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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 DANIELS 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,

Buyer acknowledges
and agrees that corrosion or erosion of materials is not covered by this warranty.
OR ANY OTHER MATTER W ITH RESPECT TO ANY OF THE GOODS OR SERVICES.

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 BUYERS CUSTOMERS.

ii

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

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

2.5
2.5.1
2.5.2
2.5.3
2.5.4

Installing the Secondary Keypad / Display . . . . . . . . . . . . . . . . . . . . . . .


Hardware Setup / Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Software Setup / Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wiring Details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-44
2-44
2-44
2-45
2-45

3.0

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Additive Injection Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Additive Injection Configuration (Typical Examples) . . . . . . . . . . . . .
Additive Meter Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Multi-Stream Injection Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Multi-Rate Additive Injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-88
3-92
3-99
3-109
3-112
3-119

3.11
3.11.1

3-121

3.11.6
3.11.7
3.11.8

Transaction Storage Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


Transaction Storage / Transaction Ticket
Setup Procedure (Example) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Default Ticket Formats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transaction Data Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Relation Between Batch Storage and
Transaction Storage Variables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Relation Between Transaction Storage Codes /
Batch Storage Codes / Program Codes . . . . . . . . . . . . . . . . . . . . . . . . .
Transaction Ticket Configuration Overview . . . . . . . . . . . . . . . . . . . .
Transaction Ticket Layout Planning . . . . . . . . . . . . . . . . . . . . . . . . . . .
Alarm BitMap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

iv

DanLoad 6000 (v6.00)

3-122
3-134
3-136
3-148
3-149
3-151
3-152
3-156

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

vi

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.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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Functional Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Configuration Parameters Setup (Table A-11) . . . . . . . . . . . .
Flow Meter Parameters Setup (Table A-12) . . . . . . . . . . . . . . . . . . . . .
Flow Control Valve Parameters Setup (Table A-13) . . . . . . . . . . . . .
Component Parameters Setup (Table A-14) . . . . . . . . . . . . . . . . . . . . .
Component Block Valve / Pump Parameters Setup (Table A-15) . . . .
Delivery Parameters Setup (Table A-16) . . . . . . . . . . . . . . . . . . . . . . .
Blending Parameters Setup (Table A-17) . . . . . . . . . . . . . . . . . . . . . . .
Temperature Compensation Parameters Setup (Table A-18) . . . . . . . .
Pressure Compensation Parameters Setup (Table A-19) . . . . . . . . . . .
Density Compensation Parameters Setup (Table A-20) . . . . . . . . . . .
Pulse Per Unit Output Parameters Setup (Table A-21) . . . . . . . . . . . .
Additive Parameters Setup (Table A-22) . . . . . . . . . . . . . . . . . . . . . .
LPG / Pressure Control Parameters Setup (Table A-23) . . . . . . . . . . .
Dynamic Data Display Parameters Setup (Table A-24) . . . . . . . . . . .
Communications / Data Logging Parameters Setup (Table A-25) . . .
Transaction Storage Parameters Setup (Table A-26) . . . . . . . . . . . . .
Transaction Ticket Parameters Setup (Table A-27) . . . . . . . . . . . . . .
Alarm Parameters Setup (Table A-28) . . . . . . . . . . . . . . . . . . . . . . . .

A-4
A-7
A-19
A-22
A-24
A-26
A-28
A-30
A-33
A-35
A-37
A-38
A-40
A-41
A-44
A-46
A-54
A-56
A-61
A-65

Configuration Record . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1

LPG Loading Configuration Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . C-1

Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table of Contents

D-1

vii

_________________________________________________________

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


Standard Enclosure Field Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Shallow Enclosure Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Shallow Enclosure Field Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Card Cage Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DC Power Supply Voltage Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AC Power Input Jumpers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CPU Board - Jumpers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CPU and Analog Inputs Board Combination Jumpers . . . . . . . . . . . . . .
CPU Board Jumpers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CPU Analog Inputs Program Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DUART Board Address Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-Ch. Meter Pulse Input Board Jumpers . . . . . . . . . . . . . . . . . . . . . . .
4-Ch. Meter Pulse Input Board Jumpers . . . . . . . . . . . . . . . . . . . . . . .
MPMC Version Comparisons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Version 1 AC I/O Board Jumpers . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Version 2 AC I/O Board Jumpers . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Version 1 Enhanced (Additive Injector) I/O Board Jumpers . . . . . . . .
Version 2 Enhanced I/O Board Jumpers . . . . . . . . . . . . . . . . . . . . . . .
DC I/O Board Jumpers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Secondary Keypad / Display Connections . . . . . . . . . . . . . . . . . . . . . . .

2-5
2-6
2-7
2-8
2-10
2-11
2-12
2-13
2-13
2-14
2-14
2-15
2-17
2-22
2-24
2-26
2-26
2-29
2-31
2-33
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Program Code Groups . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Display Format . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Program Code View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Key Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Alpha-Numeric Characters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Basic Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Set Date and Time Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Alarm Action Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Digital Flow Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Two-Stage Flow Control Valve (w/o Stem Switches) . . . . . . . . . . . .

3-5
3-6
3-7
3-8
3-12
3-18
3-24
3-30
3-47
3-75
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) . . . . . . . . . . . . . . .


Batch Record / Ticket Worksheet (Example) . . . . . . . . . . . . . . . . . . . .
DanLoad Default Ticket Formats . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Set Contrast / Backlighting Display . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Keypad Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Key Functions (Batch Delivery) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Recipe Selection Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Additive Selection Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Loading Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Diagnostic Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Input / Outputs Diagnostic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DUART Ports Diagnostic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LAN Port Diagnostic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-6
4-7
4-9
4-11
4-12
4-50
4-52
4-54
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-10
5-39
5-40
5-41

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

3-127
3-128
3-135
3-166

ix

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DanLoad 6000 (v6.00)

This page intentionally left blank.

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

____________________________________________________________ 1 - 1

DanLoad 6000 (v6.00) __________________________________________________________


#

481 / ... / 655 Name

Sequence of similar three-digit program code


numbers is too long to list all numbers. The
ellipsis (...) is a place holder for additional
program code numbers. In this example, the
ellipsis represent 28 additional recipe name
program code numbers.

Information applicable to new installations is located in the following sections.


#
#
#
#

Section 1
Section 2
Section 3
Section 6

Introduction
Installation
Setup
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

____________________________________________________________ 1 - 7

DanLoad 6000 (v6.00) __________________________________________________________


#

Additive Injection

The DanLoad 6000's additive control functionality is designed with the following objectives:
#

Allows direct control of additive injection (for up to 6 physical additives) via an


"additive panel" (additive meter and on/off valve), thus making so-called "smart"
additive injectors obsolete. This also makes the DanLoad 6000 a more attractive
economical solution for load rack automation when additive injection is required.

Allows different injection methods (additive injector types) for each logical additive
so that old and new additive injection equipment can be mixed on a single loading
arm, e.g. mix other units and additive panels on the same loading arm.

Provides multiple injection rates (concentrations) per additive via the "Multi Rate"
additive selection method.

Provides recipe gross and standard running totalizers and additive running totalizers
to facilitate product and additive inventory management.

Provides (functional) backward compatibility with previous DanLoad 6000 versions,


though actual program codes may be different.

Provides reporting (data logging) capabilities to facilitate product and additive


inventory management and configuration.

Additive volume is measured via a K-factor per additive which is used for both authorized and
unauthorized additive flow. The Multi Rate additive selection method allows multiple additive
ratios (concentrations of additive) to be configured per additive by configuring an additive ratio per
recipe. The DanLoad 6000 runs a cutoff (end of day processing) every 24 hours based on the
configured cutoff hour. The totalizer and throughput data logs can be reprinted using the Reprint
cutoff option in the program mode menu. Recipe and additive running totalizers allow product and
additive throughput for a particular customer to be monitored. The configuration summary data log
can be printed from the diagnostics menu in the manual operating mode.
#

Meter Proving

The DanLoad 6000 can be used to perform manual flow meter proofs. Tank provers, master meters,
or mechanical displacement meter proves can be used for flow meter proving.

Transaction Storage / User Defined Transaction Ticket

Various data accumulated during each batch delivery and groups of batch deliveries (transaction)
can be selected for storage in non-volatile memory. This data can be acquired by a terminal
automation system and / or printed on user defined pre-printed transaction tickets. Ticket formats
can be designed to meet the user's requirements.

1-8

____________________________________________________________ Introduction

_________________________________________________________
#

DanLoad 6000 (v6.00)

LPG / Pressure Control

LPG (liquid petroleum gas) can be measured (temperature and pressure corrected) and the flow
control valve can be automatically controlled to maintain the minimum back pressure. Other
features include Mercaptan vessel fill and display of external faults. Appendix C provides a LPG
Loading Configuration Checklist.
#

Calibration Monitoring

Preliminary support of calibration monitoring is provided in the form of a Calibration failure alarm
per meter and a CALMON status screen in the program mode. Section 3.9.3 Additive Meter
Calibration and CALMON provides a brief summary of the CALMON program codes.
1.2

Hardware Configuration

The DanLoad 6000 contains electronic modules in the form of plug-in printed circuit boards. The
basic hardware configuration of the instrument is required for normal operation. In many cases, the
instrument in the basic hardware configuration has the capacity to monitor and control the batch
delivery installation. In other cases, additional process input / output signal expansion printed
circuit boards and / or data communications modules may be required. Flow calculations and logical
control capabilities of the DanLoad 6000 in the basic hardware configuration and the fully expanded
configuration are identical. Hardware expansion of the instrument only increases the process signal
handling capacity and / or provides data signal handling capability. Information on hardware
configuration is contained in Section 2 - Installation. The basic configuration of a DanLoad 6000
is described below.
#

Integral text / graphics display and operator keypad mounted in a rugged weatherproof case,
designed for outside installation in NEC Class 1, Group D, Division 1 hazardous
atmosphere environments.

