 9999 <0>

988 LL cnt (RTD input)

0 to 9999 <0>

989 LH cnt (RTD input)

0 to 9999 <0>

990 HL cnt (RTD input)

0 to 9999 <0>

991 HH cnt (RTD input)

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

986 HL cnt

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:

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 “3850"

“3902"

BS 1904:1984 and DIN 43760 " = 0.003850

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.

" = 0.003902

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.

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. R18°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. R18°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. R55°C.

Program Code Definitions (983 to 991 Analog Inputs) ________________________________________________ Section 6 - 256

__________________________________________________________ DanLoad 6000 (v6.00) 6.28 Step

Step

CPU Version 2 Analog Calibration 1.

Equipment Required A.

Digital Voltmeter-- At least 4 digit

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.

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

NOTE:

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

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)

Program Code 695 = 135 (live pressure- Dymanic Data Display)

CPU Version 2 Analog Calibration ________________________________________

6-257

DanLoad 6000 (v6.00) __________________________________________________________

Program Codes

Calibration Values

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

Copy this page and record values.

6-258 ________________________________________

CPU Version 2 Analog Calibration

__________________________________________________________ DanLoad 6000 (v6.00) Step

Analog Calibration Low Range A.

Connect a Voltmeter across TP1-TP2.

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)

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.)

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).

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)

4-20 mA lo hi reading into PC 985 = (example 956)

RTD lolo reading into PC 988 = (Example 92)

RTD lohi reading into PC 989 = (Example 992)

CPU Version 2 Analog Calibration ________________________________________

6-259

DanLoad 6000 (v6.00) __________________________________________________________ Step

Analog Calibration High Range A.

Exit setup, and re-enter diagnostics and select 1 for 4-20 mA

With the Voltage still set to 2.700 volts across TP1-TP2. Record the displayed number. (Example 4-20 mA hi lo = 41)

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

Step

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.

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.

Adjust the R-Box to 92.55 S. The displayed Current Temperature should read -19.0°C ± 0.1 °C.

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.

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

Appendix A Installation Worksheets

Input / Output Signal Configuration

__________________________________________________________ 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.

Table

Description

Slot Number

A-1a

2-Channel Meter Pulse Board Wiring

J5 or J6

A-1b

4-Channel Meter Pulse Board Wiring

J5 or J6

A-2

AC I/O Board Wiring

J1 or J2

A-3a

Enhanced I/O Board Wiring (Old)

J1 or J2

A-3b

Enhanced I/O Board Wiring (New)

J1 or J2

A-4

DC I/O Board Wiring

J3 or J4

A-5a

2-Channel Analog Input Board Wiring

A-5b

8-Channel Analog Input Board Wiring

A-6

Power Supply Wiring

A-7

Swing Arm Input Wiring

CPU board

A-8

DUART Module Wiring

CPU module

A-9

LAN Module Wiring

Not implemented

Appendix A - 2 _________________________________________

Installation Worksheets

__________________________________________________________ DanLoad 6000 (v6.00)

Table

Description

Setup

A-10

Base Level Program Codes for System Items

A-11

General Configuration Parameters

Required

A-12

Flow Meter Parameters

Required

A-13

Flow Control Valve Parameters

Required

A-14

Component Parameters

Required

A-15

Component Block Valve / Pump Parameters

Required

A-16

Delivery Parameters

Required

A-17

Blending Parameters

Optional

A-18

Temperature Compensation Parameters

Optional

A-19

Pressure Compensation Parameters

Optional

A-20

Density Compensation Parameters

Optional

A-21

Pulse Per Unit Output Parameters

Optional

A-22

Additives Parameters

Optional

A-23

LPG / Pressure Control Parameters

Optional

A-24

Dynamic Data Display Parameters / Codes

Optional

A-25

Communications / Data Logging Parameters

Optional

A-26

Transaction Storage Parameters

Optional

A-27

Transaction Ticket Parameters

Optional

A-28

Alarm Parameters

Optional *

A-29

Analog Input Parameters (for v2 CPU)

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. Input / Output Signal Identification Process Tag

Channel Number

Description

FT-# (1 to 4)

Meter pulse input

TE-# (1 to 4)

RTD input

PT-# / DT-# (1 to 4)

4 to 20 mAdc analog input

ACI-# (1 to max AC inputs)

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

048 Number of valves

052 Valve for meter 1

065 Number of components

067 Meter for component 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)

Board Channel

Function

Meter 1 preamp power (8 - 24 Vdc)

Meter 1 pulse input

Meter 1 preamp common

Meter 2 preamp power (8 - 24 Vdc)

Meter 2 pulse input

Meter 2 preamp common

Meter 1 pulse output +

1 or 3

Meter 1 pulse output -

1 or 3

Meter 2 pulse output +

2 or 4

Meter 2 pulse output -

2 or 4

Control 2 switched + Vdc

Control 2 return - Vdc

Control 1 switched + Vdc

Control 1 return - Vdc

P / S common

Assigned Channel

1 or 3

2 or 4

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) __________________________________________________________

Board Channel

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 +

1, 3, 5

Meter 1 pulse output -

1, 3, 5

Meter 2 pulse output +

2, 4, 6

Meter 2 pulse output -

2, 4, 6

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

Assigned Channel

1, 3, 5

2, 4, 6

3, 5, 7

4, 6, 8

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

Board Channel

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

Assigned Channel

AC I/O Board Wiring (Slot J1 / J3) (Drawing CE-12695) Location:__________ Unit:________ Date:___________ Table A - 2

Installation Worksheets _________________________________________ Appendix A - 11

DanLoad 6000 (v6.00) __________________________________________________________

Function

Board Channel

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

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)

Board Channel

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

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) __________________________________________________________

Board Channel

Function

Transmitter 1 power (24 Vdc)

Transmitter 1 input

Transmitter power common

+ Vsource

RTD 1 +

RTD 1 -

RTD current source

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)

Board Channel

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

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

Vac power hot

TB1-1

Vac safety ground

TB1-2

Vac neutral (230 Vac hot)

TB1-3

Space heater Vac hot (supply)

TB1-4

Space heater Vac neutral

TB1-5

Vac permissive power input

TB2-1

Vac permissive power neutral

TB2-2

Vac permissive power output (fused)

TB2-3

Source / Destination

Power Supply Wiring (Slot J0) (Drawing CE-12692) Location:__________ Unit:________ Date:___________ Table A - 7

Physical Channel

Function

Swing arm switch 1

1 (SW1) (right)

Swing arm common

(center)

Swing arm switch 2

2 (SW2) (left)

Actual Side Per program code 312

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

Destination

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

Program Code Name

LOADING ARM ³ (at) METERS *

050

Number of meters

ENABLE FCV’s *

048

Number of valves

flow control valve ³ meter(s) *

052

ENABLE COMPONENTS *

065

meter ³ component(s) *

067

070

073

076

Meter

block valve ³ component

400

402

404

406

Block valve output

block valve ³ component(s)

408 to 422

block valve ³ component

401

403

405

407

Block valve input

pump ³ component

288

289

290

291

Pump control output

RTD x ³ meter x

318

324

330

336

Meter x temperature input

PT x ³ meter x

320

326

332

338

Meter x pres input

DT x ³ meter x

321

327

333

339

Meter x dens input

ENABLE PULSE OUTPUTS

128

pulse output ³ meter(s)

129

ENABLE ADDITIVES

135

additive ³ meter(s)

139

144

149

154

159

164

Additive control meters

block valve ³ additive

801

804

807

810

813

816

Block valve output

pump ³ additive

800

803

806

809

812

815

Pump output

055

058

061

Valve to be controlled Number of components

Component combination

Number of pulse per unit outputs 132

Control meters Number of additives

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:

Program Code

Unit: Function

Date: Default

Actual

Global 001 / 004 / 007 / 010 / 013 / 016 / 019 / 022 Passcode

Numeric passcode entry for operators and supervisors.

6000

217 Passcode per transaction

Required passcode entry per each transaction (not implemented)

002 / 005 / 008 / 011 / 014 / 017 / 020 / 023 User ID

Configurable user name

003 / 006 / 009 / 012 / 015 / 018 / 021 / 024 Supervisor privilege

Enable supervisor data access

025 Operating mode

Select manual / auto mode for unit

Manual / Auto

026 Unit type

Select type of blending

Seq. (auto)

027 Valve type

Select type of flow control valve

Std digital

028 Language

Select language for unit

English

030 Number of data item prompts

Select quantity of prompts to user

031 / 032 / 033 / 034 / 035 #x Prompt

Configurable prompt text

036 Prompt time-out (s)

Set time to display prompt

Setup (Parameter Groups) _____________________________________________________________________ Appendix A - 19

________________________________________________________________________________________ DanLoad 6000 (v6.00)

TABLE A -11

General Parameters

Location:

Program Code

Unit:

Date:

Function

Default

037 Check display

Display diagnostic

Off

038 Date format

Select date format

mm/dd/yy

039 Date separator

Select date units separator

‘/’

040 Decimal separator

Select decimal separator

‘.’

041 Data display rate

Select data display rate

28000

280 Slot 1 board

Type of input / output board installed in J1

Auto-detect

281 Slot 2 board

Type of input / output board installed in J2

Auto-detect

282 Slot 3 board

Type of input / output board installed in J3

Auto-detect

283 Slot 4 board

Type of input / output board installed in J4

Auto-detect

284 Slot 5 board

Type of input / output board installed in J5

Auto-detect

285 Slot 6 board

Type of input / output board installed in J6

Auto-detect

286 Slot 7 board

Type of input / output board installed in J7

Auto-detect

312 Side detect method

Swing-arm switch input sensing method ( v2 CPU does not have swing arm inputs)

Sgl w/o sw

315 Trip 1 output

ON during low-flow startup

316 Trip 2 output

ON during low-flow startup and high-flow

317 Trip 3 output

ON from start of loading to end of loading

343 Auto/manual change-over

Input CLOSED = automatic mode / input OPEN = manual mode

Actual

Setup (Parameter Groups) _____________________________________________________________________ Appendix A - 20

________________________________________________________________________________________ DanLoad 6000 (v6.00)

TABLE A -11

General Parameters

Location:

Program Code

Unit: Function

Date: Default

355 Primary LCD type

Type of LCD display installed

Optrex

356 Primary LCD minimum light

Controls LCD backlighing intensity based on low ambient light level

455

357 Primary LCD maximum light

Controls LCD backlighing intensity based on high ambient light level

405

358 Secondary LCD type

Type of LCD display installed

Optrex

359 Secondary LCD minimum light

Controls LCD backlighing intensity based on low ambient light level

455

360 Secondary LCD maximum light

Controls LCD backlighting intensity based on high ambient light level

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:

Program Code 050 Number of meters

Unit:

Date:

Function ENABLE 1 to 4 METERS FOR LOAD SPOT

Default

Actual

User input

Global Parameters 029 Product units

Label for volume units.

Gal

045 Round method

Select the method for rounding volume accumulations.

Individual Meter Configuration 051 / 054 / 057 / 060 Meter ID

Assign identification label to flow meter.

052 / 055 / 058 / 061 Valve to be controlled

Assign flow control valve to meter stream

Not used

Pulse Security 233 Error limit (pulses)

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)

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.

10000

Alarms 222 Minimum flow rate

Low flow rate setpoint for alarm trigger.

100

223 Low flow time (s)

Time period to ignore low flow rate before triggering alarm.

221 Low flow alarm action

Action in response to low flow rate alarm.

Primary

225 Maximum flow rate

High flow rate setpoint for alarm trigger.

660

226 High flow time (s)

Time period to ignore high flow rate before triggering alarm.

224 High flow alarm action

Action in response to high flow rate alarm.

Primary

Setup (Parameter Groups) _____________________________________________________________________ Appendix A - 22

________________________________________________________________________________________ DanLoad 6000 (v6.00)

TABLE A -12

Flow Meter Parameters

Location:

Program Code

Unit:

Date:

Function

Default

227 Overrun 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.

2.0

229 Underflow limit qty

Quantity under preset that can be delivered before triggering a Valve closed early meter x alarm.

5.0

228 Underflow alarm action

Action in response to an underflow alarm.

Off

231 No flow t-o time (s)

Time period allowed with no flow when flow is expected before triggering a Timedout - no flow detected meter x alarm.

230 No flow t-o alarm action

Action in response to a no flow time-out alarm.

Primary

232 Unauthorized flow limit qty

Quantity allowed to be measured when flow is not expected before triggering an Unauthorized flow exceeds limit meter x alarm.

10.0

269 Alarm o/p mask 1

Enable alarms to output 1 (bit mask)

16777215

287 Alarm output 1

Assign alarm output 1 to a discrete output.

270 Alarm, o/p mask 2

Enable alarms to output 2 (bit mask)

379 Alarm output 2

Assign alarm output 2 to a discrete output.

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:

Program Code

Date:

Function

048 Number of valves

ENABLE 1 to 4 FLOW CONTROL VALVES

052 / 055 / 058 / 061 Valve to be controlled

Assign flow meter(s) to flow control valve [flow control valve » flow meter(s)]

Default

Actual

Delivery Parameters - Global 027 Valve type

Select type of valve

Std digital

049 Initial flow time (s)

Startup time at initial state before beginning flow control

0.200

Delivery Parameters - Individual Components 108 Ramp clicks

Maximum attempts to ramp-up flow rate before maintaining lower flow rate

109 Maintenance clicks

Maximum attempts to maintain flow rate before falling back to a lower flow rate

114 / 118 / 122 / 126 Maint click adjustment (s)

Normal valve control ON time plus the time specified by this parameter

0.040

112 / 116 / 120 / 124 Low flow % error

Variation from low flow rate allowed before adjustment attempt is made

113 / 117 / 121 / 125 High flow % error

Variation from high flow rate allowed before adjustment attempt is made

115 / 119 / 123 / 127 Open method

Method to control FCV during initial flow time set by program code 049 Initial flow time (s)

Normal

Setup (Parameter Groups) _____________________________________________________________________ Appendix A - 24

________________________________________________________________________________________ DanLoad 6000 (v6.00)

TABLE A -13

Flow Control Valve Parameters

Location:

Program Code

Unit:

Date:

Function

Default

292 / 297 / 302 / 307 Solenoid 1 (upstream)

NO solenoid on FCV

293 / 298 / 303 / 308 Solenoid 2 (downstream)

NC solenoid on FCV

Actual

Inputs 294 / 299 / 304 / 309 Stem Switch 1

Unauthorized flow through FCV

295 / 300 / 305 / 310 Stem Switch 2

Not used

296 / 301 / 306 / 311 Close input

Pressure control (“pinch back”)

Not used

Alarms 276 Ramp down alarm action

Action in response to loss of CLOSE control of the flow control valve.

