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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) __________________________________________________________
Preface i
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 MAKES NO
WARRANTIES, EXPRESSED OR IMPLIED, INCLUDING THE IMPLIED WARRANTIES OF
MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE WITH RESPECT TO THIS
MANUAL AND, IN NO EVENT, SHALL DANIEL BE LIABLE FOR ANY INCIDENTAL, PUNITIVE,
SPECIAL OR CONSEQUENTIAL DAMAGES INCLUDING, BUT NOT LIMITED TO, LOSS OF
PRODUCTION, LOSS OF PROFITS, LOSS OF REVENUE OR USE AND COSTS INCURRED INCLUDING
WITHOUT LIMITATION FOR CAPITAL, FUEL AND POWER, AND CLAIMS OF THIRD PARTIES.
PRODUCT NAMES USED HEREIN ARE FOR MANUFACTURER OR SUPPLIER IDENTIFICATION ONLY
AND MAY BE TRADEMARKS/REGISTERED TRADEMARKS OF THESE COMPANIES.
THE CONTENTS OF THIS PUBLICATION ARE PRESENTED FOR INFORMATIONAL PURPOSES ONLY, AND
WHILE EVERY EFFORT HAS BEEN MADE TO ENSURE THEIR ACCURACY, THEY ARE NOT TO BE
CONSTRUED AS WARRANTIES OR GUARANTEES, EXPRESSED OR IMPLIED, REGARDING THE
PRODUCTS OR SERVICES DESCRIBED HEREIN OR THEIR USE OR APPLICABILITY. ALL SALES ARE
GOVERNED BY DANIEL’S TERMS AND CONDITIONS, WHICH ARE AVAILABLE UPON REQUEST. WE
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 MAINTENANCE OF ANY DANIEL
PRODUCT REMAINS SOLELY WITH 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.
_________________________________________________________ DanLoad 6000 (v6.00)
Prefaceii
WARRANTY
1. LIMITED WARRANTY: 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 WARRANTIES OF
ANY KIND, EXPRESSED OR IMPLIED, AS TO MERCHANTABILITY, FITNESS FOR PARTICULAR PURPOSE,
OR ANY OTHER MATTER WITH RESPECT TO ANY OF THE GOODS OR SERVICES. Buyer acknowledges
and agrees that corrosion or erosion of materials is not covered by this warranty.
2. LIMITATION OF REMEDY AND LIABILITY: DANIEL SHALL NOT BE LIABLE FOR DAMAGES
CAUSED BY DELAY IN PERFORMANCE. THE SOLE AND EXCLUSIVE REMEDY FOR BREACH OF
WARRANTY HEREUNDER SHALL BE LIMITED TO REPAIR, CORRECTION, REPLACEMENT OR REFUND
OF PURCHASE PRICE UNDER THE LIMITED WARRANTY CLAUSE IN SECTION 1 HEREIN. IN NO EVENT,
REGARDLESS OF THE FORM OF THE CLAIM OR CAUSE OF ACTION (WHETHER BASED IN CONTRACT,
INFRINGEMENT, NEGLIGENCE, STRICT LIABILITY, OTHER TORT OR OTHERWISE), 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 WITHOUT LIMITATION
FOR CAPITAL, FUEL AND POWER, AND CLAIMS OF BUYER’S CUSTOMERS.