One DC Voltage power supply with factory selectable power input of 115 Vac or 230 Vac,
47 to 63 Hertz.

One main processor (CPU version 1) board with two micro-controllers, shared memory,
non-volatile memory, and other related logic and process signal circuitry. Two swing arm
status inputs. And optionally (requires addition of a module to the version 1 main processor
board):
#

One RS-485 port and one RS-232 port OR two RS-485 ports.

One flow meter pulse input board, able to process two flow meter pulse inputs (two flow
meters or IP-252 pulse integrity from one flow meter) and provide two discrete DC Voltage
control outputs.

One discrete AC input / output board, able to process two status inputs and eight control
outputs (90 to 230 Vac).

Introduction

____________________________________________________________ 1 - 9

DanLoad 6000 (v6.00) __________________________________________________________


1.3

General Terminology

The terminology used throughout this manual is defined in the table below. Section 6 - Program
Code Definitions contains additional information which helps clarify these terms. Some of the
definitions are based on information contained in American Petroleum Institute (API) standards and
industry accepted use. Other national standards use similar terminology.
Term

Definition

additive

A liquid that is injected into a primary liquid component in relatively small


quantities, usually less than four percent of the delivered volume total.
Additives are injected into the primary liquid component by an injector
mechanism which places a known, fixed volume of the additive into the
primary liquid component stream for each injector pulse received from the
DanLoad 6000.

arm

(also: swing arm, loading arm) A movable pipe / hose assembly used at a
tanker truck loading island. The arm can be designed for either top loading
or bottom loading to the tanker compartments. A swing arm can be
positioned to load at either side of the loading island or the parked state.

batch

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 LPGs (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)

Note
Appendix A contains several tables with data on the physical and functional configuration of
the DanLoad 6000. These tables can be photocopied and unique configuration data can be
manually entered to provide a record of specific DanLoad 6000 installations.

This section contains DanLoad 6000 specifications and information on installation of the DanLoad
6000. Installation tasks should be performed in the following order.
#
#
#
#

Installation planning
Initial setup (described in Section 3 - Setup)
Mechanical (physical) installation
Electrical installation

The initial setup, described in Section 3 - Setup, must be performed before the DanLoad 6000 is
placed in-service. The initial setup can be performed with only a 115 or 230 Vac power source
connected to the instrument.
Mechanical and electrical installation recommendations for the DanLoad 6000 adhere to general
industry standards for this type equipment and are covered in Section 2.3 - Mechanical Installation
and Section 2.4 - Electrical Installation. The remaining part of Section 2 contains information on
installation planning for the DanLoad 6000.

Installation ______________________________________________________________ 2 - 1

DanLoad 6000 (v6.00) __________________________________________________________


2.1
#

DanLoad 6000 Specifications

Dimensions (approximate):
Standard

The standard enclosure for the DanLoad 6000.

Remote / Secondary
The short enclosure contains the front panel display and keypad only. This enclosure is
usually used as a remote operator station in a two side loading island.

Item

Standard

Remote / Secondary

Height

13-inches (330 mm)

13-inches (330 mm)

Width

14-inches (355 mm)

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

PC

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

16

32

64

128

<reserved>

on

on

on

on

on

on

on

on

off

on

on

on

on

on

on

on

on

off

on

on

on

on

on

on

off

off

on

on

on

on

on

on

on

on

off

on

on

on

on

on

255

off

off

off

off

off

off

off

off

DUART Board Address Switch


Figure 2 - 12

Installation ______________________________________________________________ 2 - 15

DanLoad 6000 (v6.00) __________________________________________________________


#

2-Ch Meter Pulse Board (MPB)


Recommended card cage locations are slots J5 and / or J6, component side faces left
(toward the power supply). The recommended location for a single meter pulse board is slot
J5.
The two-channel meter pulse board provides 8 to 15 Vdc or 24 Vdc power for two meter
pulse preamplifiers and accepts meter pulse inputs from two meter preamplifiers or dual
inputs from one meter. The 2-Ch Meter Pulse Board can be used with 1 single pulse meter,
1 dual pulse meter or 2 single pulse meters. The meter preamps or pulsers can be powered
with any one of three options. Options 1 and 2 are implemented by installing a plug-on
piggyback power supply module. These modules are adjustable 8-15 VDC power supplies
with either 15 ma (Daniel P/N 3-6000-002) or 100 mA (Daniel P/N 3-6000-022) outputs.
Option 3 uses 24 VDC supplied from the power-supply board. The DC power source for
each meter preamplifier is jumper selectable. Two optically isolated raw meter pulse outputs
(prover outputs) are provided. These outputs are for meter proving and are duplicates of the
raw meter pulse stream. Two DC Voltage control outputs are provided. These control
outputs are assignable to various functions. One common use for these outputs is to drive
external pulse per unit quantity totalizers.
#

Power Down Pulse Counting


Should power failure shut the system down, power to the pulsers and preamps will
be sustained long enough to accumulate pulses until the flow control valve closes.
This is available with the 15 mA P/S option only (P/N 3-6000-002).

Dual Pulse Security for a Single Flow Meter


Dual pulse security is available per the IP252 Level-B standard. This is
accomplished by monitoring two meter pulse inputs that are electrically 90 degrees
out of phase. Reference program codes 233 and 234 in Section 6.13 of this manual.

Note
The 2-Ch Meter Pulse Board has been replaced by the 4-Ch Meter Pulse Board and is
no longer manufactured. The 4-Ch Meter Pulse Board is a direct replacement for the
2-Ch board. Depending on your configuration, wiring changes may be necessary.
Please review the 2-Ch and 4-Ch wiring diagrams carefully.

2 - 16 ______________________________________________________________ Installation

_________________________________________________________

DanLoad 6000 (v6.00)

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)

in

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)

in

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 Daniels enhanced line-powered switcher
power supply. When using Daniels 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

in

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)

in

meter additional high frequency


filtering
( 50 Hz. low pass filter)

1A

1B

2A

2B

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 dont 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

W1

out

Input 2 90-to-240 Vac / Vdc

in

Input 2 24 Vac / Vdc

out

Input 1 90-to-240 Vac / Vdc

in

Input 1 24 Vac / Vdc

W2

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

W3

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

OPEN
NO JUMPERS

3&4

W2

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

OPEN
NO JUMPERS

5&6

W1

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
Input
Channel

External Power

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

in

Input 6 floating, 24 Vac or 24 Vdc external input

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

in

Input 6 internal 24 Vdc power furnished

W2 2-to-3

in

Input 5 floating, 24 Vac or 24 Vdc external input

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

in

Input 5 internal 24 Vdc power furnished

W3 2-to-3

in

Input 4 floating, 24 Vac or 24 Vdc external input

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

in

Input 4 internal 24 Vdc power furnished

W4 2-to-3

in

Input 3 floating, 24 Vac or 24 Vdc external input

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

in

Input 3 internal 24 Vdc power furnished

W5 2-to-3

in

Input 2 floating, 24 Vac or 24 Vdc external input

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

in

Input 2 internal 24 Vdc power furnished

W6 2-to-3

in

Input 1 floating, 24 Vac or 24 Vdc external input

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

in

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.

50

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.

98

(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 (ee)

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)

4*

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.

01

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.

J5

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 boards 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>=

Jn

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

3 - 28

_________________________________________________________________ Setup

_________________________________________________________

DanLoad 6000 (v6.00)

are performed automatically during the initial setup of the DanLoad 6000. These assignments can
be manually changed later if required. The current physical channel to logical channel assignments
can be viewed at any time. All physical input / output channel to logical channel assignments are
defined in the following program code groups. Appendix A contains worksheets that identify each
point.
#
#
#
#
#
#

Meter parameters, program codes 050 to 061


I/O parameters, program codes 280 to 360
Recipe I/O parameters, program codes 361 to 379
Component I/O parameters, program codes 400 to 425
Additive I/O parameters, program codes 380 to 399
Additive pumps / block valves, program codes 800 to 833

The channel assignments defined by these program codes are viewable while operating in Program
Mode. The rightward column of the program code display line contains a one or two digit number.
This number is the currently assigned logical channel number in the series of channel numbers
corresponding to the type of channel.
Discrete status inputs and outputs are assigned to default logical channels during setup. During
initial setup, carefully verify that all input and output point assignments match the actual wiring of
your installation. See Appendix A for default channel assignments.
Press the EXIT (ALT+CLEAR) key to exit the input / output signal configuration display area and
continue with the initial setup.

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.

3 - 30

_________________________________________________________________ Setup

_________________________________________________________

Initial setup
Is this unit a blender

DanLoad 6000 (v6.00)

No

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

_________________________________________________________________ 3 - 31

DanLoad 6000 (v6.00) __________________________________________________________

Note
For the remaining description of the initial setup procedure, it is assumed that:
Is this unit a blender? selection remains the default option No
The following description covers one flow meter, one flow control valve, and one
component. The procedure for defining multiple devices and components is similar except for
the requirement to define additional program codes for the additional devices and components.

3 - 32

_________________________________________________________________ Setup

_________________________________________________________

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

M1

Default string M1. The alpha-numeric data entry prompt is displayed on the bottom line to allow
the user to change this string to any five characters.
052 Valve to be controlled

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

_________________________________________________________________ 3 - 33

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

50

Default value 50. The entry defines the lower quantity limit, for any batch delivery, that can be
entered by the user / operator during a loading operation setup. This quantity is referred to as the
flushing quantity at some installations. Refer to Section 6.8 for details on the special value zero (0)
operation.