277 Ramp down time (s)

Time period allowed to reduce flow rate without response before issuing an alarm.

Primary

Setup (Parameter Groups) _____________________________________________________________________ Appendix A - 25

________________________________________________________________________________________ DanLoad 6000 (v6.00) A.6

Component Parameters Setup

TABLE A - 14

Component Parameters

Location:

Unit:

Program Code

Date:

Function

Default

065 Number of components

ENABLE 1 to 4 COMPONENTS (PRODUCTS)

1 or more

067 / 070 / 073 / 076 Meter

Assign component(s) to flow meter [flow meter » component(s)]

Actual

Global Parameters 026 Unit type

Specify loading / blending configuration

Seq.(auto)

045 Round method

Select method for mathmatical rounding of accumulated totals

111 Primary component

Component for blend error detection and / or line flushing

215 Master MF %

Maximum percent variance of any meter factor to corresponding master meter factor

2.00

216 Adjacent MF %

Maximum percent variance of any meter factor to adjacent meter factors.

0.25

066 / 069 / 072 / 075 Component ID

Assign identification label to component

Component #n

068 / 071 / 074 / 077 Mass adjustment

The component’s “mass computation adjustment factor”

0.000000

Meter Factors 169 Number of factors/component

Specify the number of flow rate / meter factor combinations for the component through it’s flow meter

170 Meter factor method

Select use of fixed or linearized meter factors

Fixed

171 / 182 / 193 / 204 Nominal K-factor

Pulses per engineering unit rounded to one decimal place. Obtained from meter nameplate.

23.0

172 / 183 / 194 / 205 Master meter factor

Median value of meter factor for use in validation by program code 215 Master MF %

1.0000

173 / 184 / 195 / 206 Stop rate Comp x

Set the flow rate for low-flow stop quantity at end of inline batch

120

Setup (Parameter Groups) _____________________________________________________________________ Appendix A - 26

________________________________________________________________________________________ DanLoad 6000 (v6.00)

TABLE A - 14

Component Parameters

Location:

Program Code

Unit: Function

Date: Default

174 / 185 / 196 / 207 Flow rate 1

Low calibration flow rate

200

175 / 186 / 197 / 208 Meter factor 1

Meter factor for low calibration flow rate

1.0000

176 / 187 / 198 / 209 Flow rate 2

High or fallback calibraiton flow rate

600

177 / 188 / 199 / 210 Meter factor 2

Meter factor for calibration flow rate 2

1.0000

178 / 189 / 200 / 211 Flow rate 3

High or fallback calibration flow rate

179 / 190 / 201 / 212 Meter factor 3

Meter factor for calibration flow rate 3

1.0000

180 / 191 / 202 / 213 Flow rate 4

High calibraton flow rate

181 / 192 / 203 / 214 Meter factor 4

Meter factor for high calibration flow rate

1.0000

Actual

Setup (Parameter Groups) _____________________________________________________________________ Appendix A - 27

________________________________________________________________________________________ DanLoad 6000 (v6.00) A.7 TABLE A - 15

Component Block Valve / Pump Parameters Setup Block Valve / Pump Parameters

Location:

Unit:

Program Code

Date:

Function

Default

Actual

Block Valve Control Parameters 400 / 402 / 404 / 406 Block valve output

Assign discrete output for block valve control [block valve » component]

408 to 422 Component combination nn (cccc)

Assign discrete output for block valve control [block valve » component(s)]

026 Unit type

DanLoad 6000 unit assignment for general control of block valves

Seq.(auto)

089 Block valve delay (s)

Time between opening block valve and opening the FCV

354 Delay after outputs

Time between energizing recipe and component combination outputs and checking safety circuits (used in conjunction with an automation system).

486 / ... / 660 Sequence to load

Block valve control sequence

Block Valve Status Parameters 401 / 403 / 405 / 407 Block valve input

Assign discrete input for block valve status [block valve » component]

Recipes 480 Number of recipes

Total number of recipes enabled

Setup (Parameter Groups) _____________________________________________________________________ Appendix A - 28

________________________________________________________________________________________ DanLoad 6000 (v6.00)

TABLE A - 15

Block Valve / Pump Parameters

Location:

Unit:

Program Code

Date:

Function

481 / ... / 655 Name

Configurable name for recipe

482 / ... / 656 Component 1 percentage

Percentage of Component 1 to load for Recipe rr

483 / ... / 657 Component 2 percentage

Percentage of Component 2 to load for Recipe rr

484 / ... / 658 Component 3 percentage

Percentage of Component 3 to load for Recipe rr

485 / ... / 659 Comp 4 percent or ratio qty

Percent of Component 4 to load for Recipe rr or additive ratio quantity “Multi-rate”

486 / ... / 660 Sequence or low proportion

[Sequential blending] Order to load components. [In-line blending] High / low proportion component

Default

Actual

Recipe rr

Pump Control Parameters 288 / 289 / 290 / 291 Pump control output

Assign discrete output for pump control [pump » component]

8 / ...

087 Line pack delay (s)

Time between pump start and FCV opening

088 Pump stop delay (s)

Time between FCV closing and pump stop

Alarms 248 Block valve time (s)

Time allowed for a block valve to close after deenergizing the block valve control output.

269 Alarm o/p mask 1

Enable alarm to output 1 (bit mask)

16777215

287 Alarm output 1

Discrete output for alarm mask 1

270 Alarm o/p mask 2

Enable alarm to output 2 (bit mask)

379 Alarm output 2

Discrete output for alarm mask 2

Setup (Parameter Groups) _____________________________________________________________________ Appendix A - 29

________________________________________________________________________________________ DanLoad 6000 (v6.00) A.8

Delivery Parameters Setup

TABLE A - 16

Delivery Parameters

Location:

Unit:

Program Code

Date:

Function

Default

078 Maximum preset qty

Maximum quantity that can be preset in a single batch

3000

079 Minimum preset qty

Minimum quantity that can be preset

080 Preset/delivery type

Use uncompensated or compensated quantity in computing delivery quantity

Gross

081 Delivery display type

Display delivery quantity as uncompensated or compensated quantity

Gross

082 Stop key action

Select method for terminating a batch delivery with the STOP key

Low flow

083 Fall back qty

Quantity to flow at a fall back flow rate before attempting to increase flow rate to highest flow rate

1000

108 Ramp clicks

Number of attempts to increase flow rate before maintaining fall back flow rate

109 Maintenance clicks

Number of attempts to maintain flow rate before decreasing flow rate to a fall back flow rate

110 Additive pump stop (s)

The time between stopping delivery and deenergizing additive pump outputs

111 Primary component

Primary component for blend ratio error detection and / or line flushing

341 #cmpt inputs

Specify the number of “compartment size inputs”

342 Start method

Define the method used to start a batch delivery.

Normal

Actual

Component X 084 / 090 / 096 / 102 Low flow start qty

[Sequential delivery only] Quantity to load at startup flow rate before increasing to high flow rate

085 / 091 / 097 / 103 Low flow restart qty

[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.

Setup (Parameter Groups) _____________________________________________________________________ Appendix A - 30

________________________________________________________________________________________ DanLoad 6000 (v6.00)

TABLE A - 16

Delivery Parameters

Location:

Unit:

Program Code

Date:

Function

Default

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.

087 / 093 / 099 / 105 Line pack delay (s)

Time between component pump energization and opening the flow control valves

088 / 094 / 100 / 106 Pump stop delay (s)

Time between flow control valves closing and component pump deenergization

089 / 095 / 101 / 107 Block valve delay (s)

Time between opening the component block valve and opening the flow control valve.

Actual

Recipes 480 Number of recipes

Specify the number of recipes defined.

481 / ... / 655 Recipe name

Configurable alpha-numeric name of recipe.

Recipe XX

482 / ... / 656 Component 1 percentage

Percentage of component 1 used in blend.

100

483 / ... / 657 Component 2 percentage

Percentage of component 2 used in blend.

484 / ... / 658 Component 3 percentage

Percentage of component 3 used in blend.

485 / ... / 659 Comp 4 percent or ratio qty

Percentage of component 4 used in blend or additive ratio quantity for “Multi Rate”

486 / ... / 660 Sequence or low proportion

[Sequential delivery] Sequence to load components. [ In-line delivery] Specify high / low proportion components. Recipe Selection Inputs

348 Safety circuit 4

Must be set to 0 to enable the six nnn Recipe X input functions below.

361 Recipe 1 input

Assign discrete input for selection of recipe 1

362 Recipe 2 input

Assign discrete input for selection of recipe 2

363 Recipe 3 input

Assign discrete input for selection of recipe 3

364 Recipe 4 input

Assign discrete input for selection of recipe 4

Setup (Parameter Groups) _____________________________________________________________________ Appendix A - 31

________________________________________________________________________________________ DanLoad 6000 (v6.00)

TABLE A - 16

Delivery Parameters Program Code

Location:

Unit: Function

Date: Default

365 Recipe 5 input

Assign discrete input for selection of recipe 5

366 Recipe 6 input

Assign discrete input for selection of recipe 6

Actual

Recipe Selection Outputs 367 Recipe 1 output

Assign discrete output that is ON during batch delivery of recipe 1.

368 Recipe 2 output

Assign discrete output that is ON during batch delivery of recipe 2.

369 Recipe 3 output

Assign discrete output that is ON during batch delivery of recipe 3.

370 Recipe 4 output

Assign discrete output that is ON during batch delivery of recipe 4.

371 Recipe 5 output

Assign discrete output that is ON during batch delivery of recipe 5.

372 Recipe 6 output

Assign discrete output that is ON during batch delivery of recipe 6.

373 End output method

Determine processing method for end of batch or transaction

Ba only

374 Level input

Assign discrete input for ESSO Japan’s intermediate level logic

375 Hatch input

Assign discrete input for ESSO Japan’s hatch sensor logic

Setup (Parameter Groups) _____________________________________________________________________ Appendix A - 32

________________________________________________________________________________________ DanLoad 6000 (v6.00) A.9

Blending Parameters Setup

TABLE A - 17

Blending Parameters Setup Program Code

Location:

Unit:

Date:

Function

Default

Actual

Global Parameters 341 #cmpt inputs

Define the number of “compartment size inputs”

342 Start method

Determine the method for starting batch delivery (not implemented)

Normal

711 Ramp down %

Percent of desired flow rate to ramp to if unable to maintain blend do to low pressure

712 Rate reduction

Reduction if flow rate when high flow rate cannot be maintained

100

713 Low flow start qty

Quantity to load at low flow rate before ramping to high flow rate

714 Clean line qty

Quantity of program code 111 Primary component to load at end of batch

715 Low prop fac

[In-line blending] Flow rate to deliver low-proportion components set by program code 486 / ... / 660 Sequence to load

716 Correct after qty

Quantity of blend to load before beginning blend ratio adjustment

100

717 Alarm after qty

Quantity of blend to load before checking blend ratio for purpose of generating Unable to maintain blend alarm

200

718 Adjustment qty

Quantity segment of blend used to correct the blend ratio

719 Comp % display

Quantity accumulation type for display of batch component percentages

Gross

720 Add calib delay (s)

Time between pressing “START” and beginning of first additive injection cycle

722 Blend error method

Method of computing blend ratio error for adjustment and alarms

Grspctbatch

723 Max dev %

Maximum allowed percent deviation in the blend ratio

724 Blend tol %

Maximum allowed percent tolerance in the blend

725 Max dev qty

Maximum allowed quantity units variation in the blend

Setup (Parameter Groups) _____________________________________________________________________ Appendix A - 33

________________________________________________________________________________________ DanLoad 6000 (v6.00)

TABLE A - 17

Blending Parameters Setup Program Code

Location:

Unit:

Date:

Function

Default

726 Blend tol qty

Maximum allowed quantity tolerance in the blend

727 Blend sample qty

The delivered blend quantity segment used to calculate blend ratio

Actual

Flow Meter Parameters 728 / 734 / 740 / 746 Flow adj fac

Factor for rate of adjustment of flow rate during an in-line blend

1.00

729 / 735 / 741 / 747 Ratio adj fac

Factor for rate of adjustment of blend ratio (for correction) during an in-line blend

1.00

730 / 736 / 742 / 748 Ramp %

[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.

731 CALMON analysis method

“Logic” to use for calibration monitoring analysis

Fuzzy

752 FPO basis

Factor applied to meter pulse inputs to generate factored pulse outputs

Raw

753 CALMON error limit

Number of bad analyses per CALMON reset count calibration monitoring

754 CALMON reset count

All analyses counters are zeroed out at this interval

756 / 761 / 766 / 771 FPO

The factored pulse output on the “smart” 4-ch meter pulse board

757 / 762 / 767 / 772 Number of blades

The number of magnetic blades on the meter for calibration purposes

758 / 763 / 768 / 773 Max max char dev

Maximum signature deviation computed during a calibration analyses

100

759 / 764 / 769 / 774 Max tot char devs

Sum signature deviation computed during a calibration analyses

400

760 / 765 / 770 / 775 Calibration status

Select calibrated or not calibrated - can be used to force recalibration

Not calibrated

Batch Profile Parameters 776 / 778 / 780 / 782 / 784 / 786 / 788 / 790 / 792 / 794 / 796 / 798 Low flow rate

Low flow rate for Recipe n - Batch Profile n

300

777 / 779 / 781 / 783 / 785 / 787 / 789 / 791 / 793 / 795 / 797 / 799 High flow rate

High flow rate for Recipe n - Batch Profile n

600

Setup (Parameter Groups) _____________________________________________________________________ Appendix A - 34

________________________________________________________________________________________ DanLoad 6000 (v6.00) A.10

TABLE A - 18

Temperature Compensation Parameters Setup

Temperature Compensation Parameters

Location:

Unit:

Program Code 318 / 324 / 330 / 336 Meter x temp input

Function ENABLE AND ASSIGN RTD TEMPERATURE INPUTS TO FLOW METER STREAM [RTD » meter stream]

Date: Default

Actual

Global Parameters 353 RTD range

Specify range of RTD inputs on analog input board(s)

Standard

427 Temperaure units

Engineering units: determine how meter temp is computed and control labeling

430 Reference temperature

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.

