Daniel DanLoad 6000 Script Language Owner's manual

DanLoad 6000

SCRIPT LANGUAGE

REFERENCE MANUAL

__________________________________________

DANIEL MEASUREMENT AND CONTROL

HOUSTON, TEXAS

Part Number: 3-9000-678

Revision F

SEPTEMBER 1999

This page intentionally left blank.

Year 2000 Warranty

The Company represents and warrants that computer programs in any medium, software, firmware

and combinations thereof (“Deliverables”) manufactured by the Company and incorporated into

or supplied by the Company for use with goods manufactured by the Company will, under normal

use and care:

i) recognize and accept dates falling on or after 1 January 2000;

ii) recognize and accept the year 2000 and every succeeding fourth year as leap years;

iii) recognize and accept 29 February in the year 2000 and every succeeding fourth

year;

iv) record, store, process, sequence, present and output calendar dates and data related

to dates falling on or after 1 January 2000, in the same manner and with the same

functionality as they do on or before 31 December 1999 and without errors or

omissions; and

v) lose no functionality with respect to the introduction into them of dates or data

related to dates falling on or after 1 January 2000;

provided that, in the case of any non-conforming Deliverables that are returned to the Company

promptly following discovery of the non-conformity, the Company will, at its option and cost,

repair or replace such Deliverable or refund to the Purchaser the purchase price therefor. This

shall be the Purchaser’s sole and exclusive remedy for breach of the foregoing warranty.

Notwithstanding the foregoing, the Company shall not, under any circumstances whatsoever, be

liable for any defects or errors caused by: materials or workmanship made, furnished or specified

by the Purchaser; non-compliance with the Company’s installation or operation requirements;

failure to install any revisions and/or upgrades to the Deliverables deemed mandatory by the

Company; any modifications to Deliverables not previously authorized by the Company in writing;

the use by the Purchaser of any non-authorized spare or replacement parts in connection with the

goods used in conjunction with the Deliverables; or the use of the Deliverables with any hardware

or software not supplied by the Company. The Purchaser shall at all times remain solely

responsible for the adequacy and accuracy of all information supplied by it. Any third party

content in Deliverables shall carry only the warranty extended by the original manufacturer.

THE FOREGOING CONSTITUTES THE COMPANY’S SOLE AND EXCLUSIVE

WARRANTY IN RELATION TO THE PERFORMANCE OF THE DELIVERABLES AS IT

RELATES TO THE CHANGE FROM YEAR 1999 TO YEAR 2000 OR THE OCCURRENCE

OF LEAP YEARS THEREAFTER, AND THE PURCHASER’S EXCLUSIVE REMEDY FOR

BREACH THEREOF. IN NO EVENT WILL THE COMPANY BE LIABLE FOR INDIRECT,

CONSEQUENTIAL, INCIDENTAL OR SPECIAL DAMAGES, INCLUDING LOSS OF USE,

BUSINESS INTERRUPTION OR LOSS OF PROFITS, IRRESPECTIVE OF WHETHER THE

COMPANY HAD NOTICE OF THE POSSIBILITY OF SUCH DAMAGES.

The foregoing warranty shall remain valid until the later of December 31, 2000 or one year after

the date that the Deliverable was shipped.

DANIEL INDUSTRIES, INC.

DANLOAD 6000 SCRIPT LANGUAGE

REFERENCE MANUAL

NOTICE

DANIEL INDUSTRIES, INC. AND DANIEL MEASUREMENT AND CONTROL ("DANIEL")

SHALL NOT BE LIABLE FOR TECHNICAL OR EDITORIAL ERRORS IN THIS MANUAL

OR OMISSIONS FROM THIS MANUAL. DANIEL MAKES NO WARRANTIES, EXPRESS

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 SPECIAL OR

CONSEQUENTIAL DAMAGES INCLUDING, BUT NOT LIMITED TO, LOSS OF

PRODUCTION, LOSS OF PROFITS, ETC.

PRODUCT NAMES USED HEREIN ARE FOR MANUFACTURER OR SUPPLIER

IDENTIFICATION ONLY AND MAY BE TRADEMARKS/REGISTERED TRADEMARKS

OF THESE COMPANIES.