080 Preset/delivery type

Gross

Default selection Gross. This selection indicates that the gross quantity calculation is used for
delivery control. The flow control valve always controls ramp up to high flow rate based on gross
delivered quantity. The flow control valve controls ramp down to the low flow rate and terminates
delivery based on the quantity type selection in this field.

Setup

_________________________________________________________________ 3 - 35

DanLoad 6000 (v6.00) __________________________________________________________


081 Delivery display type

Gross

Default selection Gross. This selection indicates that the Loaded, Remaining, and Transaction
values are displayed in gross quantity.

082 Stop key action

Low flow

Default selection Low flow. This selection indicates the action to take after the STOP key is pressed
during a batch delivery. The flow rate is reduced until the low flow rate is achieved and then the
load is terminated by commanding the flow control valve to close.

083 Fall back qty

1000

Default value 1000. This value is the quantity that flows at a fall back flow rate before the DanLoad
6000 attempts to ramp up to the next higher flow rate.

3 - 36

_________________________________________________________________ Setup

_________________________________________________________

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

50

Default value 50. This value indicates the quantity units that must be loaded at the low flow rate
before issuing the high flow command to the flow control valve. (Sequential unit type only.)

085 Low flow restart qty

20

Default value 20. This value indicates the quantity units that must be loaded at the low flow rate
before issuing the high flow command to the flow control valve. If the quantity specified by program
code 084 Low flow start quantity has been delivered, this quantity is used after restart of a batch
delivery that has been temporarily suspended for any reason. (Sequential unit type only.)

086 Low flow stop qty

50

Default value 50. This value indicates the quantity units that must be loaded at the low flow rate
before issuing the close command to the flow control valve at the end of a batch delivery operation.

Setup

_________________________________________________________________ 3 - 37

DanLoad 6000 (v6.00) __________________________________________________________


087 Line pack delay (s)

Default value 2. This value indicates that the pump run relay output is energized two seconds before
the command is issued to open the flow control valve to low flow rate setting.

088 Pump stop delay (s)

30

Default value 30. This value indicates that the command to close the flow control valve is issued
and 30 seconds later the pump run relay output is de-energized.

089 Block valve delay (s)

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

30

Default value 30. This value is the number of times that the DanLoad 6000 attempts to increase the
flow rate to a higher flow rate without success, before ceasing attempts and maintaining the fall back
flow rate. Click refers to the jog output to the valve control solenoids.

109 Maintenance clicks

30

Default value 30. This value is the number of times that the DanLoad 6000 attempts to maintain the
current normal flow rate without success, before ceasing attempts and falling back to the next lower
flow rate. Click refers to the jog output to the valve control solenoids.

110 Additive pump stop (s)

10

Default value 10. This value is the number of seconds between the end of the load operation and
deenergizing the additive pump control circuits.

111 Primary component

Default value 1. This value sets the number of the component to use for calculation of blend ratios
and for clean line flushing. (Only applicable when program code 722 Blend error method set to
Grspctsmpl or Stdpctsmpl .)

Setup

_________________________________________________________________ 3 - 39

DanLoad 6000 (v6.00) __________________________________________________________

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 components configured low flow stop quantity at the end of an in-line batch. The overall
flow rate of the blend at the end of a batch is the sum of the stop rates of any flowing components.

Setup

_________________________________________________________________ 3 - 41

DanLoad 6000 (v6.00) __________________________________________________________

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

_________________________________________________________________ 3 - 43

DanLoad 6000 (v6.00) __________________________________________________________

MF
215
216
217
218
219

validation
Master MF %
Adjacent MF %
Passcode per transaction
Product units mnemonic
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

No

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

No

Select either No or Yes. If No is selected, start up each component by loading its low flow
start quantity at its low flow rate. If Yes is selected, start up the first component by loading its low
flow start quantity at its low flow rate. Start up further components by loading their low flow restart
quantities at their low flow rates.

Setup

_________________________________________________________________ 3 - 45

DanLoad 6000 (v6.00) __________________________________________________________

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.)

<not applicable>

Alarm data is stored in Alarm Storage Memory.


Off

Disable monitoring of this alarm.

<not applicable>

Alarm Action Summary


Figure 3 - 9

Setup

_________________________________________________________________ 3 - 47

DanLoad 6000 (v6.00) __________________________________________________________

221
222
223
224
225
226

Alarm parameters (cont'd)


Low flow alarm action
Minimum flow rate
Low flow time (s)
High flow alarm action
Maximum flow rate
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)

10

Default value 10. This value is the elapsed time allowed for the flow rate to be continuously below
the minimum flow rate specified by program code 222 Minimum flow rate before the alarm is
triggered.

224 High flow alarm action

Primary

Default selection Primary. This selection indicates that if the High flow alarm becomes active, the
current delivery operation will be suspended.

3 - 48

_________________________________________________________________ Setup

_________________________________________________________
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)

10

Default value 10. This value is the elapsed time allowed for the flow rate to be continuously below
the minimum flow rate specified by program code 225 Maximum flow rate before the alarm is
triggered.

Setup

_________________________________________________________________ 3 - 49

DanLoad 6000 (v6.00) __________________________________________________________

227
228
229
230
231
232

Alarm parameters (cont'd)


Overrun limit qty
Underflow alarm action
Underflow limit qty
No flow t-o alarm action
No flow t-o (s)
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

_________________________________________________________________ 3 - 51

DanLoad 6000 (v6.00) __________________________________________________________

233
234
235
236
237

Alarm parameters (cont'd)


Error limit (pulses)
Reset count (pulses)
Data logging alarm action
Time-out ch. A (s)
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)

10

This value specifies the allowable time between receiving messages from the terminal automation
system before issuing a Comms failure channel A alarm. Zero disables the alarm.

237 Time-out ch. B (s)

10

This value specifies the allowable time between receiving messages from the terminal automation
system before issuing a Comms failure channel B alarm. Zero disables the alarm.

Setup

_________________________________________________________________ 3 - 53

DanLoad 6000 (v6.00) __________________________________________________________

238
239
240
241
242
243

Alarm parameters (cont'd)


Temp fail alarm action
Minimum temperature
Maximum temperature
Density fail alarm action
Minimum density/gravity
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) __________________________________________________________

244
245
246
247
248

Alarm parameters (cont'd)


Minimum pressure
Maximum pressure
Additive error limit
Additive feedback count
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)

10

This value sets the time allowed for a component block valve to close after the block valve control
output has been deenergized at the end of a loading operation or when a loading operation is
temporarily stopped.

3 - 56

_________________________________________________________________ Setup

_________________________________________________________

249
250
251
252

DanLoad 6000 (v6.00)

Alarm parameters (cont'd)


Circuit 1 alarm action
Secondary
#1 Ground detector open
Circuit 2 alarm action
Primary
#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) __________________________________________________________

253
254
255
256

Alarm parameters (cont'd)


Circuit 3 alarm action
Secondary
#3 Permissive power failure
Circuit 4 alarm action
Secondary
#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

_________________________________________________________

257
258
259
260

DanLoad 6000 (v6.00)

Alarm parameters (cont'd)


Circuit 5 alarm action
Secondary
#5 Arm down side 1
Circuit 6 alarm action
Secondary
#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) __________________________________________________________

261
262
263
264

Alarm parameters (cont'd)


Circuit 7 alarm action
Secondary
#7 Walkway down side 1
Circuit 8 alarm action
Secondary
#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

_________________________________________________________

265
266
267
268
269
270

Alarm parameters
Circuit 5 type
Circuit 6 type
Circuit 7 type
Circuit 8 type
Alarm o/p 1 mask
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 *

3 - 62

Determined by the state of the swing arm switch inputs to the CPU board and the configured
side-detect method (program code 312).

_________________________________________________________________ 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) __________________________________________________________

276
277
278
279

Alarm parameters (cont'd)


Ramp down alarm action
Primary
Ramp down time (s)
4
Additive per 1000 error limit
1
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 %

70

70

483 Comp 2 %

20

30

484 Comp 3 %

10

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 %

70

70

483 Comp 2 %

20

20

484 Comp 3 %

10

485 Comp 4 % or ratio qty

10

481 Name

486 Sequence or low proportion


Note: For an in-line blender, the sequence or low proportion should normally be filled with
zeros 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

On

On

Off

Upstream pilot valve (cavity fill)

Open

Closed

Closed

Open

Solenoid 2 (downstream)
control output

Off

On

Off

Off

Downstream pilot valve (cavity drain)

Closed

Open

Closed

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

On

On

On

Off

Solenoid
2
control
output

Off

Off

On

Off

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

On

On

Solenoid 2
control
output

Off

On

Off

Two-Stage Flow Control Valve (with Stem-Switches)


Figure 3 - 11b
The normally closed stem switch (stem switch 1) is monitored during initial opening so that the
valve can be locked at low flow start. The normally open stem switch (stem switch 2) is monitored
while ramping down from high flow so that the valve can be locked at low flow stop.