15.0

431 Sample qty

Measured quantity units between temperature readings to obtain temperature averages.

100

Individual RTD Configuration 319 / 325 / 331 / 337 Meter x offset (Ohms)

3-wire RTD interconnecting wire resistance (not recommended)

432 / 435 /438 / 441 Temperature option

Select method for calculation of CTL

Off

433 / 436 / 439 / 442 Alpha

Coefficient of thermal expansion: "T for linear equation and API tables 6C and 54C

0.0005100

434 / 437 / 440 / 443 Backup temperature

Fixed temperature used if RTD input fails.

15.0

Alarms 239 Minimum temperature

Low temperature setpoint for alarm trigger

-40.0

240 Maximum temperature

High temperature setpoint for alarm trigger

110.0

Setup (Parameter Groups) _____________________________________________________________________ Appendix A - 35

________________________________________________________________________________________ DanLoad 6000 (v6.00)

TABLE A - 18

Temperature Compensation Parameters Program Code

Location:

Unit: Function

Date: Default

238 Temp fail alarm action

Action in response to temperature alarm

Primary

269 Alarm o/p 1 mask

Enable temperature failure alarm to output 1. (Bit mask value = 512)

16777215

287 Alarm output 1

Assign a discrete output to alarm output 1.

270 Alarm o/p 2 mask

Enable temperature failure alarm to output 2. (Bit mask value = 512)

379 Alarm output 2

Assign a discrete output to alarm output 2.

Actual

Setup (Parameter Groups) _____________________________________________________________________ Appendix A - 36

________________________________________________________________________________________ DanLoad 6000 (v6.00) A.11

TABLE A - 19

Pressure Compensation Parameters Setup

Pressure Compensation Parameters

Location:

Unit:

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]

Date: Default

Actual

Global Parameters 429 Pressure units

Engineering units

psi

Individual PT Configuration 464 / 468 / 472 / 476 Pressure @4 mA

Pressure at zero scale transmitter input.

0.00

465 / 469 / 473 / 477 Pressure @20 mA

Pressure at full scale transmitter input.

0.00

444 / 447 / 450 / 453 Pressure option

Select method for calculation of CP L

Off

445 / 448 / 451 / 454 F-factor X 1000000000

Compressibility factor times 109 in volume units per pressure units.

Alarms 244 Minimum pressure

Low pressure setpoint for alarm trigger.

0.00

245 Maximum pressure

High pressure setpoint for alarm trigger.

0.00

Note:

Action in response to pressure alarm is always Primary.

269 Alarm o/p 1 mask

Enable pressure failure alarm to output 1. (Bit mask value = 1024)

C388607

287 Alarm output 1

Assign a discrete output to alarm output 1.

270 Alarm o/p 2 mask

Enable pressure failure alarm to output 2. (Bit mask value = 1024)

379 Alarm output 2

Assign a discrete output for alarm output 2.

Setup (Parameter Groups) _____________________________________________________________________ Appendix A - 37

________________________________________________________________________________________ DanLoad 6000 (v6.00) A.12

Density Compensation Parameters Setup

TABLE A - 20

Density Compensation Parameters

Location:

Unit:

Program Code 321 / 327 / 333 / 339 Meter x dens input

Function Enable and assign density analog input to flow meter stream [density transmitter » meter stream]

Date: Default

Actual

Global Parameters 428 Density units

Engineering units for density measurements.

16/ft3

426 Buoyancy

Density adjustment for buoyancy in air for mass calculation

0.0000

046 Density/gravity scale

Specify the number of digits following the decimal separator in density / gravity values.

Individual DT Configuration 466 / 470 / 474 / 478 Density @4 mA

Density at zero scale transmitter input.

467 / 471 / 475 / 479 Density @20 mA

Density at full scale transmitter input.

456 / 458 / 460 / 462 Density/gravity option

Chose an available option or disable.

Off

457 / 459 / 461 / 463 Backup density/gravity

Fixed density/gravity used when live input is not available.

Alarms 242 Minimum density/gravity

Low density/gravity setpoint for alarm trigger.

243 Maximum density/gravity

High density/gravity setpoint for alarm trigger.

241 Density fail alarm action

Action in response to density alarm.

Primary

269 Alarm o/p 1 mask

Enable density failure alarm to output 1. (Bit mask value = 4096)

16777215

287 Alarm output 1

Assign alarm output 1 to a discrete output.

Setup (Parameter Groups) _____________________________________________________________________ Appendix A - 38

________________________________________________________________________________________ DanLoad 6000 (v6.00)

TABLE A - 20

Density Compensation Parameters Program Code

Location:

Unit: Function

Date: Default

270 Alarm o/p 2 mask

Enable density failure alarm to output 2. (Bit mask value = 4096)

379 Alarm output 2

Assign alarm output 2 to a discrete output.

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:

Program Code

Function

Date: Default

128 Number of pulse per unit outputs

ENABLE 1 or 2 PULSE PER UNIT OUTPUTS

129 / 132 Control meters

Assign flow meters to pulse per unit output [pulse per unit output » flow meter(s)]

G per meter

Actual

Individual Pulse Per Unit Output Configuration 130 / 133 Factor

Output pulse = measured quantity / Factor

1.0

131 / 134 Pulse width (ms)

Pulse output ON time (milliseconds)

Outputs 313 Pulse per unit output 1

Assign output 1 to a discrete output

314 Pulse per unit output 2

Assign output 2 to a discrete output

Setup (Parameter Groups) _____________________________________________________________________ Appendix A - 40

________________________________________________________________________________________ DanLoad 6000 (v6.00) A.14

Additive Parameters Setup

TABLE A - 22

Additives Parameters

Location:

Unit:

Program Code

Function

Date: Default

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)]

G per meter

Actual

Global Parameters 044 Additive units

Engineering units for display and printing.

136 Selection method

Specify how additives are selected

External

137 Inject %

% of cycle at which injection begins

138 Clean line qty

Specity quantity of product to load without additives at end of batch.

398 Clean line output

Output energized during delivery of the quantity specified by program code 138 Clean line qty

110 Additive pump stop (s)

Delay between load stop and additive pumps stop

Individual Additive Configuration 140 / 145 / 150 / 155 / 160 / 165 Ratio qty

Quantity of product measured per each additive ratio output

141 / 146 / 151 / 156 / 161 / 166 Injection method

Select injection method: Mech, Handshake, Meter or Control

Mech

142 / 147 / 152 / 157 / 162 / 167 Volume per pulse or K-factor

Measure additive volume (depends on injection method)

0.00

143 / 148 / 153 / 158 / 163 / 168 Additive per 1000

Additive units injected per 1000 units of product.

0.0000

869 / 870 / 871 / 872 / 873 / 874 Add x

Assign space in transaction storage record for additive total

Setup (Parameter Groups) _____________________________________________________________________ Appendix A - 41

________________________________________________________________________________________ DanLoad 6000 (v6.00)

TABLE A - 22

Additives Parameters

Location:

Program Code

Unit:

Date:

Function

Default

949 / 950 / 951 / 952 / 953 / 954 Add x

Assign coordinates in transaction ticket for additive totals for transaction

895 / 896 / 897 / 898 / 899 / 900 Add x

Assign space in batch storage record for additive total

975 / 976 / 977 / 978 / 979 / 980 Add x

Assign coordinated in transaction ticket for additive totals for batch

Actual

Outputs 380 / 383 / 386 / 389 / 392 / 395 Ratio/valve outputs

Assign additive injection control to a discrete output

800 / 803 / 806 / 809 / 812 / 815 Pump output

ENABLE AND ASSIGN DISCRETE OUTPUT TO ADDITIVE PUMP

801 / 804 / 807 / 810 / 813 . 816 Block valve output

ENABLE AND ASSIGN DISCRETE OUTPUT TO ADDITIVE BLOCK VALVE

398 Clean line output

Energized during delivery of the quantity set by program code 138 Clean line qty

Inputs 382 / 385 / 388 / 391 / 394 / 397 Selection input

External input to select additive

381 / 384 / 387 / 390 / 393 / 396 Feedback/meter input

Verify and/or measure injected additive

Setup (Parameter Groups) _____________________________________________________________________ Appendix A - 42

________________________________________________________________________________________ DanLoad 6000 (v6.00)

TABLE A - 22

Additives Parameters Program Code

247 Additive feedback count

Location:

Unit:

Date:

Function

Default

Actual

Expected # feedback pulses/cycle “Mech” method or maximum feedback “on time” “Handshake” injection in seconds. Alarms

246 Additive error limit

Accumulated additive injection error count for triggering Additive x failure alarm (Mech and Handshake)

247 Additive feedback count

Maximum number of counts that an additive feedback input can be ON before an alarm is generated.

271 Unauth additive flow vol

Volume of unauthorized additive flow at which an additive X failure alarm is raised for the meter and control injection methods.

272 Prod/add -%

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

273 Prod/add +%

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

269 Alarm o/p mask 1

Enable additive failure alarm to output 1

16777215

287 Alarm output 1

Assign alarm output 1 to a discrete output

270 Alarm o/p mask 2

Enable additive failure alarm to outpt 2

379 Alarm output 2

Assign alarm output 2 to a discrete output

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:

Program Code

Unit:

Date:

Function

Default

820 Pinch back method

ENABLE BACK-PRESSURE CONTROL AND SELECT SOURCE OF PRESSURE MEASUREMENT FOR CONTROL

Off

821 Pinch back pressure

Low pressure setpoint to maintain by closing the flow control valve to a lower fall back flow rate setting

296 / 301 / 306 / 311 Close input

Assign discrete input for each flow control valve if pressure switch is used.

818 PT type

Select static pressure or differential pressure input type

819 Pe method

Select method of vapor pressure calculation

TP-15

446 / 449 / 452 / 455 Backup pressure

Component backup pressure in kPa, psi, etc. Used for quantity computation correction if > 0.

0.0

822 Atmospheric pressure

Constant used for absolute / gauge pressure conversion

14.70

823 Pinch back qty

Define the batch startup gross quantity for which pressure control is disabled

026 Unit type

Select type of blender

Seq.(auto)

027 Valve type

Select type of flow control valve

Std. digital

Actual

Setup (Parameter Groups) _____________________________________________________________________ Appendix A - 44

________________________________________________________________________________________ DanLoad 6000 (v6.00)

TABLE A - 23

LPG / Pressure Control Parameters

Location:

Program Code

Unit: Function

Date: Default

824 T1

Temperature for low Pe

0.0

825 Pe at T1

Low pressure Pe at temperature T1

0.0

826 T2

Temperature for high Pe (2-point linearization) OR Temperature for mid Pe (3-point linearization)

0.0

827 Pe at T2

High pressure Pe at temperature T2 (2-point linearization) OR Mid pressure Pe at temperature T2 (3-point linearization)

0.0

828 T3

Temperature for high Pe (3-point linearization)

0.0

829 Pe at T3

High pressure Pe at temperature T3 (3-point linearization)

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:

Program Code

Unit: Function

Date: Default

Actual

Dynamic Data Display Configuration 680 Line 1 data code

Grs batch vol

002

681 Line 2 data code

Std batch vol

003

682 Line 3 data code

Mtr 1 grs total

004

683 Line 4 data code

Mtr 1 std total

005

684 Line 5 data code

Mtr 1 grs batch

006

685 Line 6 data code

Mtr 1 std batch

007

686 Line 7 data code

Mtr 1 grs unauth

017

687 Line 8 data code

Mtr 1 flw rate

008

688 Line 9 data code

Mtr 1 factor

011

689 Line 10 data code

Mtr 1 grs load

103

690 Line 11 data code

Mtr 1 pls cnt

012

691 Line 12 data code

Mtr 1 max flw rate

010

Setup (Parameter Groups) _____________________________________________________________________ Appendix A - 46

________________________________________________________________________________________ DanLoad 6000 (v6.00)

TABLE A - 24

Dynamic Data Display Parameters

Location:

Program Code

Unit: Function

Date: Default

Actual

Dynamic Data Display Configuration 692 Line 13 data code

Mtr 1 curr temp

074

693 Line 14 data code

Cmp 1 ave temp

080

694 Line 15 data code

Cmp 1 ave vlv cls

075

695 Line 16 data code

Arm position

001

Setup (Parameter Groups) _____________________________________________________________________ Appendix A - 47

________________________________________________________________________________________ DanLoad 6000 (v6.00)

TABLE A - 24

Data Codes per Device

Device

Function

Description Global Variables

001

Arm position

0, 1, or 2 indicates the parked, side 1, or side 2 position of the loading arm.

002

Grs batch qty

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).

003

Std batch qty

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).

102

Preset quantity

Batch quantity to load.

121

Flow rate

Total (loading arm delivery) flow rate (0 to 99,999 quantity units per hour).

130

Power fail grs bch

Accumulated gross quantity of the batch delivered at power fail time (0 to 999,999 quantity units).

131

Power fail std bch

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

Device

Function

Description

132

Batch temperature

The flow weighted average temperature of the product during the batch delivery.

133

Batch density

The flow weighted average density of the product during the batch delivery.

134

Batch pressure

The flow weighted average pressure of the product during the batch delivery.

223

Flush pulse count

Pulse count accumulation for flush action.