DanLoad 6000 (v6.00) __________________________________________________________
Table of Contents iii
TABLE OF CONTENTS
Section Page
1.0 INTRODUCTION
1.1 Functional Characteristics ................................... 1-6
1.2 Hardware Configuration ..................................... 1-9
1.3 General Terminology ...................................... 1-10
2.0 INSTALLATION
2.1 DanLoad 6000 Specifications ................................. 2-2
2.2 Installation Planning ........................................ 2-9
2.2.1 Card Cage Description ...................................... 2-9
2.2.2 DanLoad 6000 Board Description and Jumper Settings . . . . . . . . . . . . . 2-11
2.3 Mechanical Installation ..................................... 2-35
2.4 Electrical Installation ...................................... 2-38
2.4.1 General Considerations .................................... 2-38
2.4.2 Selection/Installation of Electrical Wire / Cable . . . . . . . . . . . . . . . . . 2-39
2.4.2.1 Input / Output Field Signal Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-41
2.4.2.2 Electrical Grounds ........................................ 2-41
2.4.3 Selection/Installation of Wire Conduit . . . . . . . . . . . . . . . . . . . . . . . . . 2-43
2.5 Installing the Secondary Keypad / Display . . . . . . . . . . . . . . . . . . . . . . . 2-44
2.5.1 Hardware Setup / Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-44
2.5.2 Software Setup / Configuration................................ 2-44
2.5.3 Wiring Details ............................................. 2-45
2.5.4 Power Requirements ........................................ 2-45
3.0 SETUP
3.1 Overview of DanLoad 6000 Capabilities . . . . . . . . . . . . . . . . . . . . . . . . 3-2
3.2 Operator Interface .......................................... 3-7
3.2.1 Data Display Operation ..................................... 3-7
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Table of Contentsiv
3.2.2 Keypad Operation ......................................... 3-10
3.3 Initial Setup Procedure Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
3.3.1 Data Entry ............................................... 3-16
3.4 Initial Setup Procedure ..................................... 3-20
3.5 Process I/O Signal Handling ................................. 3-24
3.5.1 Physical I/O Signal Assignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25
3.5.2 Inverted Discrete Inputs .................................... 3-27
3.6 Product Delivery and Blending .............................. 3-70
3.6.1 Sequential Blending ....................................... 3-70
3.6.2 In-Line Blending .......................................... 3-71
3.7 Temperature and Pressure Compensation . . . . . . . . . . . . . . . . . . . . . . 3-78
3.7.1 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 Additive Injection ......................................... 3-88
3.10.1 Additive Injection Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-92
3.10.2 Additive Injection Configuration (Typical Examples) . . . . . . . . . . . . . 3-99
3.10.3 Additive Meter Calibration .................................. 3-109
3.10.4 Multi-Stream Injection Mode ................................ 3-112
3.10.5 Multi-Rate Additive Injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-119
3.11 Transaction Storage Overview ............................... 3-121
3.11.1 Transaction Storage / Transaction Ticket
Setup Procedure (Example) ................................. 3-122
3.11.2 Default Ticket Formats ..................................... 3-134
3.11.3 Transaction Data Storage ................................... 3-136
3.11.4 Relation Between Batch Storage and
Transaction Storage Variables ............................... 3-148
3.11.5 Relation Between Transaction Storage Codes /
Batch Storage Codes / Program Codes . . . . . . . . . . . . . . . . . . . . . . . . . 3-149
3.11.6 Transaction Ticket Configuration Overview . . . . . . . . . . . . . . . . . . . . 3-151
3.11.7 Transaction Ticket Layout Planning . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-152
3.11.8 Alarm BitMap ............................................ 3-156
3.12 Compartment Size Inputs ................................... 3-164
3.13 Cutoff (End of Day Processing) .............................. 3-165
DanLoad 6000 (v6.00) __________________________________________________________
Table of Contents v
3.14 Set Contrast / Backlighting .................................. 3-166
3.15 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 Physical Configuration ...................................... 4-3