Setup

_________________________________________________________________ 3 - 77

DanLoad 6000 (v6.00) __________________________________________________________


3.7

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

Yes

Yes

Yes

Yes

Yes

Linear

Yes

Yes

Yes

Yes

Yes

Yes

API 6A

Yes

Yes

Yes

No1

No2

No1,2

API 6B

Yes

Yes

Yes

No1

No2

No1,2

API 6C

Yes

Yes

Yes

No1

No2

No1,2

API 24A

Yes

Yes

No2

No1

No2

No1,2

API 24B

Yes

Yes

No2

No1

No2

No1,2

API 54A

Yes

Yes

No2

No1,2

Yes

No1

API 54B

Yes

Yes

No2

No1,2

Yes

No1

API 54C

Yes

Yes

No2

No1,2

Yes

No1

IMP/PEMEX

Yes

Yes

No2

No1,2

No2

No1,2

Table 24 (Old)

Yes

Yes

No2

Yes

No2

No2

Table 54 (Old)

Yes

Yes

No2

No2

Yes

Yes

Petrobras

Yes

Yes

No2

Yes3

Yes3

No1,2

TP-16

Yes

Yes

No2

Yes

No2

No2

China

Yes

Yes

Yes

Yes

Yes

Yes

API 6D

Yes

Yes

Yes

No1

No2

No1,2

API 54D

Yes

Yes

No2

No1,2

Yes

No1

4311 1

Yes

Yes

No2

Yes

No2

No2

CAN 54B

Yes

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 components 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

Note:

3 - 82

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

Density / gravity inputs are not validated by the DanLoad 6000. The table shows the valid density / gravity ranges for the temperature
compensation selections.

_________________________________________________________________ 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 86.0F 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

No

Linear

N/A

No

API 6A

60.0F

Yes

API 6B

60.0F

Yes

API 6C

N/A

No

API 24A

60.0F

Yes

API 24B

60.0F

Yes

API 54A

15.0C

Yes

API 54B

15.0C

Yes

API 54C

N/A

No

IMP

20.0C

Yes

Old 24

60.0F

Yes

Old 54

15.0C

Yes

P'Bras

20.0C

Yes

TP-16

60.0C

Yes

China

20.0C

Yes

6D

60.0F

Yes

54D

15.0C

Yes

4311 1

60.0F

Yes

NH3

60.0F

Yes

CAN 54B

15.0C

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

60.0F

80.9F

35.10

0.9903

60.0F

86.0F

35.10

0.9879

86.0F

80.9F

35.10

1.0024

API 24A, PC 427 = F


Ref. temp.

Observed
temp.

Density or
gravity

CTL factor

60.0F

56.5F

0.8760

1.00160

60.0F

66.5F

0.8760

0.99710

66.5F

56.5F

0.8760

1.00451

API 54A, PC 427 = C


Ref. temp.

Observed
temp.

Density or
gravity

CTL factor

15.0C

22.5C

740.0

0.9916

15.0C

20.0C

740.0

0.9944

20.0C

22.5C

740.0

0.9972

IMP, PC 427 = C
Ref. temp.

Setup

Observed
temp.

Density or
gravity

CTL factor

20.0C

6.0C

0.7210

1.01743

20.0C

17.5C

0.7210

1.00311

17.5C

6.0C

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.

Allows different injection methods (additive injector types) for each logical additive so that
old and new additive injection equipment can be mixed on a single loading arm, e.g. mix
additive panels on the same loading arm.

Provides multiple injection rates (concentrations) per additive via the "Multi Rate" additive
selection method.

Provides recipe gross and standard running totalizers and additive running totalizers to
facilitate product and additive inventory management.

3 - 88

_________________________________________________________________ Setup

_________________________________________________________

DanLoad 6000 (v6.00)

Provides (functional) backward compatibility with previous DanLoad 6000 versions, though
actual program codes may be different.

Provides reporting (data logging) capabilities to facilitate product and additive inventory
management and configuration.

Provides an additive meter calibration screen with a step-by-step procedure for computing
an additive meters 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

39

40

100

0.0264

1515

79

100

0.0264

2992

80

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

16

32

For example, in order to select additives 3 and 5 to be injected into the midgrade recipe enter
"Midgrade______20" for the recipe name. (4 + 16 = 20, the underscore character represents a
space.)
The additive "ratio volume" (per additive) is now in whole units of product. However, if the "Multi
Rate" additive selection method is used, the recipe's component 4 percentage (truncated from
hundredths to whole units) is used for the additive ratio volume. (The ratio volume in the additive
delivery parameters setup group must still be configured if verification using the volume of additive
per 1000 of product is to be performed.)
"140 Ratio volume" (1 to 9999). The volume (possibly a combination of gross and/or standard
quantities through multiple component meters) in product units (program code 29) which controls
one additive injection cycle. The default value is 40.

Setup

_________________________________________________________________ 3 - 93

DanLoad 6000 (v6.00) __________________________________________________________


"141 Injection method". The first two injection methods ("Mech" and "Handshake") totalize additive
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

_________________________________________________________

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 %

139

Control meters

140

Ratio qty

138

Clean line qty

111

Primary component

100
G
40.0

Test Results

Setup

Preset
Quantity

Additive Ratio computed by


DanLoad 6000

Additive
injections

400

40.00

10

_________________________________________________________________ 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 %

139

Control meters

140

Ratio qty

138

Clean line qty

20

111

Primary component

100
G
40.0

Test Results
Preset
Quantity

Additive Ratio computed by


DanLoad 6000

Additive
injections

400

(400 - 20) (400 40) = 38.00

10

3 - 100 _________________________________________________________________ Setup

_________________________________________________________

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 %

139

Control meters

140

Ratio qty

138

Clean line qty

111

Primary component

10

100
G
40.0

Test Results
Preset
Quantity

Additive Ratio computed by


DanLoad 6000

Additive
injections

400

(400 - 10) (400 40) = 39.00

10

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 %

139

Control meters

140

Ratio qty

138

Clean line qty

20

111

Primary component

10

100
G
40.0

Test Results
Preset
Quantity

Additive Ratio computed by


DanLoad 6000

Additive
injections

400

(400 - 10 - 20) (400 40) = 37.00

10

3 - 102 _________________________________________________________________ Setup

_________________________________________________________

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

139

Control meters

GX

140

Ratio qty

40.0

138

Clean line qty (additive)

111

Primary component

714

Clean line qty (component)

60.00
40.00
1
2

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

139

Control meters

GX

140

Ratio qty

40.0

138

Clean line qty (additive)

60

111

Primary component

714

Clean line qty (component)

60.00
40.00
1
2

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

_________________________________________________________

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

139

Control meters

GX

140

Ratio qty

40.0

138

Clean line qty (additive)

111

Primary component

714

Clean line qty (component)

30

60.00
40.00
1
2

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

139

Control meters

GX

140

Ratio qty

40.0

138

Clean line qty (additive)

60

111

Primary component

714

Clean line qty (component)

30

60.00
40.00
1
2

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

139

Control meters

GX

140

Ratio qty

40.0

138

Clean line qty (additive)

60

111

Primary component

714

Clean line qty (component)

30

60.00
40.00
1
2

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

139

Control meters

GG

140

Ratio qty

40.0

138

Clean line qty (additive)

60

111

Primary component

714

Clean line qty (component)

30

60.00
40.00
1
2

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

10

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 meters 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
additives 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 DanLoads diagnostics to energize the discrete output wired to the
additive solenoid valve which allows additive to flow into a test beaker. The
DanLoads 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 DanLoads 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.

1.

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)

2.

Determine the amount of additive injected per pulse:


Vol/pulse = ((PC 140) / 1000) x (PC 143)

3.

Determine the additive ratio:


Additive ratio = ((Vol/pulse) x 1000) / (Desired Additive per 1000)

4.

Enter the new additive ratio into PC 485.

5.

If another additive ratio is required, then use the calculation in steps 2 and 3 and enter the
value into PC 491 (Component 4 % or ratio quantity for recipe 2).

Setup _________________________________________________________________ 3 - 119

DanLoad 6000 (v6.00) __________________________________________________________


Example:

Additive injection using Multi-Rate selection and Meter method.

1.

Program Code (PC) Setup:


135 = 1 (Number of additives)
136 = Multi Rate (Selection method)
140 = 40 (Ratio Quantity. This value is ignored when Multi-Rate is selected).
141 = Meter (Injection Method)
142 = 21 (Volume/Pulse or K factor)
143 = 0.4 (Additive per 1000)
480 = 2 (Number of recipies)
485 = x (Component 4 % or ratio quantity for recipe 1)

2.

Determine the amount of additive delivered per injection:


Vol/pulse = (Total additive injected) / (# of pulses)

3.

Determine the additive ratio:


Additive ratio = ((Vol/pulse) x 1000) / (Desired Additive per 1000)

4.

Enter the new additive ratio into PC 485.

5.

If another additive ratio is required, then use the calculation in steps 2 and 3 and enter the
value into PC 491 (Component 4 % or ratio quantity for recipe 2).

In both examples above the DanLoad 6000 also computes the volume/pulse which is also known as
1 additive unit. This additive unit is used in additive error checking. If the delivered additive falls
outside of PC 278 (Additive/1000 error limit) and has also exceeded the parameters of PC 272 and
PC 273 (low and high % of the ideal quantity at any point in a batch) the DanLoad 6000 will
terminate loading and display an Additive x failure message, where x is the additive injector that
failed.

3 - 120 _________________________________________________________________ Setup

_________________________________________________________
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.

Setup _________________________________________________________________ 3 - 121

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

OR

Bnn, rrr, cc, b, m

Type number T for TSC, B for BSC and TSC or BSC number

rrr

three-digit (leading zeros) row number on ticket

cc

two-digit (leading zeros) column number on ticket

3 - 122 _________________________________________________________________ Setup

_________________________________________________________

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

30

Maximum number of batches in each transaction is 6. Because the batches per


transaction should never exceed 6, set program code 047 Batches/transaction = 6 at
this time to limit the number of batches allowed per each transaction.
However, almost all transactions are composed of 4 batches. Typically 4 batches
times 30 bytes each batch equals 120 bytes per each transaction stored in the batch
storage record. (At the end of transaction, a 150 byte transaction record will also be
stored.)