BY DANIEL MEASUREMENT AND CONTROL

HOUSTON, TEXAS, U.S.A.

copied in any form or by any means - graphic, electronic or

mechanical - without first receiving the written permission of

Daniel Measurement and Control, Houston, Texas, U.S.A.

WARRANTY

Daniel Measurement and Control ("Daniel") warrants all equipment manufactured by it to be free

from defects in workmanship and material, provided that such equipment was properly selected

for the service intended, properly installed, and not misused. Equipment which is returned,

transportation prepaid to Daniel within twelve (12) months of the date of shipment (eighteen (18)

months from date of shipment for destinations outside of the United States), which is found after

inspection by Daniel to be defective in workmanship or material, will be repaired or replaced at

Daniel' s sole option, free of charge, and return-shipped at lowest cost transportation. All

transportation charges and export fees will be billed to the customer. Warranties on devices

purchased from third party manufacturers not bearing a Daniel label shall have the warranty

provided by the third party manufacturer.

The warranties specified herein are in lieu of any and all other warranties, express or implied,

including any warranty of merchantability or fitness for a particular purpose.

Daniel shall be liable only for loss or damage directly caused by its sole negligence. Daniel's

liability for any loss or damage arising out of, connected with, or resulting from any breach hereof

shall in no case exceed the price allocable to the equipment or unit thereof which gives rise to the

claim. Daniel's liability shall terminate one year after the delivery of the equipment except for

overseas deliveries and extended warranty products as noted above.

In no event, whether as a result of breach of warranty or alleged negligence, shall Daniel be liable

for special or consequential damages, including, but not limited to, loss of profits or revenue; loss

of equipment or any associated equipment; cost of capital; cost of substitute equipment, facilities

or services; downtime costs; or claims of customers of the purchaser for such damages.

i

TABLE OF CONTENTS

1.0 INTRODUCTION

1.1 Functional Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

1.2 Hardware Configuration ............................. 1-9

1.3 General Terminology .............................. 1-11

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 Input / Output Board Description and Jumper Settings . . . . . . . . . . 2-11

2.3 Mechanical Installation ............................ 2-30

2.4 Electrical Installation .............................. 2-34

2.4.1 General Considerations ............................ 2-34

2.4.2 Selection / Installation of Electrical Wire and Cable . . . . . . . . . . 2-36

2.4.2.1 Input / Output Field Signal Wiring . . . . . . . . . . . . . . . . . . . . . 2-39

2.4.2.2 Electrical Grounds ............................... 2-40

2.4.3 Selection / Installation of Wire Conduit . . . . . . . . . . . . . . . . . . 2-42

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 SETU P

3.1 Overview ...................................... 3-3

3.2 Man-Machine Interface ............................. 3-9

3.2.1 Data Display Operation ............................ 3-10

3.2.2 Keypad Operation ................................ 3-13

3.2.3 Script Language Support ............................. 3-20

3.3 Initial Setup Procedure Overview . . . . . . . . . . . . . . . . . . . . . . 3-24

ii

3.3.1 Data Entry .................................... 3-25

3.4 Initial Setup Procedure ............................. 3-30

3.5 Process I/O Signal Handling . . . . . . . . . . . . . . . . . . . . . . . . . 3-35

3.5.1 Physical I/O Signal Assignment . . . . . . . . . . . . . . . . . . . . . . . 3-36

3.5.2 Flow Measurement and General Parameters . . . . . . . . . . . . . . . 3-85

3.6 Product Blending ................................ 3-89

3.6.1 Sequential Blending ............................... 3-89

3.6.2 In-Line Blending ................................. 3-91

3.6.3 Off-Rack Blending ............................... 3-91

3.7 Additive Injection ................................ 3-95

3.8 Mass Loading Using a Volumetric Flow Meter . . . . . . . . . . . . 3-103

3.9 Setup Checklist ................................ 3-106

3.10 Set Contrast / Backlighting . . . . . . . . . . . . . . . . . . . . . . . . . 3-120

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 ........................................ 4-7