4.1.1 Displays and Controls ....................................... 4-3
4.1.1.1 LED Status Indicators ....................................... 4-3
4.1.1.2 LCD Alpha-Numeric / Graphic Data Display . . . . . . . . . . . . . . . . . . . . 4-5
4.1.1.3 Keypad .................................................. 4-6
4.2 Batch Delivery Procedure .................................... 4-9
4.2.1 Controlling the Batch Delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
4.3 Additive Injection ......................................... 4-19
4.4 Data Logging ............................................ 4-20
4.4.1 Example Data Logs ....................................... 4-21
4.5 Alarm Analysis / Correction / Diagnostic Tests . . . . . . . . . . . . . . . . . . 4-30
4.5.1 Alarm Messages .......................................... 4-31
4.5.2 Diagnostic Tests .......................................... 4-50
5.0 FLOW METER PROVING
5.1 General Considerations ..................................... 5-6
5.1.1 Initial Setup ............................................. 5-17
5.2 Tank Prover Method ....................................... 5-21
5.2.1 Meter Proof RUN 1 ....................................... 5-22
5.2.2 Meter Proof RUN 2 ....................................... 5-23
5.2.3 Meter Proof RUN 3 ....................................... 5-23
5.2.4 Meter Proof RUN 4 ....................................... 5-24
5.2.5 Meter Proofs for Component 2 ............................... 5-24
5.3 Master Meter Method ...................................... 5-28
5.3.1 Meter Proof RUN 1 ....................................... 5-29
5.3.2 Meter Proof RUN 2 ....................................... 5-30
5.3.3 Meter Proof RUN 3 ....................................... 5-31
5.3.4 Meter Proof RUN 4 ....................................... 5-31
5.3.5 Meter Proofs for Component 2 ............................... 5-31
_________________________________________________________ DanLoad 6000 (v6.00)
Table of Contentsvi
6.0 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 Dynamic Data Display ..................................... 6-190
6.20.1 Dynamic Data Display Data Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-195
6.21 Data Logging ............................................ 6-202
DanLoad 6000 (v6.00) __________________________________________________________
Table of Contents vii
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 Physical Configuration ..................................... A-4
A.2 Functional Configuration ................................... A-7
A.3 General Configuration Parameters Setup (Table A-11) . . . . . . . . . . . . A-19
A.4 Flow Meter Parameters Setup (Table A-12) . . . . . . . . . . . . . . . . . . . . . A-22
A.5 Flow Control Valve Parameters Setup (Table A-13) . . . . . . . . . . . . . A-24
A.6 Component Parameters Setup (Table A-14) . . . . . . . . . . . . . . . . . . . . . A-26
A.7 Component Block Valve / Pump Parameters Setup (Table A-15) . . . . A-28
A.8 Delivery Parameters Setup (Table A-16) . . . . . . . . . . . . . . . . . . . . . . . A-30
A.9 Blending Parameters Setup (Table A-17) . . . . . . . . . . . . . . . . . . . . . . . A-33
A.10 Temperature Compensation Parameters Setup (Table A-18) . . . . . . . . A-35
A.11 Pressure Compensation Parameters Setup (Table A-19) . . . . . . . . . . . A-37
A.12 Density Compensation Parameters Setup (Table A-20) . . . . . . . . . . . A-38
A.13 Pulse Per Unit Output Parameters Setup (Table A-21) . . . . . . . . . . . . A-40
A.14 Additive Parameters Setup (Table A-22) . . . . . . . . . . . . . . . . . . . . . . A-41
A.15 LPG / Pressure Control Parameters Setup (Table A-23) . . . . . . . . . . . A-44
A.16 Dynamic Data Display Parameters Setup (Table A-24) . . . . . . . . . . . A-46
A.17 Communications / Data Logging Parameters Setup (Table A-25) . . . A-54
A.18 Transaction Storage Parameters Setup (Table A-26) . . . . . . . . . . . . . A-56
A.19 Transaction Ticket Parameters Setup (Table A-27) . . . . . . . . . . . . . . A-61
A.20 Alarm Parameters Setup (Table A-28) . . . . . . . . . . . . . . . . . . . . . . . . A-65
B Configuration Record ....................................... B-1
C LPG Loading Configuration Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . C-1
D Spare Parts............................................... D-1
_________________________________________________________ DanLoad 6000 (v6.00)
Table of Contentsviii
E Field Wiring Drawings ...................................... E-1
F Other Drawings ............................................ F-1
FIGURES
1-1 Typical Load Rack ......................................... 1-5