Let's assume that most transactions are composed of 4 batches. In this case, at each
transaction close, 150 bytes are stored in the transaction file as the transaction record
for the completed transaction nnnn. And 120 bytes are stored in the batch file as
FOUR batch records that make up the completed transaction nnnn.

3 - 124 _________________________________________________________________ Setup

_________________________________________________________
#

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.

Setup _________________________________________________________________ 3 - 125

DanLoad 6000 (v6.00) __________________________________________________________

Transaction Ticket (Typical)


Figure 3-12

3 - 126 _________________________________________________________________ Setup

_________________________________________________________

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

_________________________________________________________

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.

3 - 130 _________________________________________________________________ Setup

_________________________________________________________

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

3 - 132 _________________________________________________________________ Setup

_________________________________________________________

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.

Setup _________________________________________________________________ 3 - 133

DanLoad 6000 (v6.00) __________________________________________________________


3.11.2

Default Ticket Formats

Three default ticket formats are preconfigured in the DanLoad. Refer to program code 838 for a
complete description of the Transaction Ticket Format. The basic formats are:
Format #1
Format #2
Format #3

Ticket without batch data


Ticket with batch data
Ticket with only batch data

See Figure 3-16 on the following page for an example of these formats.
Note: The first line under each format heading (numbers 1-8) and the very next line are used to
indicate the column number (1-80) of the preconfigured ticket format. Transaction storage
codes are in plain type. Batch storage codes are underlined. Field widths are indicated by
dots to the right of the storage codes, even though the values may be right-justified within
the fields.
Reference TSC and BSC codes on pages 3-129 to 3-131 for Field Identifier.

3 - 134 _________________________________________________________________ Setup

_________________________________________________________

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.

3 - 136 _________________________________________________________________ Setup

_________________________________________________________

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.

Setup _________________________________________________________________ 3 - 137

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>

<yes>

<yes>

<yes>

<yes>

<yes>

<yes>

Notes:
#

The transaction and batch file keys are not stored in their respective records. The DanLoad
6000 maintains these index numbers internally.

<yes> indicates that this field is stored in the corresponding record type.
<blank> indicates that the field is not applicable to the corresponding record type.

The fields contained in each record are defined below.


Batch Sequence Number (internal pointer to batch record)
The Batch Sequence Number is a sequential number between 0000 and 9999 that is
maintained internally by the batch record counter in the DanLoad 6000. This number is not
stored in any record field. However, because all batch deliveries and therefore batch
numbers are sequential, the DanLoad 6000 can locate any batch record by setting the batch
record counter.
Transaction Sequence Number (stored as part of batch record header)
The Transaction Sequence Number is a sequential number between 0000 and 9999 that is
maintained internally by the transaction record counter in the DanLoad 6000. This number
is not stored in transaction records. However, the current Transaction Sequence Number is
stored in the record header of each batch record. Because all transactions and therefore
transaction numbers are sequential, the DanLoad 6000 can locate any transaction record by
setting the transaction record counter. The Transaction Record Number stored in the batch
record header is used to group multiple batches into one transaction.

3 - 138 _________________________________________________________________ Setup

_________________________________________________________

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

_________________________________________________________

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

_________________________________________________________

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

6/

PC 038, 039

17 End date

856

936

end trns

6/

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

4/

22 Dens *

861

941

end trns

4/

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

_________________________________________________________

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

_________________________________________________________

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

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

10 Comp gross

10 Comp gross

10 Comp gross

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

11 Comp std

11 Comp std

11 Comp std

11 Comp std

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

M eter2
(PC-070)

M eter4
PC-073)

M eter1
(PC-076)

25 End gross

25 End gross

25 End gross

25 End gross

23 Start gross

23 Start gross

23 Start 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

26 End std

26 End std

26 End std

24 Start std

24 Start std

24 Start 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

_________________________________________________________

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

_________________________________________________________

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

_________________________________________________________

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

TRUE

TRUE

TRUE

TRUE

TRUE

TRUE

TRUE

TRUE

TRUE

TRUE

TRUE

TRUE

TRUE

TRUE

TRUE

TRUE

TRUE

TRUE

TRUE

TRUE

TRUE

TRUE

TRUE

TRUE

TRUE

TRUE

TRUE

TRUE

TRUE

TRUE

TRUE

Note: The bit is set TRUE if the corresponding alarm occurs during the transaction. The
combination of TRUE alarms determines the character printed.

Setup _________________________________________________________________ 3 - 157

DanLoad 6000 (v6.00) __________________________________________________________


The alarm bitmap is described on the following pages. The Alarm BitMap for Position:
000000000000000000000 table indicates the character position and the bit weight within each
character that is set TRUE when the alarm was active during the transaction. The alarm bitmap is
stored, by assignment of TSC 27, as 10 bytes with two-digits in each byte. Each character position
contains indicators (bits) for 4 alarms. Since each alarm is independent from other alarms, the
occurrence of no alarm or any combination of from 1 to 4 alarms assigned to each character position
will determine what character is printed in each position of the bitmap. The characters that can be
printed in each character position are 0 through 9, a, b, c, d, e, f. This is the hexadecimal
numbering system. The bitmap is read from right to left for both character position and bit position.
Example:

09876543210987654321

8421

< bitmap character position number

< 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

10

Density failure com ponent 3

10

Density failure com ponent 4

10

Pressure failure m eter 1

10

Pressure failure m eter 2

11

Pressure failure m eter 3

11

Pressure failure m eter 4

11

Additive 1 failure

11

Additive 2 failure

12

Additive 3 failure

12

Additive 4 failure

12

Additive 5 failure

12

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

13

Unable to m aintain blend

13

Unable to close block valve 1

13

Unable to close block valve 2

13

Unable to close block valve 3

14

Unable to close block valve 4

14

Circuit 1 alarm

14

Circuit 2 alarm

14

Circuit 3 alarm

15

Circuit 4 alarm

15

Circuit 5 alarm

15

Circuit 6 alarm

15

Circuit 7 alarm

16

Circuit 8 alarm

16

Storage m em ory full

16

Power failure

16

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).

10

Calibration sample could not be acquired meter 1.

11

Calibration sample could not be acquired meter 2.

12

Monitoring sample could not be acquired meter 1.

13

Monitoring sample could not be acquired meter 2.

14

Calibration checksum invalid meter 1.

15

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 LEDs 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

ON

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
Started XXXXXXXX 99:99:99
Gross
Gal
Component #1 IDX 999999
Component #2 IDX 999999
Component #3 IDX 999999
Component #4 IDX 999999

Additive
Additive
Additive
Additive
Additive
Additive

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

Gross 999999 Std 999999


<-- batch data
Stopped XXXXXXXX 99:99:99
Std
Temp
Dens
Pres
Gal
Deg C lb/ft3
psi <-- from PC's 029, 427, 428, 429
999999 -999.9 9999.9 9999.99 <-- Component data
999999 -999.9 9999.9 9999.99
999999 -999.9 9999.9 9999.99
999999 -999.9 9999.9 9999.99

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
gross
gross
Meter 1 totalizer nnnnnnnnn
Meter 2 totalizer nnnnnnnnn
Meter 3 totalizer nnnnnnnnn
Meter 4 totalizer nnnnnnnnn

Start
End
std
std
nnnnnnnnn nnnnnnnnn
nnnnnnnnn nnnnnnnnn
nnnnnnnnn nnnnnnnnn
nnnnnnnnn nnnnnnnnn

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.

<message>

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.

<message>

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
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
Additive
Additive
Additive
Additive
Additive
Additive

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

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.
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).

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).

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.
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)

10

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)

10

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

10

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)

10

0 to 300

237 Time-out ch. B (s)

10

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)

10

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.

2.

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 MPMCs 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
Local loopback
External loopback
baud rates
data formats
interrupts
Press ALT+CLEAR to

Ch. A
256/256
203/256
PPPPPPPF
PFP
PPP
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

Flow Meter Proving

(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

______________________________________________________ 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

=
=
=
=
1XXX

100
0
0
0

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

=
=
=
=
2XXX

0
100
0
0

(Continue to define a third recipe for component 3 and a forth recipe for component 4 meter proofs
if required.)

Flow Meter Proving

______________________________________________________ 5 - 7

DanLoad 6000 (v6.00) __________________________________________________________


The gross loaded volume, with the current meter factor applied, that the DanLoad 6000 measures
during the delivery operation must be displayable after a meter proof is completed. The following
data element codes are available for this purpose.
Data Code
103
104
105
106

Default Program Code

Mtr 1 grs load


Mtr 2 grs load
Mtr 3 grs load
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

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.

rack meter corrected gross volume


The volume obtained from the Dynamic Data Display element Mtr
m grs load, corrected for the effect of temperature on the liquid
measured and optionally the effect of pressure on the liquid measured.

Meter proving calculation 2:


Calculate the percentage error between the prover volume (prover tank or master meter) and the
rack meter measured volume.
rack meter 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).

rack meter corrected gross volume


The volume obtained from the Dynamic Data Display element Mtr
m grs load, corrected for the effect of temperature on the liquid
measured and optionally the effect of pressure on the liquid measured.

5 - 12 ______________________________________________________ Flow Meter Proving

__________________________________________________________ DanLoad 6000 (v6.00)


If this calculation produces a percentage error that is within the tolerances of the regulating
organizations and your organization, the current meter factor is considered to be acceptable and no
further action is required. The exact value must be determined by the governing regulations.
Example:

A typical calculation might produce a result of 0.01 which is equal to one percent
error.