4.2 Batch Delivery Procedure ........................... 4-10

4.2.1 Controlling the Batch Delivery . . . . . . . . . . . . . . . . . . . . . . . 4-15

4.3 Additive Injection ................................ 4-22

4.3.1 Additive Injection Control . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23

4.4 Data Logging ................................... 4-34

4.4.1 Example Data Logs ............................... 4-35

4.5 Alarms /Fault Analysis / Correction /Diagnostic Tests . . . . . . . . 4-43

4.5.1 Alarm Messages ................................. 4-44

4.5.2 Diagnostic Tests ................................. 4-61

4.5.3 Crash Memory Log ............................... 4-65

5.0 FLOW METER PROVING

5.1 General Considerations ............................. 5-8

5.1.1 Initial Setup .................................... 5-22

5.2 Tank Prover Method .............................. 5-26

5.2.1 Meter Proof RUN 1 .............................. 5-27

5.2.2 Meter Proof RUN 2 .............................. 5-28

5.2.3 Meter Proof RUN 3 .............................. 5-29

5.2.4 Meter Proof RUN 4 .............................. 5-29

iii

5.2.5 Meter Proofs for Component 2 . . . . . . . . . . . . . . . . . . . . . . . 5-29

5.3 Master Meter Method ............................. 5-34

5.3.1 Meter Proof RUN 1 .............................. 5-36

5.3.2 Meter Proof RUN 2 .............................. 5-37

5.3.3 Meter Proof RUN 3 .............................. 5-38

5.3.4 Meter Proof RUN 4 .............................. 5-38

5.3.5 Meter Proofs for Component 2 . . . . . . . . . . . . . . . . . . . . . . . 5-38

6.0 PROGRAM CODE DESCRIPTIONS

6.1 Program Code Attributes ............................ 6-2

6.2 Parameter Groups ................................. 6-7

6.3 Security Parameters ............................... 6-14

6.4 Unit Parameters ................................. 6-18

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

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

6.7 Component Parameters ............................ 6-38

6.8 Delivery Parameters .............................. 6-40

6.9 Digital Valve Parameters ........................... 6-48

6.10 Pulse Per Unit Outputs ............................. 6-52

6.11 Additive Delivery Parameters . . . . . . . . . . . . . . . . . . . . . . . . 6-56

6.12 Factors ........................................ 6-66

6.13 Alarms ....................................... 6-74

6.14 I/O Parameters ................................. 6-102

6.15 Additive I/O Parameters ........................... 6-126

6.16 Component I/O Parameters . . . . . . . . . . . . . . . . . . . . . . . . . 6-128

6.17 Temperature / Pressure / Density Parameters . . . . . . . . . . . . . . 6-134

6.18 Recipes ...................................... 6-152

6.19 Data Communications ............................ 6-158

6.20 Dynamic Data Display ............................ 6-162

6.20.1 Dynamic Data Display Data Codes . . . . . . . . . . . . . . . . . . . . 6-166

6.21 Data Logging .................................. 6-170

6.22 Blending ..................................... 6-176

6.23 Additive pumps / Block Valves . . . . . . . . . . . . . . . . . . . . . . 6-188

iv

APPENDICES

A Installation Worksheets ............................ A-1

A.1 Flow Meter Logical Input Signals . . . . . . . . . . . . . . . . . . . . . . A-7

A.2 Component Logical I/O Signals . . . . . . . . . . . . . . . . . . . . . . . A-8

A.3 Flow Control Valve Logical I/O Signals . . . . . . . . . . . . . . . . . A-9

A.4 Additive Injection Logical I/O Signals . . . . . . . . . . . . . . . . . . . A-10

A.5 Miscellaneous Logical I/O Signals . . . . . . . . . . . . . . . . . . . . . A-11

Worksheets 1 to 16 ............................... A-15

B.1 Program Code Default Value Assignments . . . . . . . . . . . . . . . . . B-2

B.2 Version Dependent Program Codes . . . . . . . . . . . . . . . . . . . . B-51

C Recommended Spare Parts ........................... C-1

D Drawings ..................................... D-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 & Analog Inputs Board Combination Jumpers . . . . . . . . . . 2-14