2-1 Standard Enclosure Dimensions ............................... 2-5
2-2 Standard Enclosure Field Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
2-3 Shallow Enclosure Dimensions ............................... 2-7
2-4 Shallow Enclosure Field Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
2-5 Card Cage Layout ......................................... 2-10
2-6 DC Power Supply Voltage Use .............................. 2-11
2-7 AC Power Input Jumpers ................................... 2-12
2-8 CPU Board - Jumpers ....................................... 2-13
2-9 CPU and Analog Inputs Board Combination Jumpers . . . . . . . . . . . . . . 2-13
2-10 CPU Board Jumpers ........................................ 2-14
2-11 CPU Analog Inputs Program Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
2-12 DUART Board Address Switch ............................... 2-15
2-13 2-Ch. Meter Pulse Input Board Jumpers . . . . . . . . . . . . . . . . . . . . . . . 2-17
2-14 4-Ch. Meter Pulse Input Board Jumpers . . . . . . . . . . . . . . . . . . . . . . . 2-22
2-15 MPMC Version Comparisons ................................. 2-24
2-16 Version 1 AC I/O Board Jumpers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26
2-17 Version 2 AC I/O Board Jumpers . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26
2-18 Version 1 Enhanced (Additive Injector) I/O Board Jumpers . . . . . . . . 2-29
2-19 Version 2 Enhanced I/O Board Jumpers . . . . . . . . . . . . . . . . . . . . . . . 2-31
2-20 DC I/O Board Jumpers ..................................... 2-33
2-21 Secondary Keypad / Display Connections . . . . . . . . . . . . . . . . . . . . . . . 2-46
3-1 Menu Tree ............................................... 3-5
3-2 Program Code Groups ...................................... 3-6
3-3 General Display Format ..................................... 3-7
3-4 Program Code View ........................................ 3-8
3-5 Key Functions ........................................... 3-12
3-6 Alpha-Numeric Characters .................................. 3-18
3-7 Basic Configuration ....................................... 3-24
3-8 Set Date and Time Display .................................. 3-30
3-9 Alarm Action Summary .................................... 3-47
3-10 Digital Flow Control Valve ................................. 3-75
3-11 Two-Stage Flow Control Valve (w/o Stem Switches) . . . . . . . . . . . . 3-76
3-12 Transaction Ticket (Typical) ................................ 3-126
DanLoad 6000 (v6.00) __________________________________________________________
Table of Contents ix
3-13 Transaction Record / Ticket Worksheet (Example) . . . . . . . . . . . . . . . 3-127
3-14 Batch Record / Ticket Worksheet (Example) . . . . . . . . . . . . . . . . . . . . 3-128
3-15 DanLoad Default Ticket Formats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-135
3-16 Set Contrast / Backlighting Display . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-166
4-1 Keypad Layout ............................................ 4-6
4-2 Key Functions (Batch Delivery) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
4-3 Recipe Selection Display .................................... 4-9
4-4 Additive Selection Display .................................. 4-11
4-5 Loading Display .......................................... 4-12
4-6 Diagnostic Menu ......................................... 4-50
4-7 Input / Outputs Diagnostic .................................. 4-52
4-8 DUART Ports Diagnostic ................................... 4-54
4-9 LAN Port Diagnostic ...................................... 4-54
5-1 Prover / Meter Volume Relationship . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
5-2 Meter Proving Report For Tank Prover Method . . . . . . . . . . . . . . . . . 5-39
5-3 Meter Proving Report For Master Meter Method . . . . . . . . . . . . . . . . 5-40
Master Meter Meter-Factors Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-41
6-1 Menu Tree ............................................... 6-8
6-2 Parameters List Overview ................................... 6-9
6-3 CPU v2 Analog Calibration Set Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-262
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Table of Contentsx
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Section 1
Introduction
Functional Characteristics
Hardware Configuration
General Terminology
_________________________________________________________ DanLoad 6000 (v6.00)
Introduction ____________________________________________________________ 1 - 1
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).