Meter proving calculation 3:


Calculate the adjustment to be applied to the current meter factor, if it has been determined that the
percentage of error (calculation 2) is not acceptable.
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 components 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 new meter factor, which should always be near 1.0000, is manually entered into the
DanLoad 6000 for the active program code ccc Comp p meter factor f, where ccc is one of
the following program codes: 175 / 177 / 179 / 181 / 186 / 188 / 190 / 192 / 197 / 199 / 201
/ 203 / 208 / 210 / 212 / 214 dependent on the component number p (1 to 4) and the meter
factor number f (1 to 4).

The prover counter is manually reset to zero and the steps listed above are repeated until the
corrected meter registration is within 0.02 percent of the corrected prover volume.

5.3.1

Master Meter Meter-Proof RUN 1

For this example, assume that the loading system is a two component blender and that each
component is loaded at one of three flow rates [low flow start / stop, fall back, and normal (high)
flow]. Any other configuration, from a one component - one flow rate system to a four component four flow rate system is proved in a similar manner by proving each component (flow meter) at
each flow rate, in flow rate ascending order. The component order of proving is not important.
#

Make the system mechanically and electrically ready for delivery of a liquid batch through
the master meter by connecting the master meter in series with the rack meter by high
integrity block valves. All flow must pass through both the master meter and the rack meter
no bypass leakage is allowed.

Connect the master meter to a flow totalizer capable of measuring and displaying indicated
volume units (without internal meter factor or temperature / pressure compensation) to a
resolution of one one-hundredth of a volume unit (such as gallons).

Select the previously defined recipe for proving component 1 (recipe definitions are in the
program codes 480 to 661).

Flow Meter Proving ______________________________________________________ 5 - 29

DanLoad 6000 (v6.00) __________________________________________________________


#

Set program code 169 Number of factors/component to 1 to assure that one the low flow rate
is used.

Verify or set the low flow rate with program code 174.

Exit the Setup Menu

At the Loading Display, enter the preset volume as the minimum proving volume required.

Initiate the batch delivery.

Monitor the volume delivered in the dynamic data display. Press SELECT - 9 - 9 keys to
display item 10 (Mtr 1 grs load n.nn). This volume is the gross uncompensated volume
units delivered, adjusted by the current active meter factor, to hundredths of a volume unit.

After the delivery is terminated, determine the new meter factor by entering the data in a
copy of the METER PROVING REPORT FOR TANK PROVER METHOD form RUN 1
column.

5.3.2

Master Meter Meter-Proof RUN 2

At this point the new meter factor, program code 175 Comp 1 meter factor 1, is within tolerance
and accepted. The next higher flow rate, program code 176 Comp 1 flow rate 2, is used to
determine the meter factor for that flow rate. Assume that flow rate 2 is 400 GPM, an fall back flow
rate that is used as a fall-back flow rate if the maximum flow rate cannot be maintained. Set
program code 176 Comp 1 flow rate 2 to 400.
Set program code 169 Number of factors/component to 2 at this time to enable flow at the next
higher flow rate. The meter proof for component 1 flow rate 2 is performed similar to the meter
proof for component 1 flow rate 1 except that the DanLoad 6000 is permitted to ramp up and ramp
down the flow rate with the flow control valve. The flow rate during start and stop times is
determined by the value of program code 174 Comp 1 flow rate 1.

5 - 30 ______________________________________________________ Flow Meter Proving

__________________________________________________________ DanLoad 6000 (v6.00)


Example:
If the flow rate is 200 GPM and the start / stop volumes are 50 gallons, the time at low flow is
approximately 15 seconds during startup and 15 seconds during shutdown. All of the program codes
that in any way affect the flow rates, volumes, or meter factors at lower flow rates must be set to
their normal operational values before conducting meter proofs at higher flow rates. After the rack
meter is proved at the highest flow rate for a component. The values of any of the program codes
that affect meter proofs for that component should not be changed. If it is necessary to re-Prove a
rack meter at a flow rate less than the highest flow rate, re-Prove at all lower flow rates in flow rate
ascending order.

5.3.3

Master Meter Meter-Proof RUN 3

At this point the new meter factor, program code 177 Comp 1 meter factor 2, is within tolerance
and accepted. The next higher flow rate, program code 178 Comp 1 flow rate 3, is used to
determine the meter factor for that flow rate. Assume that flow rate 3 is 600 GPM, the maximum
(normal) loading flow rate for component 1. Set program code 178 Comp 1 flow rate 3, to 600.
The meter proof for component 1 flow rate 3 is performed similar to the meter proof for component
1 flow rate 2.

5.3.4

Master Meter Meter-Proof RUN 4 (if Required)

If the fourth flow rate for component 1 were defined, the meter proof at this flow rate would be
conducted in a similar manner as described above.

5.3.5

Meter Proofs for Component 2

Assume at this point that the meter factors for component 1 at flow rates 1, 2 , 3, and 4 (as
required) have been determined and entered into program code 175 / 177 / 179 / 181 (as required).
In order to perform the meter proof or proofs for component 2, component 1 must be disabled and
component 2 enabled. This is accomplished by selecting the previously defined recipe for proving
component 2 (recipe definitions are in program code 480 to 661).

Flow Meter Proving ______________________________________________________ 5 - 31

DanLoad 6000 (v6.00) __________________________________________________________


The set of from one to four meter proofs, corresponding to flow rates, for component 2 can now
be conducted. Follow the steps described above for meter proof sequences.
The fields contained in the METER PROVING REPORT FOR MASTER METER METHOD, Figure
5 - 3, are described below.
Field

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)

The accumulated gross volume units at the end of the rack meter
proof run, obtained from the Dynamic data display - Mtr 1 grs load,
Mtr 2 grs load, Mtr 3 grs load, or Mtr 4 grs load as applicable.
(Note: This value is uncompensated gross volume with the current
active meter factor applied.)

13 Mtr m grs load (Initial)


The meter registration for gross volume before the meter proof run is
started. Equal to 0 at start of delivery.
14 Rack Meter Measured Gross Volume
The gross volume accumulated during the meter proof run, obtained
by subtracting Mtr m grs load (Final) from Mtr m grs load (Initial).
15 Rack Meter Temperature
The temperature of the product close to the upstream or downstream
side of the flow meter (usually upstream).
16 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.)

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

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

RUN

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

L IN E

DEGREES

RUN

RUN

RUN

RUN

RUN

RUN

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
7

(AV G ),

@ 60 F

5)

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

R AC K M E TE R D ATA

6)

[DA N LO AD 6000]

RUN

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 )

10

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

12

13

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

14

15

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)
PSIG

(C H A P 11.2)

(L IN E 12 X

L IN E

CCFM

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

17

R AC K M E T E R V O L U M E E R R O R

18

R AC K M E T E R P E R C E N T E R R O R

19

ADJUSTM ENT

20

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

21

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 17 / L IN E 16)

(L IN E 7 / L IN E 16)

(L IN E 19 X

S IG N AT U R E

L IN E

20)

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

MFG:

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

MODEL:

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

T O T AN K N O :

@ 60 F:

S E R IAL N O :

Report:
D A TE :

T IM E :

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

S IZ E :

K-F AC T O R :

RUN

RUN

RUN

RUN

RUN

RUN

RUN

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

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

TLP

(T A B L E 6)
PSIG

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

10

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

(L IN E 6 X
11

L IN E

8X

L IN E

CCFP

9)

M AS T E R M E T E R C O R R E C TE D G R O S S V O 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]

12

MT R

M G R S L O AD

(F IN A L )

13

MT R

M G R S L O AD

(IN IT IA L )

14

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

RUN

RUN

RUN

(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

16

17

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

18

19

TLM

PLM

(T A B L E 6)
PSIG

(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

(L IN E 16 X
20

L IN E

CCFM

18)

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)

22

R AC K M E T E R P E R C E N T E R R O R

23

ADJUSTM ENT

24

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

25

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

(L IN E 21 / L IN E 20)

(L IN E 11 / L IN E 20)

(L IN E 23 X

S IG N AT U R E

L IN E

24)

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

AV E R AG E

__________________________________________________________ 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.

No

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
1
2
3
4

027 Valve type

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

028 Language

0
1
2
3
4
5
6
7

Seq. (auto) (* for sequential unit types)


Seq. (manual)
In-line (* for in-line unit types)
Off-rack (not used)
Dispenser

English *
English 2
Spanish
German
Portuguese
Dutch
French
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
1
2
3
4
5
6

Off
Bbl
Dek
L
Gal *
lbs
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
1
2
3
4
5

1200 bps
2400 bps
4800 bps
9600 bps
19200 bps
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>

<hyphen>

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
1
2
3

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>

cc *
in3
Gal
L

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.)
#

cc

0.0 to 9999999.99 cubic centimeters

in3

0.0 to 9999999.99 cubic inches


Internal calculation:
Vol(in3) = Vol(cc) / 16.387064

Gal

0.0 to 99999.9999 US gallons


Internal calculation:
Vol(Gal) = Vol(cc) / 3785.412

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>

<depends on
choices made
during initial
setup>

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 components 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. 15C/4C
r.d. 60F/60F
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
55.00API

lb

U.S. Gal @60F

r.d. 60F/60F

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
@15C
@60F
@60F

For example, if your K-Factor is for U.S gallons, your density is in relative density 60F/60F and you wish to compute mass in
lbs, configure the components 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

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

________________________________________________________________________________________ DanLoad 6000 (v6.00)


6.9

Digital Valve Parameters (continued)

Closed

Flow control valve solenoid 1 and solenoid 2 are deenergized


during program code 049 Initial flow time. (Note: The
component does not flow during initial flow time. This effectively
increases the line-pack delay. See program codes 087 / 093 / 099
/ 105.)