Meter

Flow Meters Variables

004

021

038

055

Mtr x grs total

Accumulated gross quantity total (non-reset) for meter x (0 to 999,999,999 quantity units).

005

022

039

056

Mtr x std total

Accumulated standard quantity total (non-reset) for meter x (0 to 999,999,999 quantity units).

006

023

040

057

Mtr x grs batch

Accumulated gross quantity for the current batch delivery (0 to 999,999 quantity units). Value is rounded per program code 045 Round method.

007

024

041

058

Mtr x std batch

Accumulated standard quantity for the current batch delivery (0 to 999,999 quantity units). Value is rounded per program code 045 Round method.

008

025

042

059

Mtr x flow rate

Current instantaneous flow rate for meter x (0 to 99,999 quantity units per hour).

009

026

043

060

Mtr x CCF

Combined correction factor for meter x.

Setup (Parameter Groups) _____________________________________________________________________ Appendix A - 49

________________________________________________________________________________________ DanLoad 6000 (v6.00)

TABLE A - 24

Data Codes per Device

Device

Function

Description

010

027

044

061

Mtr x max flw rate

The maximum flow rate for meter x.

011

028

045

062

Mtr x factor

The current meter factor for meter x.

012

029

046

063

Mtr x pls count

Total pulse accumulation = Mtr x pls flrt1 + Mtr x pls flrt2 + Mtr x pls flrt3 + Mtr x pls flrt4

013

030

047

064

Mtr x pls flrt1

Pulse accumulation at Mtr x flow rate 1 (0 at start of load)

014

031

048

065

Mtr x pls flrt2

Pulse accumulation at Mtr x flow rate 2 (0 at start of load)

015

032

049

066

Mtr x pls flrt3

Pulse accumulation at Mtr x flow rate 3 (0 at start of load)

016

033

050

067

Mtr x pls flrt4

Pulse accumulation at Mtr x flow rate 4 (0 at start of load)

017

034

051

068

Mtr x grs unauth

Accumulated unauthorized gross quantity for meter x.

018

035

052

069

Mtr x std unauth

Accumulated unauthorized standard quantity for meter x.

019

036

053

070

Mtr x grs start

Accumulated gross quantity at start of batch ( 0 to 999,999,999 quantity units).

020

037

054

071

Mtr x std start

Accumulated standard quantity at start of batch (0 to 999,999,999 quantity units).

Setup (Parameter Groups) _____________________________________________________________________ Appendix A - 50

________________________________________________________________________________________ DanLoad 6000 (v6.00)

TABLE A - 24

Data Codes per Device

Device

Function

Description

074

080

086

092

Mtr x curr temp

The current temperature (live or fixed) for meter stream x.

103

104

105

106

Mtr x grs load

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.

126

127

128

129

Mtr x Ctl

The internally calculated or fixed value of Ctl (correction factor for the affect of temperature on the quantity of the liquid).

135

136

137

138

Mtr x curr pres

The current pressure (live or fixed) for meter stream x.

139

140

141

142

Mtr x Cpl

Internally calculated or fixed value of Cpl (correction factor for the effect of pressure on the quantity of the liquid).

143

144

145

146

Mtr x curr dens

The current density (live or fixed) for meter stream x.

147

148

149

150

Mtr x std ld data

The delivery accumulted total volume data for meter x standard load.

219

220

221

222

Mtr x calib stat

Meter calibration status for up to 4 meters.

Component

Component Variables

072

078

084

090

Cmp x grs batch

Accumulated gross quantity of component x for the batch delivery. Value is rounded per program code 045 Round method.

073

079

085

091

Cmp x std batch

Accumulated standard quantity of component x for the batch delivery. Value is rounded per program code 045 Round method.

075

081

087

093

Cmp x ave temp

Flow weighted average temperature of component x for the batch delivery.

076

082

088

094

Cmp x ave vlv cls

Average flow control valve closure time when flowing component x.

077

083

089

095

Cmp x batch %

The percentage of component x in the current batch delivery. Quantitys are independent from the selection of program code 722 Blend error method.

107

109

111

113

Cmp x ave dens

Flow weighted average density of component x for the batch delivery. Format dependent on program code 046 Density/gravity scale.

108

110

112

114

Cmp x ave pres

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

Device

Function

Description

122

123

124

125

Cmp x adjust %

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.

151

153

155

157

Cmp x grs total

Accumulated gross total quantity for component x

152

154

156

158

Cmp x std total

Accumulated standard total quantity for component x

Recipe

Function

Description

159 171 183 195 207

161 173 185 197 209

163 175 187 199 211

165 177 189 201 213

167 179 191 203 215

169 181 193 205 217

Rec x grs tot

Recipe x gross total quantity for delivery. Refer to program codes 480-661 for recipe parameters for up to 30 recipes.

160 172 184 196 208

162 174 186 198 210

164 176 188 200 212

166 178 190 202 214

168 180 192 204 216

170 182 194 206 218

Rec x std tot

Recipe x standard total quantity for delivery. Refer to program codes 480-661 for recipe parameters for up to 30 recipes.

Safety Circuit 224 230

225 231

226

227

Function 228

229

Circuit x safety state

Additive 096

097

098

099

Description State of safety circuit x (up to 8 safety circuits).

Additive Variables 100

101

Add x total

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

Device 115

116

117

118

Function 119

120

Add x batch

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:

Program Code

Function

Date: Default

Actual

Data Port Configuration 663 / 668 Mode

Ch. A / B Data protocol selection

Not used

664 / 669 Data rate

Ch. A / B Baud selection

9600

665 / 670 Word size

Ch. A / Ch. B Bits in data word selection

666 / 671 Stop bits

Ch. A / Ch. B Stop bits selection

667 / 672 Parity

Ch. A / Ch. B Parity type selection

EVEN

236 Time-out ch. A (s)

Time-out in seconds for comms failure on channel A.

237 Time-out ch. B (s)

Time-out in seconds for comms failure on channel B.

269 Alarm o/p mask 1

Enable alarms to output 1 (bit mask value = 2))

16777215

287 Alarm output 1

Assign alarm output 1 to discrete output

270 Alarm o/p mask 2

Enable alarms to output 2 (bit mask value = 2)

379 Alarm output 2

Assign alarm output 2 to a discrete output

Data Logging 696 Batch summary

Configure printer output for standard Batch Summary report

Off

697 Transaction summary

Configure printer output for standard Transaction Summary report

Off

698 Alarm log

Configure printer output for Alarm logging

Off

699 Power fail log

Configure printer output for Power Fail logging

Off

700 Program mode entry/exit

Configure printer output for Entry / Exit of Program Mode logging

Off

Setup (Parameter Groups) _____________________________________________________________________ Appendix A - 54

________________________________________________________________________________________ DanLoad 6000 (v6.00)

TABLE A - 25

Communications Parameters

Location:

Program Code

Unit:

Date:

Function

Default

701 W&M switch open/closed

Configure printer output for OPEN / CLOSE W&M switch logging

Off

702 Program code value change log

Configure printer output for modification of program code value logging

Off

703 Configuration summary

Configure printer output for configuration summary printing

Off

704 Crash memory summary

Configure printer output for program crash memory logging

Off

705 Totalizers

Enable / disable automatic printing every 24 hours OR manual printing

Off

706 Transaction ticket

Configure printer output for printing user defined Transaction Ticket

Off

707 Transaction ticket reprint

Configure printer output for reprinting user defined Transaction Ticket

Off

708 Thruput

Enable / disable automatic printing every 24 hours of change in totalizers

Off

709 Sequence numbers

Enable / disable printing of report / log sequence numbers on each report / log on a per printer basis.

Off

710 Cutoff hour

The hour at which a cutoff (end of day) processing run is to be run.

0 (midnight)

Actual

Alarms - Data Logging 235 Data logging alarm action

Action in response to a Data logging memory full alarm

Info

269 Alarm /p mask 1

Enable alarms to output 1

16777215

287 Alarm output 1

Assign alarm output 1 to discrete output

270 Alarm o/p mask 2

Enable alarms to output 2

379 Alarm output 2

Assign alarm output 2 to a discrete output

Setup (Parameter Groups) _____________________________________________________________________ Appendix A - 55

________________________________________________________________________________________ DanLoad 6000 (v6.00) A.18

Transaction Storage Parameters Setup

TABLE A - 26

Transaction Storage Parameters

Location:

Unit:

Program Code

Function

Date: Default

Actual

Transaction Storage - Global 042 Transaction #

Transaction sequence number (0000 to 9999)

9999

043 Batch #

Batch sequence number (0000 to 9999)

9999

047 Batches/transaction

Maximum allowed batches in each transaction (0 to 10000) 0 = unlimited

217 Passcode per transaction

Prompt for passcode entry for each transaction (not implemented)

834 Transaction record length

Number of memory bytes allocated for each stored transaction record.

835 Start page and # pages

Allocation of the start page and number of pages in the transaction file.

602

836 Batch record length

Number of memory bytes allocated for each stored batch record.

837 Start page and # pages

Allocation of the start page and number of pages in the batch file.

838 Tr tk format

Specify default transaction ticket

Lock

839 Time out tr

Specify whether or not a transaction should be timed out automatically

Transaction Record Storage Allocation 840 1 Addr

Record offset for storage Unit Address

841 2 Tr seq #

Record offset for storage of Transaction Sequence Number

842 3 Recipe #

Record offset for storage of Recipe Number

843 4 Recipe name

Record offset for storage of Recipe Name

844 5 Side

Record offset for storage of Swing-arm side

845 6 Prompt 1

Record offset for storage of Prompt 1

Setup (Parameter Groups) _____________________________________________________________________ Appendix A - 56

________________________________________________________________________________________ DanLoad 6000 (v6.00)

TABLE A - 26

Transaction Storage Parameters

Location:

Program Code

Unit:

Date:

Function

Default

846 7 Prompt 2

Record offset for storage of Prompt 2

847 8 Prompt 3

Record offset for storage of Prompt 3

848 9 Prompt 4

Record offset for storage of Prompt 4

849 10 Prompt 5

Record offset for storage of Prompt 5

850 11 Data item 1

Record offset for storage of Data item 1

851 12 Data item 2

Record offset for storage of Data item 2

852 13 Data item 3

Record offset for storage of Data item 3

853 14 Data item 4

Record offset for storage of Data item 4

854 15 Data item 5

Record offset for storage of Data item 5

855 16 Start date

Record offset for storage of Transaction Start Date

856 17 End date

Record offset for storage of Transaction End Date

857 18 Gross

Record offset for storage of accumulated gross total for the tansaction

858 19 Std

Record offset for storage of accumulated std total for tjhe transaction

859 20 Temp

Record offset for storage of average temperature for the tansaction

860 21 Pres

Record offset for storage of average pressure for the transaction

861 22 Dens

Record offset for storage of average density for the transaction

862 23 Start gross

Record offset for storage of the accumulated gross total at the start of the transaction

863 24 Start std

Record offset for storage of the accumujlated std total at the start of the transaction

864 25 End gross

Record offset for storge of hte accumulated gross total at hte end of the transaction

865 26 End std

Reocord offset for storage of the accumulated std total at te end of th transaction

Actual

Setup (Parameter Groups) _____________________________________________________________________ Appendix A - 57

________________________________________________________________________________________ DanLoad 6000 (v6.00)

TABLE A - 26

Transaction Storage Parameters Program Code

Location:

Unit:

Date:

Function

Default

866 27 Alarm bit map

Record offset for storage of a bit map of the alarms that occured during the transaction

867 28 Prim alarm

Record offset for storage of a Primary alarm that occurred during the transaction

868 29 Temp alarm

Record offset for storage of a Temperature alarm that occured during the transaction

869 30 Add 1

Record offset for storage of the accumulated quantity of additive 1 during the transaction

870 31 Add 2

Record offset for storage of te accumulated quantity of additive 2 during the transaction

871 32 Add 3

Record offset for storage of the accumulated quantity of additive 3 during the transaction

872 33 Add 4

Record offset for storage of the accumulated quantity of additive 4 during the transaction

873 34 Add 5

Record offset for storage of the accumulated quantity of additive 5 during the transaction

874 35 Add 6

Record offset for storage of the accumulated quantity of additive 6 during the transaction

875 36 Op mode

Record offset for storage of the operating mode during the transaction

876 37 Gross units

Record offset for storage of the operating mode during the transaction

877 38 Std units

Record offset for storage of the operating mode during the transaction

Actual

Batch Record Storage Allocation 880 1 Addr

Record offset for storage of the Unit Address

881 2 Ba seq #

Record offset for storage of the Batch Sequence Number

882 3 Tr seq #

Record offset for storage of the Transaction Sequence Number

883 4 Temp

Record offset for storage of the average temperature during the batch

Setup (Parameter Groups) _____________________________________________________________________ Appendix A - 58

________________________________________________________________________________________ DanLoad 6000 (v6.00)

TABLE A - 26

Transaction Storage Parameters Program Code

Location:

Unit:

Date:

Function

Default

884 5 Pres

Record offset for storage of the average pressure during the batch

885 6 Dens

Record offset for storage of the average density during the batch

886 7 Preset

Record offset for storage of the Preset value for the batch

887 8 Gross

Record offset for storage of the accumulated gross quantity for the batch

888 9 Std

Record offset for storage of hte accumulated standard quantity for the batch

889 10 Comp gross

Record offset for storage of the accumulated gross quantities of each component in the batch

890 11 Comp std

Record offset for storage of the accumulated standard quantitys of each component in the batch

891 12 Comp temp

Record offset for storage of the average temperature of each component in the batch

892 13 Comp dens

Record offset for storage of the average density of each component in the batch

893 14 Comp pres

Record offset for storage of the aveerage pressure of each component in the batch

894 15 Comp %

Record offset for storage of the percentage of each component in the batch

Actual

Setup (Parameter Groups) _____________________________________________________________________ Appendix A - 59

________________________________________________________________________________________ DanLoad 6000 (v6.00)

TABLE A - 26

Transaction Storage Parameters Program Code

Location:

Unit:

Date:

Function

Default

895 16 Add 1

Record offset for storage of the accumulated quantityn of additive 1 for the batch

896 17 Add 2

Record offset for storage of the accumulated quantityn of additive 2 for the batch

897 18 Add 3

Record offset for storage of the accumulated quantityn of additive 3 for the batch

898 19 Add 4

Record offset for storage of the accumulated quantityn of additive 4 for the batch

899 20 Add 5

Record offset for storage of the accumulated quantityn of additive 5 for the batch

900 21 Add 6

Record offset for storage of the accumulated quantityn of additive 6 for the batch

901 22 Op mode

Record offset for storage of the operation mode during the batch

902 23 CCF

Record offset for storage of the combined correction factor during the batch

Actual

Alarms 274 Storage alarm action

Action in response to a memory full condition for transaction storage or batch storage memory.