DanLoad 6000 (v6.00) __________________________________________________________
1 - 2 ____________________________________________________________ Introduction
# 481 / ... / 655 Name Sequence of similar three-digit program code
numbers is too long to list all numbers. The
ellipsis (...) is a place holder for additional
program code numbers. In this example, the
ellipsis represent 28 additional recipe name
program code numbers.
Information applicable to new installations is located in the following sections.
# Section 1 - Introduction
# Section 2 - Installation
# Section 3 - Setup
# Section 6 - Program Code Definitions
Information applicable to operation of an existing system is located in the following sections.
# Section 4 - Operation
# Section 5 - Flow Meter Proving
The individual sections contain the following information.
# Section 1 - Introduction (this section)
This section contains an overview of the capabilities of the DanLoad 6000. A glossary of
terms used throughout the manual is located at the rear of this section.
# Section 2 - Installation
This section contains information on installation planning, mechanical installation, and
electrical installation of the DanLoad 6000. Design considerations for on-site placement,
mounting, and wiring methods are included in this section. Also read Section 3, Section 6,
Appendix A, Appendix B, and Appendix C before installing the instrument.
# Section 3 - Setup
This section contains information on the initial setup (functional configuration) and
modification of setup parameters stored in the DanLoad 6000. The DanLoad 6000 retains
setup information in non-volatile memory. Therefore, the initial setup can be performed in
a shop or office, before on-site physical installation of the instrument. Also read Section 2,
Section 6, Appendix A, Appendix B, and Appendix C before installing the instrument.
_________________________________________________________ DanLoad 6000 (v6.00)
Introduction ____________________________________________________________ 1 - 3
# 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.
DanLoad 6000 (v6.00) __________________________________________________________
1 - 4 ____________________________________________________________ Introduction
Overview
The DanLoad 6000 can be operated in an independent stand-alone mode with batch delivery
operations monitored and controlled from the operator control panel located on front of the DanLoad
6000. The DanLoad 6000 can also function as a slave unit in a terminal automation system network.
The information contained in this manual covers local operation of the DanLoad 6000 in the Stand-
alone Mode. The DanLoad 6000 accepts process input signals from and provides process control
signals to the common instruments and devices used in liquid batch delivery systems. These
instruments / devices include: liquid flow meters (turbine and positive displacement type), solenoid
controlled digital flow control valves, additive injectors, security devices for verifying electrical
ground connections and compartment overfills, electric motor driven pumps, and motor operated
block valves. The DanLoad 6000 can be easily setup (configured) to deliver single component
liquids or to blend up to four liquid components in precise ratios, with or without additive injection.
The various possible delivery and blending functions of the DanLoad 6000 are controlled by operator
selectable recipes (predefined delivery control procedures). Additive injection is controlled by
manual selection, recipe selection, or automatic selection from a terminal automation system. These
features allow one DanLoad 6000 and the associated liquid delivery equipment to deliver many
different combinations of liquid products, based on requirements of the client or receiver of the
delivered product.
One common application for a DanLoad 6000 is as an on-site controller for delivering refined
hydrocarbon liquid products from loading terminal storage tanks to mobile tanks, such as tanker
trucks, rail tank cars, and tank barges. Some other applications include liquid component blending
and / or additive injection in refinery or chemical plant processes. In addition, liquid components
can be blended with or without additive injection into flowing pipelines or into storage tanks. A
typical load rack installation with a DanLoad 6000 and associated equipment is shown in Figure 1 -
1.
_________________________________________________________ DanLoad 6000 (v6.00)
Introduction ____________________________________________________________ 1 - 5
Figure 1-1
DanLoad 6000 (v6.00) __________________________________________________________
1 - 6 ____________________________________________________________ Introduction
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.
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