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

Section 6 - 53

________________________________________________________________________________________ DanLoad 6000 (v6.00)


6.10

Pulse Per Unit Outputs

PC # / Function

Range <Default> OR Option (* = Default)

128 Number of pulse per unit outputs

0 to 2 <2> for sequential unit type


<0> for in-line unit type

129 / 132 Control meters

4 characters <GXXX>
(Only G, S and X are valid)

130 / 133 Factor

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

=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
1
2
3
4

137 Inject Percentage

0 to 100 <50>

138 Clean line qty

0 to 9999 <0>

External *
Prompt
Inputs
Recipe
Multi Rate

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
1
2
3

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>

Mech *
Handshake
Meter
Control

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

16

32

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 batchs 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 additives 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 meters K-factor, i.e. pulses
per product unit (Product units per program code 29). An
additive meters nominal K-factor is usually marked on the meter,
and provides a good starting value. The additive meters 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

2)

Additive per 1000 = Additive PPM / 1000

Program Code Definitions (135 to 168 Additive Delivery Parameters) ___________________________________ Section 6 - 66

________________________________________________________________________________________ DanLoad 6000 (v6.00)

CONTINUE

Program Code Definitions (135 to 168 Additive Delivery Parameters) ___________________________________ Section 6 - 67

________________________________________________________________________________________ DanLoad 6000 (v6.00)


6.12

Factors

PC # / Function
(Four Components)

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 components meter.
[In-line units] Number of flow rates at which to calibrate each
components 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 components 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

________________________________________________________________________________________ DanLoad 6000 (v6.00)


6.12

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 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.

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


components low flow restart quantity should be used for starting
up components after loading the first component in the recipes
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.

No

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) ___________________________________________

Section 6 - 77

________________________________________________________________________________________ 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
1
2
3

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>

Off
Info
Secondary
Primary *

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) ___________________________________________

Section 6 - 79

________________________________________________________________________________________ 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
1
2
3

231 No flow t-o time (s)

1 to 99 <5>

232 Unauthorized flow limit qty

0.0 to 99.9 <10>

Off
Info
Secondary
Primary *

Program Code Definitions (220 to 279 Alarm Parameters) ___________________________________________

Section 6 - 82

________________________________________________________________________________________ DanLoad 6000 (v6.00)


6.13

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) ___________________________________________

Section 6 - 83

________________________________________________________________________________________ DanLoad 6000 (v6.00)


6.13

Alarms (continued)

231 No flow t-o time (s)


This program code sets the elapsed time to allow for no flow
pulse input to be detected after opening the flow control valve.
The default value is 5 seconds. (Note: This delay can be set to
1 or 2 seconds if detection of a meter pulse input failure or other
cause of the no flow condition must be detected immediately.)

232 Unauthorized flow limit quantity


This program code sets the allowable quantity to be recorded as
unauthorized flow before the Unauthorized flow exceeds limit
meter # primary alarm is issued. The default value is 10 product
units.

If the unauthorized flow quantity is set to something point 1",


e.g. 0.1, 1.1 or 2.1, then a meters 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.

A
B

jk_jk_jk_jk_jk_
jk_jk_jk_jk_jk_
))))))))) 6

time

DanLoad 6000 dual pulse security is available per the IP252


level-B standard. This is accomplished by monitoring the two
meter pulse inputs that are electrically 90 89 out of phase.
The algorithm is in the firmware of a Program Logic Device
Integrated Circuit (PLD).
The PLD performs a level B security check while a load is in
progress. The Channel A input stream is sent directly to the CPU
for totalizing the product flow.

Program Code Definitions (220 to 279 Alarm Parameters) ___________________________________________

Section 6 - 86

________________________________________________________________________________________ DanLoad 6000 (v6.00)


6.13

Alarms (continued)

Channel B is used as a comparison input stream to determine


flow direction and errors. The PLD samples the two input
streams at 6 MHZ and watches for a state transition in either
channel. As soon as one of the channels changes states, the PLD
determines if it was a forward transition. If the change was not a
forward transition, the PLD decrements the error counter by one.
As soon as the error counter reaches zero, the meter board triggers
an interrupt to the CPU which will halt the load.
While in a no load condition, the PLD will set a REV flag if any
reverse state transitions are seen. This will inhibit channel A
output to the CPU. A forward transition will clear the REV flag
and enable channel A output to the CPU on the next forward
transition. This will eliminate any pulses sent by a blade rocking
across a pick-up.
The level-B security-checking PLD is U9 on the 2-Channel Meter
Pulse board or U9 and U10 on the 4-Channel Meter Pulse board.

Possible Pulse Security Inputs


Meter Pulse Boards
Installed

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) ___________________________________________

Section 6 - 87

________________________________________________________________________________________ DanLoad 6000 (v6.00)


6.13

Alarms (continued)

234 Reset count (pulses)


This program code sets the value of raw pulses accumulated
during pulse error checking before resetting the accumulator to
zero. This value defines a window of accumulated raw pulses
that is used to determine if program code 233 Error limit value
is exceeded. A zero entry resets the error count only at the start
of each batch delivery. A value greater than zero indicates that
the accumulated error count will be cleared each time the
accumulated raw pulses equal the entry. This field is not used if
the value of program code 233 Error limit is set to zero.

PC # / Function

Range <Default> OR Option (* = Default)

235 Data logging alarm action

0 Info *
3 Primary

236 Time-out ch. A (s)

0 to 300 <10>

237 Time-out ch. B (s)

0 to 300 <10>

Program Code Definitions (220 to 279 Alarm Parameters) ___________________________________________

Section 6 - 88

________________________________________________________________________________________ DanLoad 6000 (v6.00)


6.13

Alarms (continued)

235 Data logging alarm action

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 channels 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 channels communications mode (program code 663) is
configured for Modbus RTU, i.e. automation system
communications, and the DanLoad 6000 does not receive a query
(with its communications address) on the channel for the
configured number of seconds. Zero disables the alarm. The
default value is 10.

Program Code Definitions (220 to 279 Alarm Parameters) ___________________________________________

Section 6 - 89

________________________________________________________________________________________ DanLoad 6000 (v6.00)


6.13

Alarms (continued)

PC # / Function

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) ___________________________________________

Section 6 - 90

________________________________________________________________________________________ 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) ___________________________________________

Section 6 - 91

________________________________________________________________________________________ DanLoad 6000 (v6.00)


6.13

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) ___________________________________________

Section 6 - 92

________________________________________________________________________________________ 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) ___________________________________________

Section 6 - 93

________________________________________________________________________________________ DanLoad 6000 (v6.00)


6.13

Alarms (continued)

PC # / Function

Range <Default> OR Option (* = Default)

249 Circuit 1 alarm action

0
1
2
3

250 #1 <message>

Up to 32 characters
<Ground detector open>

251 Circuit 2 alarm action

0
1
2
3

252 #2 <message>

Up to 32 characters
<Overspill detector open>

253 Circuit 3 alarm action

0
1
2
3

254 #3 <message>

Up to 32 characters
<Permissive power failure>

Off
Info
Secondary *
Primary

Off
Info
Secondary
Primary *

Off
Info
Secondary *
Primary

Program Code Definitions (220 to 279 Alarm Parameters) ___________________________________________

Section 6 - 94

________________________________________________________________________________________ DanLoad 6000 (v6.00)


6.13

Alarms (continued)

Safety Circuit Alarm Action

Note: Refer to Section 4.5.1 for alarm message and alarm action
configuration.
Alarm program codes 249 to 268 define the operation of eight
configurable safety circuit inputs (permissive circuits). All eight
safety circuits are configurable to be either side independent or
dedicated to side 1 or dedicated to side 2. The safety circuit 3 and
4 alarms have alternate uses as the end and recipe selection
alarms respectively. Safety Circuit #3 can also be used as the
additive meter flush alarm in multi-stream injection mode, if so
configured.
The physical discrete inputs for the safety circuits are assigned
with program codes 345 to 352.

249 Circuit 1 alarm action


This program code selects the response (either primary or
secondary alarm action) to an OPEN state for the discrete input
assigned to this function by program code 344 Safety circuit 1.

Off
The associated input, if any, is read, and its current status
is made available in the dynamic data display (if
configured) and via the automation system Request Status
and Enhanced Request Status commands. The DanLoad
6000 performs no other processing on the input. This
allows an automation system to process discrete inputs
independently of the DanLoad 6000 with no
communications overhead.

Info
If the associated input (safety circuit input or redirected
input) is open at any time in loading mode, i.e. in the
recipe selection screen, the additive selection screen or the
loading screen, and there is no higher priority
(secondary or primary) alarm active then the associated
alarm message is displayed for the first 10 seconds of
every 15 second period. If multiple informational safety
circuit alarms are active, the associated alarm messages
are displayed in rotation, i.e. a new message every 15
seconds.