Off

Setup (Parameter Groups) _____________________________________________________________________ Appendix A - 60

________________________________________________________________________________________ DanLoad 6000 (v6.00) A.19

Transaction Ticket Parameters Setup

TABLE A - 27

Transaction Ticket Parameters Program Code

Location:

Unit: Function

Date: Default

Actual

Ticket Coordinates for Transaction Storage Codes 920 1 Addr

Transaction ticket coordinates for Unit Address

921 2 Tr seq #

Transaction ticket coordinates for the Transaction Sequence Number

922 3 Recipe #

Transaction ticket coordinates for the Recipe Number

923 4 Recipe name

Transaction ticket coordinates for the Recipe Name

924 5 Side

Transaction ticket coordinates for the Swing-Arm Side

925 6 Prompt 1

Transaction ticket coordinates for Prompt 1

926 7 Prompt 2

Transaction ticket coordinates for Prompt 2

927 8 Prompt 3

Transaction ticket coordinates for Prompt 3

928 9 Prompt 4

Transaction ticker coordinated for Prompt 4

929 10 Prompt 5

Transaction ticket coordinates for Prompt 5

930 11 Data item 1

Transaction ticket t coordinates for Data item 1

931 12 Data item 2

Transaction ticket coordinates for Data item 2

932 13 Data item 3

Transaction ticket coordinates for Data item 3

933 14 Data item 4

Transaction ticket coordinates for Data item 4

934 15 Data item 5

Transaction ticket coordinates for Data item 5

Setup (Parameter Groups) _____________________________________________________________________ Appendix A - 61

________________________________________________________________________________________ DanLoad 6000 (v6.00)

TABLE A - 27

Transaction Ticket Parameters Program Code

Location:

Unit:

Date:

Function

Default

935 16 Start date

Transaction ticket coordinates for Start Transaction Date

936 17 End date

Transaction ticket coordinates for End Transaction Date

937 18 Gross

Transaction ticket coordinates for accumulated gross quantity for the transaction

938 19 Std

Transaction ticket coordinates for accumulated standard quantity for the transaction

939 20 Temp

Transaction ticket coordinates for average temperature for the transaction

940 21 Pres

Transaction ticket coordinates for average pressure for the transaction

941 22 Dens

Transaction ticket coordinates for average pressure for the transaction

942 23 Start gross

Transaction ticket coordinates for the gross totalizer reading at start of transaction

943 24 Start std

Transaction ticket coordinates for th std totalizer reading t start of transaction

944 25 End gross

Transaction ticket coordinates for the gross totalizer reading at end of transaction

945 26 End std

Transaction ticket coordinates for the std totalizer reading at end of transaction

946 27 Alarm bit map

Transaction ticket coordinates for the alarm bit map

947 28 Prim alarm

Transaction ticket coordinate for a Primary alarm

948 29 Temp alarm

Transaction ticket coordinates for the Temperature alarm

Actual

Setup (Parameter Groups) _____________________________________________________________________ Appendix A - 62

________________________________________________________________________________________ DanLoad 6000 (v6.00)

TABLE A - 27

Transaction Ticket Parameters Program Code

Location:

Unit:

Date:

Function

Default

949 30 Add 1

Transaction ticket coordinates for the total Additive 1 quantity for the transaction

950 31 Add 2

Transaction ticket coordinates for the total Additive 2 quantity for the transaction

951 32 Add 3

Transaction ticket coordinates for the total Additive 3 quantity for the transaction

952 33 Add 4

Transaction ticket coordinates for the total Additive 4 quantity for the transaction

953 34 Add 5

Transaction ticket coordinates for the total Additive 5 quantity for the transaction

954 35 Add 6

Transaction ticket coordinates for the total Additive 6 quantity for the transaction

955 36 Op mode

Transaction ticket coordinates for the Operation Mode during the transaction

956 37 Gross units

Transaction ticket coordinates for the Operation Mode during the transaction

957 38 Std units

Transaction ticket coordinates for the Operation Mode during the transaction

Actual

Ticket Coordinates for Batch Storage Codes 960 1 Addr

Transaction ticket coordinates for the Unit Address during batch

961 2 Ba seq #

Transaction ticket coordinates for the Batch Sequence Number

962 3 Tr seq #

Transaction ticket coordinates for the Transaction Sequence Number

963 4 Temp

Transaction ticket coordinates for the average temperature during the batch

964 5 Pres

Transaction ticket coordinates for the average pressure during the batch

965 6 Dens

Transaction ticket coordinates for the average density during the batch

966 7 Preset

Transaction ticket coordinates for the batch Preset quantity

967 8 Gross

Transaction ticket coordinates for the batch gross quantity

968 9 Std

Transaction ticket coordinates for the batch standard quantity

969 10 Comp gross

Transaction ticket coordinates for the component gross quantities for the batch

Setup (Parameter Groups) _____________________________________________________________________ Appendix A - 63

________________________________________________________________________________________ DanLoad 6000 (v6.00)

TABLE A - 27

Transaction Ticket Parameters Program Code

Location:

Unit:

Date:

Function

Default

970 11 Comp std

Transaction ticket coordinates for the component standard quantities for the batch

971 12 Comp temp

Transaction ticket coordinates for the average temperatures of the components for the batch

972 13 Comp dens

Transaction ticket coordinations for the average density of the components for the batch

973 14 Comp pres

Transaction ticket coordinates for the average pressure of the components for the batch

974 15 Comp %

Transaction ticket coordinates for the component percentages for the batch

975 16 Add 1

Transaction ticket coordinates for the Additive 1 quantity for the batch

976 17 Add 2

Transaction ticket coordinates for the Additive 2 quantity for the batch

977 18 Add 3

Transaction ticket coordinates for the Additive 3 quantity for the batch

978 19 Add 4

Transaction ticket coordinates for the Additive 4 quantity for the batch

979 20 Add 5

Transaction ticket coordinates for the Additive 5 quantity for the batch

980 21 Add 6

Transaction ticket coordinates for the Additive 6 quantity for the batch

981 22 Op mode

Transaction ticket coordinates for the Operation Mode during the batch

982 23 CCF

Transaction ticket coordinates for the Combined Correction Factor during the batch

Actual

Setup (Parameter Groups) _____________________________________________________________________ Appendix A - 64

________________________________________________________________________________________ DanLoad 6000 (v6.00) A.20

TABLE A - 28

Alarm Parameters Setup

Alarm Parameters

Location:

Unit:

Program Code

Date:

Function

Default

Actual

Safety Circuit Configuration 220 Secondary alarm reset (s)

Time period to allow a secondary alarm to be active before it is reset automatically.

300

222 Minimum flow rate

Setpoint for Flow rate too low meter x alarm trigger.

100

223 Low flow time (s)

Time allowed at flow less than setpoint before triggering alarm.

221 Low flow alarm action

Response to low flow alarm.

Primary

225 Maximum flow rate

Setpoint for Flow rate too high meter x alarm trigger.

660

226 High flow time (s)

Time allowed at flow greater than setpoint before triggering alarm.

224 High flow alarm action

Response to high flow alarm.

Primary

227 Overrun limit qty

Setpoint for Unable to close valve meter x alarm trigger. (PRIMARY)

2.0

229 Underflow limit qty

Setpoint for Valve closed early meter x alarm trigger.

5.0

228 Underflow alarm action

Response to underflow alarm.

Off

231 No flow t-o time (s)

Setpoint for Timed-out - no flow detected meter x alarm trigger.

230 No flow t-o alarm action

Response to no flow time-out alarm.

Primary

232 Unauthorized flow limit qty

Setpoint for Unauthorized flow exceeds limit meter x alarm trigger. (PRIMARY)

10.0

233 Error limit (pulses)

Setpoint for Pulse security error meter x alarm trigger. (PRIMARY)

234 Reset count (pulses)

Pulse error accumulation before RESET counter is issued.

10000

235 Data logging alarm action

Response to Data logging memory full alarm.

Info

236 Time-out ch. A (s)

Set time out in seconds for Comms failure channel A

Setup (Parameter Groups) _____________________________________________________________________ Appendix A - 65

________________________________________________________________________________________ DanLoad 6000 (v6.00)

TABLE A - 28

Alarm Parameters

Location:

Unit:

Program Code

Function

Date: Default

237 Time-out ch. B (s)

Set time out in seconds for Comms failure channel B

239 Minimum temperature

Low setpoint for Temperature failure meter x alarm trigger.

-40.0

240 Maximum temperature

High setpoint for Temperature failure meter x alarm trigger.

110.0

238 Temp fail alarm action

Response to temperature failure alarm.

Primary

242 Minimum density/gravity

Low setpoint for Density failure component x alarm trigger.

243 Maximum density/gravity

High setpoint for Density failure component x alarm trigger.

241 Density fail alarm action

Response to density failure alarm.

Primary

244 Minimum pressure

Low setpoint for Pressure failure meter x alarm trigger. (PRIMARY)

0.00

245 Maximum pressure

High setpoint for Pressure failure meter x alarm trigger.

0.00

246 Additive error limit

Setpoint for Additive x failure alarm trigger. (PRIMARY)

247 Additive feedback count

Expected number of feedback pulses per additive ratio cycle.

248 Block valve time (s)

Setpoint for Unable to close block valve x alarm trigger.

Actual

Safety Circuit Configuration 345 Safety circuit 1

Assign discrete input to alarm

249 Circuit 1 alarm action

Response to TRUE input to Safety circuit 1

Secondary

250 #1 Ground detector open

Configurable message for Safety circuit 1

Setup (Parameter Groups) _____________________________________________________________________ Appendix A - 66

________________________________________________________________________________________ DanLoad 6000 (v6.00)

TABLE A - 28

Alarm Parameters

Location:

Program Code

Unit: Function

Date: Default

346 Safety circuit 2

Assign discrete input to alarm

251 Circuit 2 alarm action

Response to TRUE input to Safety circuit 2

Primary

252 #2 Overspill detector open

Configurable message for Safety circuit 2

347 Safety circuit 3

Assign discrete input to alarm

253 Circuit 3 alarm action

Response to TRUE input to Safety circuit 3

Secondary

254 #3 Permissive power failure

Configurable message for Safety circuit 3

348 Safety circuit 4

Assign discrete input to alarm

255 Circuit 4 alarm action

Response to TRUE input to Safety circuit 4

Secondary

256 #1 Additive injection failure

Configurable message for Safety circuit 4

349 Safety circuit 5

Assign discrete input to alarm

257 Circuit 5 alarm action

Response to TRUE input to Safety circuit 5

Secondary

258 #5 Arm down side 1

Configurable message for Safety circuit 5

265 Circuit 5 type

Enable / disable / define swing-arm side checking for this circuit.

350 Safety circuit 6

Assign discrete input to alarm

259 Circuit 6 alarm action

Response to TRUE input to Safety circuit 6

Secondary

260 #6 Arm down side 2

Configurable message for Safety circuit 6

266 Circuit 6 type

Enable / disable / define swing-arm side checking for this circuit.

351 Safety circuit 7

Assign discrete input to alarm

261 Circuit 7 alarm action

Response to TRUE input to Safety circuit 7

Secondary

262 #7 Walkway down side 1

Configurable message for Safety circuit 7

Actual

Setup (Parameter Groups) _____________________________________________________________________ Appendix A - 67

________________________________________________________________________________________ DanLoad 6000 (v6.00)

TABLE A - 28

Alarm Parameters

Location:

Unit:

Program Code

Function

Date: Default

267 Circuit 7 type

Enable / disable / define swing-arm side checking for this circuit.

352 Safety circuit 8

Assign discrete input to alarm

263 Circuit 8 alarm action

Response to TRUE input to Safety circuit 2

Secondary

264 #8 Walkway down side 2

Configurable message for Safety circuit 2

268 Circuit 8 type

Enable / disable / define swing-arm side checking for this circuit.

Actual

Discrete Control Output for Alarms 269 Alarm o/p mask 1

Enable alarms to output 1 (bit mask).

16777215

287 Alarm output 1

Assign alarm output 1 to a discrete output.

270 Alarm o/p mask 2

Enable alarms to output 2 (bit mask).

379 Alarm output 2

Assign alarm output 2 to a discrete output.

Setup (Parameter Groups) _____________________________________________________________________ Appendix A - 68

________________________________________________________________________________________ DanLoad 6000 (v6.00)

TABLE A - 29

Analog Inputs Program Code

Location:

Unit: Function

Date: Default

Actual

Analog Inputs Configuration 983 RTD Alpha

Set the alpha value for temperature calculations

3850

984 LLcnt

Set A/D value for Low channel Low calibration point for 4-20 mA input

985 LH cnt

Set A/D value for Low channel High calibration point for 4-20 mA input

986 HL cnt

Set A/D value for High channel Low calibration point for 4-20 mA input

987 HH cnt

Set A/D value for High channel High calibration point for 4-20 mA input

988 LL cnt

Set A/D value for Low channel Low calibration point for RTD input

989 LH cnt

Set A/D value for Low channel High calibration point for RTD input

990 HL cnt

Set A/D value for High channel Low calibration point for RTD input

991 HH cnt

Set A/D value for High channel High calibration point for RTD input

Setup (Parameter Groups) _____________________________________________________________________ Appendix A - 69

________________________________________________________________________________________ DanLoad 6000 (v6.00)

This page intentionally left blank.