Program Code Definitions (220 to 279 Alarm Parameters) ___________________________________________

Section 6 - 95

________________________________________________________________________________________ DanLoad 6000 (v6.00)


6.13

Alarms (continued)

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
1
2
3

256 #4 <message>

Up to 32 characters <Additive injection failure>

257 Circuit 5 alarm action

0
1
2
3

258 #5 <message>

Up to 32 characters <Arm down side 1>

259 Circuit 6 alarm action

0
1
2
3

260 #6 <message>

Up to 32 characters <Arm down side 2>

Off
Info
Secondary *
Primary

Off
Info
Secondary *
Primary

Off
Info
Secondary *
Primary

Program Code Definitions (220 to 279 Alarm Parameters) ___________________________________________

Section 6 - 98

________________________________________________________________________________________ DanLoad 6000 (v6.00)


6.13

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) ___________________________________________

Section 6 - 99

________________________________________________________________________________________ DanLoad 6000 (v6.00)


6.13

Alarms (continued)

PC # / Function

Range <Default> OR Option (* = Default)

261 Circuit 7 alarm action

0
1
2
3

262 #7 <message>

Up to 32 characters <Walkway down side 1>

263 Circuit 8 alarm action

0
1
2
3

264 #8 <message>

Up to 32 characters <Walkway down side 2>

Off
Info
Secondary *
Primary

Off
Info
Secondary *
Primary

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.

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 circuits 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 circuits
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 circuits
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

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.

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.

Program Code Definitions (220 to 279 Alarm Parameters) ___________________________________________ Section 6 - 103

________________________________________________________________________________________ DanLoad 6000 (v6.00)


6.13

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 types mask value in the sum configures the


alarm output to respond per the alarms 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.

Program Code Definitions (220 to 279 Alarm Parameters) ___________________________________________ Section 6 - 105

________________________________________________________________________________________ DanLoad 6000 (v6.00)


6.13

Alarms (continued)
Alarm Type Mask Values
Alarm Type

Mask Value

0=

Display failure

1=

Comms failure

2=

Unable to maintain
blend

3=

Flow rate to low

4=

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

16 =

Data logging memory full

65536

5=

Valve closed early

32

17 =

Memory check failed

131072

6=

Timed out - not flow


detected

64
18 =

Storage memory full

262144

Unauthorized flow
exceeds limit

128
19 =

Power failure

524288

8=

Pulse security error

256

20 =

Unable to ramp down

1048576

9=

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

7=

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
1
2
3
4
5
6
7

281 Slot 2 board

<same as above>

282 Slot 3 board

<same as above>

283 Slot 4 board

<same as above>

284 Slot 5 board

<same as above>

285 Slot 6 board

<same as above>

286 Slot 7 board

<same as above>

Empty
DC I/O
AC I/O
8-Ch. Analog Input
2-Ch. Pulse Input
Enhanced I/O
2-Ch. Analog Input
4-Ch. Pulse Input

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

11

291

15

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

10

307

13

308

14

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 valves 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 valves 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
1
2
3
4
5

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>

Sgl w/o sw. *


Sgl 1 sw. (SW2)
Sgl 1 sw. (SW1)
Dbl 1 sw. (SW2)
Dbl 1 sw. (SW1)
Dbl 2 sw.

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

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 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

NA

NA

PC 645 x 100

350

259

PC 650 x 100

PC 651 x 100

PC 646 x 100

351

261

NA

NA

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
1
2
3

356 Primary LCD min light

0 to 1023 <455>

357 Primary LCD max light

0 to 1023 <405>

358 Secondary LCD type

0
1
2
3

359 Secondary LCD min light

0 to 1023 <455>

360 Secondary LCD max light

0 to 1023 <405>

Unknown
Standish
Optrex *
Old Optrex

Unknown
Standish
Optrex *
Old Optrex

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
LCDs 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"
LCDs marked Y-LY on the back of Optrexs LCD board (not
on Daniels display board attached to the Optrex display board).
Most DanLoad 6000's shipped since 1993 have Optrex" LCDs,
usually marked YJ-LY on the back of the Optrex LCD board,
although a few of the earlier Optrex" LCDs had the same mark
as the Old Optrex" LCDs. 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 LCDs 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 recipes
selection input is configured, the recipe can be loaded only if the
recipes selection input is closed. If the recipes 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
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

1 1XXX

This program code assigns a physical discrete control output to a


block valve, block valves, or other device. This output is
CLOSED when the indicated components are being blended
(selected by the active recipe).
[component 1 only]

409

410

3 12XX

This program code assigns a physical discrete control output to a


block valve, block valves, or other device. This output is
CLOSED when the indicated components are being blended
(selected by the active recipe).
[components 1 and 2]

411

4 XX3X

This program code assigns a physical discrete control output to a


block valve, block valves, or other device. This output is
CLOSED when the indicated components are being blended
(selected by the active recipe).
[component 3 only]

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

This program code assigns a physical discrete control output to a


block valve, block valves, or other device. This output is
CLOSED when the indicated components are being blended
(selected by the active recipe)
[components 1 and 3]

This program code assigns a physical discrete control output to a


block valve, block valves, or other device. This output is
CLOSED when the indicated components are being blended
(selected by the active recipe).
[components 1, 2, and 3]

413

415

6 X23X

This program code assigns a physical discrete control output to a


block valve, block valves, or other device. This output is
CLOSED when the indicated components are being blended
(selected by the active recipe).
[components 2 and 3]

8 XXX4

This program code assigns a physical discrete control output to a


block valve, block valves, or other device. This output is
CLOSED when the indicated components are being blended
(selected by the active recipe).
[component 4 only]

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

________________________________________________________________________________________ DanLoad 6000 (v6.00)


6.16

416

Component I/O Parameters (continued)

9 1XX4

This program code assigns a physical discrete control output to a


block valve, block valves, or other device. This output is
CLOSED when the indicated components are being blended
(selected by the active recipe).
[components 1 and 4]
417

418

11 12X4

This program code assigns a physical discrete control output to a


block valve, block valves, or other device. This output is
CLOSED when the indicated components are being blended
(selected by the active recipe).
[components 1, 2, and 4]

10 X2X4
419

This program code assigns a physical discrete control output to a


block valve, block valves, or other device. This output is
CLOSED when the indicated components are being blended
(selected by the active recipe).
[components 2 and 4]

12 XX34

This program code assigns a physical discrete control output to a


block valve, block valves, or other device. This output is
CLOSED when the indicated components are being blended
(selected by the active recipe).
[components 3 and 4]

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

________________________________________________________________________________________ DanLoad 6000 (v6.00)


6.16

420

Component I/O Parameters (continued)

13 1X34

This program code assigns a physical discrete control output to a


block valve, block valves, or other device. This output is
CLOSED when the indicated components are being blended
(selected by the active recipe).
[components 1, 3, and 4]

421

422

15 1234

This program code assigns a physical discrete control output to a


block valve, block valves, or other device. This output is
CLOSED when the indicated components are being blended
(selected by the active recipe).
[components 1, 2, 3, and 4]

14 X234

This program code assigns a physical discrete control output to a


block valve, block valves, or other device. This output is
CLOSED when the indicated components are being blended
(selected by the active recipe).
[components 2, 3, and 4]

Program Code Definitions (400 through 425 Component I/O Parameters) ______________________________ Section 6 - 154

________________________________________________________________________________________ DanLoad 6000 (v6.00)

CONTINUE

Program Code Definitions (400 through 425 Component I/O Parameters) ______________________________ Section 6 - 155

________________________________________________________________________________________ DanLoad 6000 (v6.00)


6.16

Component I/O Parameters (continued)

PC# / Function

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
1
2
3
4
5

lb/ft3 *
kg/m3
g/cm3
60/60 F
15/4 C
20/4 C

429 Pressure units

0
1
2
3
4
5
6
7

psi *
Pa
in. H2O
in. Hg
bar
mbar
kPa
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 Pbras [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

Pa

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

"T

Correction for the effect of temperature on


a liquid.
Observed temperature from an RTD input
or the fixed entry in program code
434/437/440/443 Backup temperature.
Reference temperature from program code
430 Reference temperature.
Coefficient of thermal expansion for the
liquid at base temperature, from program
code 433/436/439/442 Alpha.

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

Section 6 - 162

________________________________________________________________________________________ DanLoad 6000 (v6.00)


6.17

Temperature / Pressure / Density


(continued)

API Temperature Compensation Tables:


#

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 IMPs 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.
#

Pbras (Petrobras - Brazil)


Petrobras Departamento Comercial - Diviso de
Controle das Movimentaes -- Biblioteca Geral
de Aplicativos para a rea de Movimentaes de
Produto - Mdulo 4: Programa para Clculo de
Densidade 20oC/4oC e Fator de Correo de
Volume para 20oC, July 1988. Only part 3,
Clculo do Fator de Correo 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 LPGs, 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
1
2
3
4
5
6
7
8

Off *
Const
11.2.1
11.2.2
11.2.1M
11.2.2M
Pbras
Pbras LPG
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:
Abs.Dns.(kg/m3)
638 to 1074

Temp.(deg.C) Press(kPa)
-30 to +90

0 to 10300

11.2.2M
Light hydrocarbon liquids, correction of volume
to 0 kiloPascals against absolute density at 15
degrees Celsius. The table inputs are absolute
density at 15 degrees Celsius obtained live or
from program code 457 / 459 / 461 / 463 Backup
density/gravity and the F-factor obtained from
program code 445 / 448 / 451 / 454 F-factor X
1000000000 and the operating pressure obtained
from a pressure transmitter, ranges for the table
are:
Abs.Dns(kg/m3)
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)
#

Pbras

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.

Pbras 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 LPGs 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

DT

#
#
#
#
#
#
#

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

L2

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 components 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 meters 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

662

Address

0 to 255 <0>

663

668

Mode

0
1
2
3

Not used *
Modbus RTU
ASCII
Data logging (ch. B only)

664

669

Data Rate

0
1
2
3
4
5
6
7

300 bps
600 bps
1200 bps
2400 bps
4800 bps
9600 bps
19200 bps
38400 bps

665

670

Word Size

0
1
2
3

5 bits
6 bits
7 bits
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 Registers 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

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) _____________________________

150
152
0.0
597

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 displa