Setup (Parameter Groups) _____________________________________________________________________ Appendix A - 70

Appendix B Configuration Record

Configuration Record for a DanLoad 6000 Installation

__________________________________________________________ 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: Code

Unit ID:

Date:

Parameter

Value / Selection USER 1

001

Passcode

002

User ID

003

Supervisor privilege USER 2

004

Passcode

005

User ID

006

Supervisor privilege USER 3

007

Passcode

008

User ID

009

Supervisor privilege USER 4

010

Passcode

011

User ID

012

Supervisor privilege USER 5

013

Passcode

014

User ID

015

Supervisor privilege USER 6

016

Passcode

017

User ID

018

Supervisor privilege UNIT PARAMETERS <PAGE 1>

023

"Side" Stream Blending

Appendix B - 2 _____________________________________________ Configuration Record

__________________________________________________________ DanLoad 6000 (v6.00)

Code 024

Parameter

Value / Selection

“Sequential” proportional UNIT PARAMETERS <PAGE 2>

025

Operating mode

026

Unit type

027

Valve type

028

Language

029

Product Units UNIT PARAMETERS <PAGE 3>

030

Number of data items

031

#1 Enter data item #1

032

#2 Enter data item #2

033

#3 Enter data item #3

034

#4 Enter data item #4

035

#5 Enter data item #5 UNIT PARAMETERS <PAGE 4>

036

Prompt time-out (s)

037

Check display

038

Date format

039

Date separator

040

Decimal separator

041

Display data rate UNIT PARAMETERS <PAGE 5>

042

Transaction #

043

Batch #

044

Additive units

045

Round method

046

Density/gravity scale

Configuration Record ___________________________________________ Appendix B - 3

DanLoad 6000 (v6.00) __________________________________________________________

Code 047

Parameter

Value / Selection

Batches/transaction VALVE PARAMETERS

048

Number of valves

049

Initial flow time (s) METER PARAMETERS

050

Number of meters METER 1 PARAMETERS

051

Meter ID

052

Valve to be controlled

053

"Side" Stream Meter METER 2 PARAMETERS

054

Meter ID

055

Valve to be controlled

056

"Side" Stream Meter METER 3 PARAMETERS

057

Meter ID

058

Valve to be controlled

059

"Side" Stream Meter METER 4 PARAMETERS

060

Meter ID

061

Valve to be controlled

062

"Side" Stream Meter METER PARAMETERS

063

Midgrade Primary blend stream meter COMPONENT PARAMETERS

065

Number of components

Appendix B - 4 _____________________________________________ Configuration Record

__________________________________________________________ DanLoad 6000 (v6.00)

Code

Parameter

Value / Selection COMPONENT 1

066

Component ID

067

Meter

068

Mass adjustment COMPONENT 2

069

Component ID

070

Meter

071

Mass adjustment COMPONENT 3

072

Component ID

073

Meter

074

Mass adjustment COMPONENT 4

075

Component ID

076

Meter

077

Mass adjustment DELIVERY PARAMETERS

078

Maximum preset qty

079

Minimum preset qty

080

Preset/delivery type

081

Delivery display type

082

Stop key action

083

Fall back qty COMP 1 DELIVERY PARAMETERS

084

Low flow start qty

085

Low flow restart qty

086

Low flow stop qty

Configuration Record ___________________________________________ Appendix B - 5

DanLoad 6000 (v6.00) __________________________________________________________

Code

Parameter

087

Line pack delay (s)

088

Pump stop delay (s)

089

Block valve delay (s)

Value / Selection

COMP 2 DELIVERY PARAMETERS 090

Low flow start qty

091

Low flow restart qty

092

Low flow stop qty

093

Line pack delay (s)

094

Pump stop delay (s)

095

Block valve delay (s) COMP 3 DELIVERY PARAMETERS

096

Low flow start qty

097

Low flow restart qty

098

Low flow stop qty

099

Line pack delay (s)

100

Pump stop delay (s)

101

Block valve delay (s) COMP 4 DELIVERY PARAMETERS

102

Low flow start qty

103

Low flow restart qty

104

Low flow stop qty

105

Line pack delay (s)

106

Pump stop delay (s)

107

Block valve delay (s) DELIVERY PARAMETERS (continued)

108

Ramp clicks

109

Maintenance clicks

Appendix B - 6 _____________________________________________ Configuration Record

__________________________________________________________ DanLoad 6000 (v6.00)

Code

Parameter

110

Additive pump stop (s)

111

Primary component

Value / Selection

DIGITAL VALVE 1 PARAMETERS 112

Low flow % error

113

High flow % error

114

Maint click adjustment (s)

115

Open method DIGITAL VALVE 2 PARAMETERS

116

Low flow % error

117

High flow % error

118

Maint click adjustment (s)

119

Open method DIGITAL VALVE 3 PARAMETERS

120

Low flow % error

121

High flow % error

122

Maint click adjustment (s)

123

Open method DIGITAL VALVE 4 PARAMETERS

124

Low flow % error

125

High flow % error

126

Maint click adjustment (s)

127

Open method PULSE PER UNIT OUTPUTS

128

Number of pulse per unit outputs PULSE PER UNIT OUTPUT 1

129

Control meters

130

Factor

Configuration Record ___________________________________________ Appendix B - 7

DanLoad 6000 (v6.00) __________________________________________________________

Code 131

Parameter

Value / Selection

Pulse width (ms) PULSE PER UNIT OUTPUT 2

132

Control meters

133

Factor

134

Pulse width (ms) ADDITIVE PARAMETERS

135

Number of additives

136

Additive Selection method

137

Inject percentage

138

Clean line qty ADDITIVE 1 PARAMETERS

139

Control meters

140

Ratio qty

141

Injection method

142

Volume/pulse or K-factor

143

Additive per 1000 ADDITIVE 2 PARAMETERS

144

Control meters

145

Ratio qty

146

Injection method

147

Volume/pulse or K-factor

148

Additive per 1000 ADDITIVE 3 PARAMETERS

149

Control meters

150

Ratio qty

151

Injection method

152

Volume/pulse or K-factor

Appendix B - 8 _____________________________________________ Configuration Record

__________________________________________________________ DanLoad 6000 (v6.00)

Code 153

Parameter

Value / Selection

Additive per 1000 ADDITIVE 4 PARAMETERS

154

Control meters

155

Ratio qty

156

Injection method

157

Volume/pulse or K-factor

158

Additive per 1000 ADDITIVE 5 PARAMETERS

159

Control meters

160

Ratio qty

161

Injection method

162

Volume/pulse or K-factor

163

Additive per 1000 ADDITIVE 6 PARAMETERS

164

Control meters

165

Ratio qty

166

Injection method

167

Volume/pulse or K-factor

168

Additive per 1000 METER FACTORS

169

Number of factors/component

170

Meter factor method COMPONENT 1 FACTORS

171

Nominal K-factor

172

Master meter factor

173

Stop rate

Configuration Record ___________________________________________ Appendix B - 9

DanLoad 6000 (v6.00) __________________________________________________________

Code

Parameter

Value / Selection

COMPONENT 1 FACTOR 1 174

Flow rate 1

175

Meter factor 1 COMPONENT 1 FACTOR 2

176

Flow rate 2

177

Meter factor 2 COMPONENT 1 FACTOR 3

178

Mlow rate 3

179

Meter factor 3 COMPONENT 1 FACTOR 4

180

Flow rate 4

181

Meter factor 4 COMPONENT 2 FACTORS

182

Nominal K-factor

183

Master meter factor

184

Stop rate COMPONENT 2 FACTOR 1

185

Flow rate 1

186

Meter factor 1 COMPONENT 2 FACTOR 2

187

Flow rate 2

188

Meter factor 2 COMPONENT 2 FACTOR 3

189

Flow rate 3

190

Meter factor 3 COMPONENT 2 FACTOR 4

191

Flow rate 4

Appendix B - 10 _____________________________________________Configuration Record

__________________________________________________________ DanLoad 6000 (v6.00)

Code 192

Parameter

Value / Selection

Meter factor 4 COMPONENT 3 FACTORS

193

Nominal K-factor

194

Master meter factor

195

Stop rate COMPONENT 3 FACTOR 1

196

Flow rate 1

197

Meter factor 1 COMPONENT 3 FACTOR 2

198

Flow rate 2

199

Meter factor 2 COMPONENT 3 FACTOR 3

200

Flow rate 3

201

Meter factor 3 COMPONENT 3 FACTOR 4

202

Flow rate 4

203

Meter factor 4 COMPONENT 4 FACTORS

204

Nominal K-factor

205

Master meter factor

206

Stop rate COMPONENT 4 FACTOR 1

207

Flow rate 1

208

Meter factor 1 COMPONENT 4 FACTOR 2

209

Flow rate 2

Configuration Record ___________________________________________ Appendix B - 11

DanLoad 6000 (v6.00) __________________________________________________________

Code 210

Parameter

Value / Selection

Meter factor 2 COMPONENT 4 FACTOR 3

211

Flow rate 3

212

Meter factor 3 COMPONENT 4 FACTOR 4

213

Flow rate 4

214

Meter factor 4 MF VALIDATION

215

Master MF %

216

Adjacent MF %

217

Gross units mnemonic

218

Std units mnemonic

219

Use restart qty ALARM PARAMETERS <PAGE 1>

220

Secondary alarm reset (s) ALARM PARAMETERS <PAGE 2>

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) ALARM PARAMETERS <PAGE 3>

227

Overrun limit qty

228

Underflow alarm action

229

Underflow limit qty

230

No flow t-o alarm action

Appendix B - 12 _____________________________________________Configuration Record

__________________________________________________________ DanLoad 6000 (v6.00)

Code

Parameter

231

No flow t-o time (s)

232

Unauth flow qty

Value / Selection

ALARM PARAMETERS <PAGE 4> 233

Error limit (pulses)

234

Reset count (pulses)

235

Data logging alarm action

236

Time-out ch. A (s)

237

Time-out ch. B (s) ALARM PARAMETERS <PAGE 5>

238

Temp fail alarm action

239

Minimum temperature

240

Maximum temperature

241

Density fail alarm action

242

Minimum density/gravity

243

Maximum density/gravity ALARM PARAMETERS <PAGE 6>

244

Minimum pressure

245

Maximum pressure

246

Additive error limit

247

Additive feedback count

248

Block valve time (s) ALARM PARAMETERS <PAGE 7>

249

Circuit 1 alarm action

250

#1 Ground detector open

251

Circuit 2 alarm action

252

#2 Overspill detector open ALARM PARAMETERS <PAGE 8>

Configuration Record ___________________________________________ Appendix B - 13

DanLoad 6000 (v6.00) __________________________________________________________

Code

Parameter

253

Circuit 3 alarm action

254

#3 Permissive power failure

255

Circuit 4 alarm action

256

#4 Additive injection failure

Value / Selection

ALARM PARAMETERS <PAGE 9> 257

Circuit 5 alarm action

258

#5 Arm down side 1

259

Circuit 6 alarm action

260

#6 Arm down side 2 ALARM PARAMETERS <PAGE 10>

261

Circuit 7 alarm action

262

#7 Walkway down side 1

263

Circuit 8 alarm action

264

#8 Walkway down side 2 ALARM PARAMETERS <PAGE 11>

265

Circuit 5 type

266

Circuit 6 type

267

Circuit 7 type

268

Circuit 8 type

269

Alarm o/p 1 mask

270

Alarm o/p 2 mask ALARM PARAMETERS <PAGE 12>

271

Unauth additive flow vol

272

Prod/add -%

273

Prod/add +%

274

Storage alarm action

275

Power fail alarm action

Appendix B - 14 _____________________________________________Configuration Record

__________________________________________________________ DanLoad 6000 (v6.00)

Code

Parameter

Value / Selection

276

Ramp down alarm action

277

Ramp down time (s)

278

Additive per 1000 error limit

279

End time (s) I/O PARAMETERS <PAGE 1>

280

Slot 1 board

281

Slot 2 board I/O PARAMETERS <PAGE 2>

282

Slot 3 board

283

Slot 4 board

284

Slot 5 board

285

Slot 6 board

286

Slot 7 board I/O PARAMETERS <PAGE 3>

287

Alarm output 1 COMPONENT 1 I/O

288

Pump control output COMPONENT 2 I/O

289

Pump control output COMPONENT 3 I/O

290

Pump control output COMPONENT 4 I/O

291

Pump control output VALVE 1 I/O

292

Solenoid 1 (upstream)

293

Solenoid 2 (downstream)

294

Stem switch 1 (normally closed)

Configuration Record ___________________________________________ Appendix B - 15

DanLoad 6000 (v6.00) __________________________________________________________

Code

Parameter

Value / Selection

295

Stem switch 2 (normally open)

296

Close input VALVE 2 I/O

297

Solenoid 1 (upstream)

298

Solenoid 2 (downstream)

299

Stem switch 1 (normally closed)

300

Stem switch 2 (normally open)

301

Close input VALVE 3 I/O

302

Solenoid 1 (upstream)

303

Solenoid 2 (downstream)

304

Stem switch 1 (normally closed)

305

Stem switch 2 (normally open)

306

Close input VALVE 4 I/O

307

Solenoid 1 (upstream)

308

Solenoid 2 (downstream)

309

Stem switch 1 (normally closed)

310

Stem switch 2 (normally open)

311

Close input I/O PARAMETERS <PAGE 12>

312

Side detect method

313

Pulse per unit output 1

314

Pulse per unit output 2

315

Trip 1 output

316

Trip 2 output

Appendix B - 16 _____________________________________________Configuration Record

__________________________________________________________ DanLoad 6000 (v6.00)

Code 317

Parameter

Value / Selection

Trip 3 output I/O PARAMETERS <PAGE 13>

318

Meter 1 temp input

319

Meter 1 offset (Ohms)

320

Meter 1 pres input

321

Meter 1 dens input

322

Meter 1 flow input I/O PARAMETERS <PAGE 14>

324

Meter 2 temp input

325

Meter 2 offset (Ohms)

326

Meter 2 pres input

327

Meter 2 dens input

328

Meter 2 flow input I/O PARAMETERS <PAGE 15>

330

Meter 3 temp input

331

Meter 3 offset (Ohms)

332

Meter 3 pres input

333

Meter 3 dens input

334

Meter 3 flow input I/O PARAMETERS <PAGE 16>

336

Meter 4 temp input

337

Meter 4 offset (Ohms)

338

Meter 4 pres input

339

Meter 4 dens input

340

Meter 4 flow input I/O PARAMETERS <PAGE 17>

341

#cpmt inputs

Configuration Record ___________________________________________ Appendix B - 17

DanLoad 6000 (v6.00) __________________________________________________________

Code

Parameter

342

Start method

343

Auto/manual change-over

344

Primary alarm reset

Value / Selection

I/O PARAMETERS <PAGE 18> 345

Safety circuit 1

346

Safety circuit 2

347

Safety circuit 3

348

Safety circuit 4 I/O PARAMETERS <PAGE 19>

349

Safety circuit 5

350

Safety circuit 6

351

Safety circuit 7

352

Safety circuit 8 I/O PARAMETERS <PAGE 20>

353

RTD range

354

Delay after outputs I/O PARAMETERS <PAGE 21>

355

Primary LCD type

356

Primary LCD minimum light

357

Primary LCD maximum light

358

Secondary LCD type

359

Secondary LCD minimum light

360

Secondary LCD maximum light I/O PARAMETERS <PAGE 22>

361

Recipe 1 input

362

Recipe 2 input

363

Recipe 3 input

Appendix B - 18 _____________________________________________Configuration Record

__________________________________________________________ DanLoad 6000 (v6.00)

Code

Parameter

364

Recipe 4 input

365

Recipe 5 input

366

Recipe 6 input

Value / Selection

I/O PARAMETERS <PAGE 23> 367

Recipe 1 output

368

Recipe 2 output

369

Recipe 3 output

370

Recipe 4 output

371

Recipe 5 output

372

Recipe 6 output I/O PARAMETERS <PAGE 24>

373

End output method I/O PARAMETERS <PAGE 25>

374

Level input

375

Hatch input

376

Swing 1 input

377

Swing 2 input

378

Low flow input

379

Alarm output 2 ADDITIVE 1 I/O PARAMETERS

380

Ratio/valve output

381

Feedback/meter input

382

Selection input ADDITIVE 2 I/O PARAMETERS

383

Ratio/valve output

384

Feedback/meter input

Configuration Record ___________________________________________ Appendix B - 19

DanLoad 6000 (v6.00) __________________________________________________________

Code 385

Parameter

Value / Selection

Selection input ADDITIVE 3 I/O PARAMETERS

386

Ratio/valve output

387

Feedback/meter input

388

Selection input ADDITIVE 4 I/O PARAMETERS

389

Ratio/valve output

390

Feedback/meter input

391

Selection input ADDITIVE 5 I/O PARAMETERS

392

Ratio/valve output

393

Feedback/meter input

394

Selection input ADDITIVE 6 I/O PARAMETERS

395

Ratio/valve output

396

Feedback/meter input

397

Selection input ADDITIVE I/O PARAMETERS

398

Clean line output

399

Flush output COMPONENT 1 BLOCK VALVE

400

Block valve output

401

Block valve input COMPONENT 2 BLOCK VALVE

402

Block valve output

403

Block valve input COMPONENT 3 BLOCK VALVE

Appendix B - 20 _____________________________________________Configuration Record

__________________________________________________________ DanLoad 6000 (v6.00)

Code

Parameter

404

Block valve output

405

Block valve input

Value / Selection

COMPONENT 4 BLOCK VALVE 406

Block valve output

407

Block valve input COMPONENT COMBINATIONS <PAGE 5>

408

Combination 1 (1XXX)

409

Combination 2 (X2XX)

410

Combination 3 (12XX)

411

Combination 4 (XX3X)

412

Combination 5 (1X3X) COMPONENT COMBINATIONS <PAGE 6>

413

Combination 6 (X23X)

414

Combination 7 (123X)

415

Combination 8 (XXX4)

416

Combination 9 (1XX4)

417

Combination 10 (X2X4) COMPONENT COMBINATIONS <PAGE 7>

418

Combination 11 (12X4)

419

Combination 12 (XX34)

420

Combination 13 (1X34)

421

Combination 14 (X234)

422

Combination 15 (1234) END <PAGE 8>

423

End output

424

End input

Configuration Record ___________________________________________ Appendix B - 21

DanLoad 6000 (v6.00) __________________________________________________________

Code 425

Parameter

Value / Selection

Flush pulses TEMPERATURE PARAMETERS

426

Buoyancy

427

Temperature units

428

Density units

429

Pressure units

430

Reference temperature

431

Sample qty COMP 1 TEMPERATURE PARAMETERS

432

Temperature option

433

Alpha

434

Backup temperature COMP 2 TEMPERATURE PARAMETERS

435

Temperature option

436

Alpha

437

Backup temperature COMP 3 TEMPERATURE PARAMETERS

438

Temperature option

439

Alpha

440

Backup temperature COMP 4 TEMPERATURE PARAMETERS

441

Temperature option

442

Alpha

443

Backup temperature COMP 1 PRESSURE PARAMETERS

444

Pressure option

445

F-factor X 1000000000

Appendix B - 22 _____________________________________________Configuration Record

__________________________________________________________ DanLoad 6000 (v6.00)

Code 446

Parameter

Value / Selection

Backup pressure COMP 2 PRESSURE PARAMETERS

447

Pressure option

448

F-factor X 1000000000

449

Backup pressure COMP 3 PRESSURE PARAMETERS

450

Pressure option

451

F-factor X 1000000000

452

Backup pressure COMP 4 PRESSURE PARAMETERS

453

Pressure option

454

F-factor X 1000000000

455

Backup pressure COMP 1 DENSITY/GRAVITY

456

Density/gravity option

457

Backup density/gravity COMP 2 DENSITY/GRAVITY

458

Density/gravity option

459

Backup density/gravity COMP 3 DENSITY/GRAVITY

460

Density/gravity option

461

Backup density/gravity COMP 4 DENSITY/GRAVITY

462

Density/gravity option

463

Backup density/gravity METER 1

464

Pressure @4 mA

Configuration Record ___________________________________________ Appendix B - 23

DanLoad 6000 (v6.00) __________________________________________________________

Code

Parameter

465

Pressure @20 mA

466

Density @4 mA

467

Density @20 mA

Value / Selection

METER 2 468

Pressure @4 mA

469

Pressure @20 mA

470

Density @4 mA

471

Density @20 mA METER 3

472

Pressure @4 mA

473

Pressure @20 mA

474

Density @4 mA

475

Density @20 mA METER 4

476

Pressure @4 mA

477

Pressure @20 mA

478

Density @4 mA

479

Density @20 mA RECIPES

480

Number of recipes RECIPE 1

481

Name

482

Component 1 %

483

Component 2 %

484

Component 3 %

485

Comp 4 % or ratio qty

Appendix B - 24 _____________________________________________Configuration Record

__________________________________________________________ DanLoad 6000 (v6.00)

Code 486

Parameter

Value / Selection

Sequence or low proportion RECIPE 2

487

Name

488

Component 1 %

489

Component 2 %

490

Component 3 %

491

Comp 4 % or ratio qty

492

Sequence or low proportion RECIPE 3

493

Name

494

Component 1 %

495

Component 2 %

496

Component 3 %

497

Comp 4 % or ratio qty

498

Sequence or low proportion RECIPE 4

499

Name

500

Component 1 %

501

Component 2 %

502

Component 3 %

503

Comp 4 % or ratio qty

504

Sequence or low proportion RECIPE 5

505

Name

506

Component 1 %

507

Component 2 %

508

Component 3 %

Configuration Record ___________________________________________ Appendix B - 25

DanLoad 6000 (v6.00) __________________________________________________________

Code

Parameter

509

Comp 4 % or ratio qty

510

Sequence or low proportion

Value / Selection

RECIPE 6 511

Name

512

Component 1 %

513

Component 2 %

514

Component 3 %

515

Comp 4 % or ratio qty

516

Sequence or low proportion RECIPE 7

517

Name

518

Component 1 %

519

Component 2 %

520

Component 3 %

521

Comp 4 % or ratio qty

522

Sequence or low proportion RECIPE 8

523

Name

524

Component 1 %

525

Component 2 %

526

Component 3 %

527

Comp 4 % or ratio qty

528

Sequence or low proportion RECIPE 9

529

Name

530

Component 1 %

531

Component 2 %

Appendix B - 26 _____________________________________________Configuration Record

__________________________________________________________ DanLoad 6000 (v6.00)

Code

Parameter

532

Component 3 %

533

Comp 4 % or ratio qty

534

Sequence or low proportion

Value / Selection

RECIPE 10 535

Name

536

Component 1 %

537

Component 2 %

538

Component 3 %

539

Comp 4 % or ratio qty

540

Sequence or low proportion RECIPE 11

541

Name

542

Component 1 %

543

Component 2 %

544

Component 3 %

545

Comp 4 % or ratio qty

546

Sequence or low proportion RECIPE 12

547

Name

548

Component 1 %

549

Component 2 %

550

Component 3 %

551

Comp 4 % or ratio qty

552

Sequence or low proportion RECIPE 13

553

Name

554

Component 1 %

Configuration Record ___________________________________________ Appendix B - 27

DanLoad 6000 (v6.00) __________________________________________________________

Code

Parameter

555

Component 2 %

556

Component 3 %

557

Comp 4 % or ratio qty

558

Sequence or low proportion

Value / Selection

RECIPE 14 559

Name

560

Component 1 %

561

Component 2 %

562

Component 3 %

563

Comp 4 % or ratio qty

564

Sequence or low proportion RECIPE 15

565

Name

566

Component 1 %

567

Component 2 %

568

Component 3 %

569

Comp 4 % or ratio qty

570

Sequence or low proportion RECIPE 16

571

Name

572

Component 1 %

573

Component 2 %

574

Component 3 %

575

Comp 4 % or ratio qty

576

Sequence or low proportion RECIPE 17

577

Name

Appendix B - 28 _____________________________________________Configuration Record

__________________________________________________________ DanLoad 6000 (v6.00)

Code

Parameter

578

Component 1 %

579

Component 2 %

580

Component 3 %

581

Comp 4 % or ratio qty

582

Sequence or low proportion

Value / Selection

RECIPE 18 583

Name

584

Component 1 %

585

Component 2 %

586

Component 3 %

587

Comp 4 % or ratio qty

588

Sequence or low proportion RECIPE 19

589

Name

590

Component 1 %

591

Component 2 %

592

Component 3 %

593

Comp 4 % or ratio qty

594

Sequence or low proportion RECIPE 20

595

Name

596

Component 1 %

597

Component 2 %

598

Component 3 %

599

Comp 4 % or ratio qty

600

Sequence or low proportion RECIPE 21

Configuration Record ___________________________________________ Appendix B - 29

DanLoad 6000 (v6.00) __________________________________________________________

Code

Parameter

601

Name

602

Component 1 %

603

Component 2 %

604

Component 3 %

605

Comp 4 % or ratio qty

606

Sequence or low proportion

Value / Selection

RECIPE 22 607

Name

608

Component 1 %

609

Component 2 %

610

Component 3 %

611

Comp 4 % or ratio qty

612

Sequence or low proportion RECIPE 23

613

Name

614

Component 1 %

615

Component 2 %

616

Component 3 %

617

Comp 4 % or ratio qty

618

Sequence or low proportion RECIPE 24

619

Name

620

Component 1 %

621

Component 2 %

622

Component 3 %

623

Comp 4 % or ratio qty

624

Sequence or low proportion

Appendix B - 30 _____________________________________________Configuration Record

__________________________________________________________ DanLoad 6000 (v6.00)

Code

Parameter

Value / Selection RECIPE 25

625

Name

626

Component 1 %

627

Component 2 %

628

Component 3 %

629

Comp 4 % or ratio qty

630

Sequence or low proportion RECIPE 26

631

Name

632

Component 1 %

633

Component 2 %

634

Component 3 %

635

Comp 4 % or ratio qty

636

Sequence or low proportion RECIPE 27

637

Name

638

Component 1 %

639

Component 2 %

640

Component 3 %

641

Comp 4 % or ratio qty

642

Sequence or low proportion RECIPE 28

643

Name

644

Component 1 %

645

Component 2 %

646

Component 3 %

647

Comp 4 % or ratio qty

Configuration Record ___________________________________________ Appendix B - 31

DanLoad 6000 (v6.00) __________________________________________________________

Code 648

Parameter

Value / Selection

Sequence or low proportion RECIPE 29

649

Name

650

Component 1 %

651

Component 2 %

652

Component 3 %

653

Comp 4 % or ratio qty

654

Sequence or low proportion RECIPE 30

655

Name

656

Component 1 %

657

Component 2 %

658

Component 3 %

659

Comp 4 % or ratio qty

660

Sequence or low proportion ADDITIVE CALIBRATION

661

# add calib cycles DATA COMMUNICATIONS

662

Address Ch. A

663

Mode

664

Data rate

665

Word size

666

Stop bits

667

Parity Ch. B

668

Mode

Appendix B - 32 _____________________________________________Configuration Record

__________________________________________________________ DanLoad 6000 (v6.00)

Code

Parameter

669

Data rate

670

Word size

671

Stop bits

672

Parity

673

Alarm in manual

Value / Selection

DYNAMIC DATA DISPLAY <PAGE 1> 679

Mode

680

Line 1 data code

681

Line 2 data code

682

Line 3 data code

683

Line 4 data code DYNAMIC DATA DISPLAY <PAGE 2>

684

Line 5 data code

685

Line 6 data code

686

Line 7 data code

687

Line 8 data code DYNAMIC DATA DISPLAY <PAGE 3>

688

Line 9 data code

689

Line 10 data code

690

Line 11 data code

691

Line 12 data code DYNAMIC DATA DISPLAY <PAGE 4>

692

Line 13 data code

693

Line 14 data code

694

Line 15 data code

695

Line 16 data code DATA LOGGING <PAGE 1>

Configuration Record ___________________________________________ Appendix B - 33

DanLoad 6000 (v6.00) __________________________________________________________

Code

Parameter

696

Batch summary

697

Transaction summary

698

Alarm log

699

Power fail log

700

Program mode entry/exit

701

W&M switch opened/closed

Value / Selection

DATA LOGGING <PAGE 2> 702

Program value change log

703

Configuration summary data log

704

Crash memory summary

705

Totalizers

706

Transaction ticket

707

Transaction ticket reprint DATA LOGGING <PAGE 3>

708

Thruput

709

Sequence numbers

710

Cutoff hour BLENDING <PAGE 1>

711

Ramp down %

712

Rate reduction

713

Low flow start qty

714

Clean line qty

715

Low prop fac BLENDING <PAGE 2>

716

Correct after qty

717

Alarm after qty

718

Adjustment qty

Appendix B - 34 _____________________________________________Configuration Record

__________________________________________________________ DanLoad 6000 (v6.00)

Code

Parameter

719

Comp % display

720

Add calib delay (s)

Value / Selection

BLENDING <PAGE 3> 722

Blend error method

723

Max dev %

724

Blend tol %

725

Max dev vol

726

Blend tol vol

727

Blend sample qty METER 1

728

Flow adj fac

729

Ratio adj fac

730

Ramp %

731

CALMON analysis method METER 2

734

Flow adj fac

735

Ratio adj fac

736

Ramp %

737

CALMON analysis method METER 3

740

Flow adj fac

741

Ratio adj fac

742

Ramp %

743

CALMON analysis method METER 4

746

Flow adj fac

747

Ratio adj fac

Configuration Record ___________________________________________ Appendix B - 35

DanLoad 6000 (v6.00) __________________________________________________________

Code

Parameter

748

Ramp %

749

CALMON analysis method

Value / Selection

MPMC 752

FPO basis

753

CALMON error limit

754

CALMON reset count

755

Calib fail alarm action METER 1

756

FPO

757

Number of blades

758

Max max char dev

759

Max tot char devs

760

Calibration sample METER 2

761

FPO

762

Number of blades

763

Max max char dev

764

Max tot char devs

765

Calibration sample METER 3

766

FPO

767

Number of blades

768

Max max char dev

769

Max tot char devs

770

Calibration sample METER 4

771

FPO

Appendix B - 36 _____________________________________________Configuration Record

__________________________________________________________ DanLoad 6000 (v6.00)

Code

Parameter

772

Number of blades

773

Max max char dev

774

Max tot char devs

775

Calibration sample

Value / Selection

RECIPE 1 776

Low flow rate

777

High flow rate RECIPE 2

778

Low flow rate

779

High flow rate RECIPE 3

780

Low flow rate

781

High flow rate RECIPE 4

782

Low flow rate

783

High flow rate RECIPE 5

784

Low flow rate

785

High flow rate RECIPE 6

786

Low flow rate

787

High flow rate RECIPE 7

788

Low flow rate

789

High flow rate RECIPE 8

790

Low flow rate

Configuration Record ___________________________________________ Appendix B - 37

DanLoad 6000 (v6.00) __________________________________________________________

Code 791

Parameter

Value / Selection

High flow rate RECIPE 9

792

Low flow rate

793

High flow rate RECIPE 10

794

Low flow rate

795

High flow rate RECIPE 11-20

796

Low flow rate

797

High flow rate RECIPE 21-30

798

Low flow rate

799

High flow rate ADDITIVE 1

800

Pump output

801

Block valve output ADDITIVE 2

803

Pump output

804

Block valve output ADDITIVE 3

806

Pump output

807

Block valve output ADDITIVE 4

809

Pump output

810

Block valve output ADDITIVE 5

812

Pump output

Appendix B - 38 _____________________________________________Configuration Record

__________________________________________________________ DanLoad 6000 (v6.00)

Code 813

Parameter

Value / Selection

Block valve output ADDITIVE 6

815

Pump output

816

Block valve output LPG/pressure

818

PT type

819

Pe method

820

Pinch back method

821

Pinch back pressure

822

Atmospheric pressure

823

Pinch back qty

824

825

Pe1 at T1

826

827

Pe2 at T2

828

829

Pe at T3 SAFETY CIRCUITS

830

Circuit 1 type

831

Circuit 2 type

832

Circuit 3 type

833

Circuit 4 type TRANSACTION / BATCH FILE CONFIGURATION <PAGE 1>

834

Transaction record length

835

Start page and # pages

836

Batch record length

837

Start page and # pages

Configuration Record ___________________________________________ Appendix B - 39

DanLoad 6000 (v6.00) __________________________________________________________

Code

Parameter

838

Tr tk format

839

Time out tr

Value / Selection

TRANSACTION FILE OFFSETS <PAGE 2> 840

1 Addr

841

2 Tr seq #

842

3 Recipe #

843

4 Recipe name

844

5 Side

845

6 Prompt 1 TRANSACTION FILE OFFSETS <PAGE 3>

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 TRANSACTION FILE OFFSETS <PAGE 4>

852

13 Data item 3

853

14 Data item 4

854

15 Data item 5

855

16 Start date

856

17 End date

857

18 Gross TRANSACTION FILE OFFSETS <PAGE 5>

858

19 Std

859

20 Temp

860

21 Pres

Appendix B - 40 _____________________________________________Configuration Record

__________________________________________________________ DanLoad 6000 (v6.00)

Code

Parameter

861

22 Dens

862

23 Start gross

863

24 Start std

Value / Selection

TRANSACTION FILE OFFSETS <PAGE 6> 864

25 End gross

865

26 End std

866

27 Alarm bit map

867

28 Prim alarm

868

29 Temp alarm

869

30 Add 1 TRANSACTION FILE OFFSETS <PAGE 7>

870

31 Add 2

871

32 Add 3

872

33 Add 4

873

34 Add 5

874

35 Add 6

875

36 Op mode TR FILE OFFSETS <PAGE 8>

876

37 Gross units

877

38 Std units BATCH FILE OFFSETS <PAGE 9>

880

1 Addr

881

2 Ba seq #

882

3 Tr seq #

883

4 Temp

884

5 Pres

885

6 Dens

Configuration Record ___________________________________________ Appendix B - 41

DanLoad 6000 (v6.00) __________________________________________________________

Code

Parameter

Value / Selection

BATCH FILE OFFSETS <PAGE 10> 886

7 Preset

887

8 Gross

888

9 Std

889

10 Comp gross

890

11 Comp std

891

12 Comp temp BATCH FILE OFFSETS <PAGE 11>

892

13 Comp dens

893

14 Comp pres

894

15 Comp %

895

16 Add 1

896

17 Add 2

897

18 Add 3 BATCH FILE OFFSETS <PAGE 12>

898

19 Add 4

899

20 Add 5

900

21 Add 6

901

22 Op mode

902

23 CCF TSC PRINT ROW/COLUMN <PAGE 1>

920

1 Addr

921

2 Tr seq #

922

3 Recipe #

923

4 Recipe name

924

5 Side

925

6 Prompt 1

Appendix B - 42 _____________________________________________Configuration Record

__________________________________________________________ DanLoad 6000 (v6.00)

Code

Parameter

Value / Selection

TSC PRINT ROW/COLUMN <PAGE 2> 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 TSC PRINT ROW/COLUMN <PAGE 3>

932

13 Data item 3

933

14 Data item 4

934

15 Data item 5

935

16 Start date

936

17 End date

937

18 Gross TSC PRINT ROW/COLUMN <PAGE 4>

938

19 Std

939

20 Temp

940

21 Pres

941

22 Dens

942

23 Start gross

943

24 Start std TSC PRINT ROW/COLUMN <PAGE 5>

944

25 End gross

945

26 End std

946

27 Alarm bit map

947

28 Prim alarm

948

29 Temp alarm

Configuration Record ___________________________________________ Appendix B - 43

DanLoad 6000 (v6.00) __________________________________________________________

Code 949

Parameter

Value / Selection

30 Add 1 TSC PRINT ROW/COLUMN <PAGE 6>

950

31 Add 2

951

32 Add 3

952

33 Add 4

953

34 Add 5

954

35 Add 6

955

36 Op mode TSC PRINT ROW/COLUMN <PAGE 7>

956

37 Gross units

957

38 Std units ROW/COLUMN <PAGE 8>

960

1 Addr

961

2 Ba seq #

962

3 Tr seq #

963

4 Temp

964

5 Pres

965

6 Dens BSC PRINT ROW/COLUMN <PAGE 9>

966

7 Preset

967

8 Gross

968

9 Std

969

10 Comp gross

970

11 Comp std

971

12 Comp temp BSC PRINT ROW/COLUMN <PAGE 10>

972

13 Comp dens

Appendix B - 44 _____________________________________________Configuration Record

__________________________________________________________ DanLoad 6000 (v6.00)

Code

Parameter

973

14 Comp pres

974

15 Comp %

975

16 Add 1

976

17 Add 2

977

18 Add 3

Value / Selection

BSC PRINT ROW/COLUMN <PAGE 11> 978

19 Add 4

979

20 Add 5

980

21 Add 6

981

22 Op mode

982

23 CCF ANALOG INPUTS (v2 CPU)

983

RTD Alpha CPU 4-20 mA (v2 CPU)

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) CPU RTD (v2 CPU)

988

LL cnt (RTD input)

989

LH cnt (RTD input)

990

HL cnt (RTD input)

991

HH cnt (RTD input)

Configuration Record ___________________________________________ Appendix B - 45

DanLoad 6000 (v6.00) __________________________________________________________

This page intentionally left blank.

Appendix B - 46 _____________________________________________Configuration Record

Appendix C LPG Loading Configuration Checklist

__________________________________________________________ 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. +)), .....................................................................................................))-

Configure the dynamic data display (program code 680, etc.) so that the CTL factor per meter (data 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 Pd = Pm - Pe must be computed for the pressure correction 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. +)),

.....................................................................................................))Configure the dynamic data display (program code 680, etc.) so that the CPL factor per meter (data 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 PRESSURE METHOD since Pd = Pm - Pe must be computed. +)), .....................................................................................................))-

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 (Pe) method (program code 819) based on the user's requirements, industry standards or local standards. “TP-15" is typically used in the United States. The vapor pressure is required in order to compute the differential pressure (Pm - Pe) which is used for pressure 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. WARNING: Component vapor pressures (Pe) are used to determine differential pressure (Pm - Pe), which is used for pressure correction (standard quantities) and 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 correctly for display, printing, and calculation, i.e. 1 for kg/m3 (format 9999.9), 2 for °API (format 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

Appendix D Spare Parts

Spare Parts - DanLoad 6000 Item

Quantity

Model No.

Part No.

6000-(--------)

Description Model number from unit tag

Spare Printed Circuit Board Assemblies 1

(---1----)

3-6000-002

2-Ch. Meter Pulse Board CE-12604

(---2----)

3-6000-042

4-Ch. Meter Pulse Board

(----1---)

3-6000-005

AC I/O Board CE-12613

(-----1--)

3-6000-006

DC I/O Board CE-12616

(-------2)

3-6000-020

DUART (2) RS-485 Ports CE-12625-2

(-------1)

3-6000-009

DUART (1) RS-232 / (1) RS-485 Port CE-12625-1

(----2---)

3-6000-010

Additive Injection Board CE-12628

3-6000-048

Enhanced I/O Board (3 HIGH & 3 LOW status points)

3-6000-049

Enhanced I/O Board (All HIGH status points)

(------2-)

3-6000-007

A/D 8-Channel Board CE-12619-2

(------1-)

3-6000-026

A/D 2 Channel Board CE-12725

(--1-----)

3-6000-027

115 Vac Power Supply CE-12575-1

(--2-----)

3-6000-031

230 Vac Power Supply CE-12575-2

(-1------)

3-6000-052

Keypad Assembly [English] CE-12680

(-3------)

3-6000-054

Keypad Assembly [French] CE-12680

(-2------)

3-6000-055

Keypad Assembly [Spanish] CE-12680

All

3-6000-038

Display CE-12578

All

3-6000-029

CPU Board CE-12581

All

3-6000-030

Keyboard CE-12584

All

3-6000-032

Motherboard CE-12590

Optional Assemblies 21

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

Spare Parts - DanLoad 6000 Item

Quantity

26 27

Model No.

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)]

Optional Mechanical Parts 28

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 32

3-9000-670

DanLoad 6000 Reference Manual

3-9000-674

DanLoad 6000 Communications Specification

Optional Auxillary Equipment 34

1-6000-006

RAM Copy Eraser

1-6000-005

DanLoad 6000 Simulator

3-6000-123

2-Channel Pulse Simulator

Appendix E Field Wiring Drawings

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

Appendix F Other Drawings

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

DANIEL MEASUREMENT AND CONTROL, INC. RETURN POLICY FOR WARRANTY AND NON-WARRANTY MATERIAL Use the following procedure for returning equipment to the Daniel factory in the United States.

Step 1

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 daniel.support@emersonprocess.com.

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. 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.

Step 2

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. 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.

Step 3

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. 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.

Step 4

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.

Step 5

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.

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.

Daniel Measurement and Control, Inc. Returned Material Authorization 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

[ ] Yes

[ ] No

[ ] Yes

[ ] No

[ ] Yes

[ ] No

[ ] Yes

[ ] No

[ ] Yes

[ ] No

EPA Waste Code if used for hazardous waste

Circle any hazards and/or process fluid types that apply: Infectious

Radioactive

Explosive

Pyrophoric

Poison Gas

Cyanides

Sulfides

Corrosive

Oxidizer

Flammable

Carcinogen

Peroxide

Reactive-Air

Reactive-Water

Reactive-Other (list)

Poison

Other hazard category (list):

Describe decontamination/cleaning process. Include MSDS description for substances used in decontamination and cleaning processes. Attach additional documents if necessary.

Shipping Requirements 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)

Title:

(Print name)

Date:

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