2-10 DUART Board Address Switch . . . . . . . . . . . . . . . . . . . . . . . 2-15

2-11 2-Channel Meter Pulse Input Board Jumpers . . . . . . . . . . . . . . . 2-17

2-12 Version 1 AC I/O Board Jumpers . . . . . . . . . . . . . . . . . . . . . . 2-20

v

2-13 Version 2 AC I/O Board Jumpers . . . . . . . . . . . . . . . . . . . . . . 2-20

2-14 Version 1 Enhanced (Additive Injector) I/O Board Jumpers . . . . . . 2-24

2-15 Version 2 Enhanced I/O Board Jumpers . . . . . . . . . . . . . . . . . . . 2-25

2-16 DC I/O Board Jumpers .............................. 2-27

2-17 Secondary Keypad / Display Connections . . . . . . . . . . . . . . . . . . 2-46

3-1 Menu Tree ..................................... 3-6

3-2 Parameters List Overview ............................ 3-7

3-3 General Display Format ............................ 3-10

3-4 Parameter View ................................. 3-10

3-5 Keypad (English Version) ............................ 3-13

3-6 Key Functions .................................. 3-14

3-7 Chinese Script Characters Bitmap (Part 1) . . . . . . . . . . . . . . . . . . 3-21

3-8 Chinese Script Characters Bitmap (Part 2) . . . . . . . . . . . . . . . . . . 3-22

3-9 Thai Script Character Bitmap . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22

3-10 Alphanumeric Codes for Thai Bitmap Construction . . . . . . . . . . . . 3-23

3-11 Alpha-Numeric Characters . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27

3-12 Basic Configuration ............................... 3-35

3-13 Set Date and Time Display .......................... 3-42

3-14 Alarm Action Summary ............................ 3-64

3-15 Flow Measurement - General . . . . . . . . . . . . . . . . . . . . . . . . 3-86

3-16 Delivery - Blending ............................... 3-92

3-17 Digital Flow Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . 3-109

3-18 Two-Stage Flow Control Valve . . . . . . . . . . . . . . . . . . . . . . 3-111

(without Stem-Switches)

3-19 Two-Stage Flow Control Valve . . . . . . . . . . . . . . . . . . . . . . 3-112

(with Stem-Switches)

3-20 Set Contrast / Backlighting Display . . . . . . . . . . . . . . . . . . . . 3-120

4-1 Keypad Layout ................................... 4-7

4-2 Key Functions (Batch Delivery) . . . . . . . . . . . . . . . . . . . . . . . 4-8

4-3 Recipe Selection Display (Typical) . . . . . . . . . . . . . . . . . . . . . 4-10

vi

4-4 Additive Selection Display . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12

4-5 Loading Display ................................. 4-13

4-6 Diagnostic Menu ................................ 4-61

4-7 Input / Outputs Diagnostic . . . . . . . . . . . . . . . . . . . . . . . . . . 4-63

4-8 DUART Ports Diagnostic ........................... 4-64

5-1 Prover / Meter Volume Relationship . . . . . . . . . . . . . . . . . . . . 5-13

5-2 Meter Proving Report for Tank Prover Method (Typical) . . . . . . . 5-47

5-3 Meter Proving Report for Master Meter Method (Typical) . . . . . . 5-48

Master Meter Meter-Factors Table . . . . . . . . . . . . . . . . . . . . . 5-49

6-1 Menu Tree .................................... 6-10

6-2 Parameters List Overview ........................... 6-11

APN A Worksheets 1 to 16 ......................... A-15 to A-30

APN B Parameter List ............................. B-3 to B-50

Section 1

Introduction

Functional Characteristics

Hardware Configuration

General Terminology

_____________________________________________________ DanLoad 6000

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.

Note

This manual covers the Script Language DanLoad 6000 software configuration version 1.20.

Several configuration parameters (Program Codes) and functions have been added or changed

from the Script Language DanLoad 6000 software version 1.00 and version B of this manual.

The Script Language DanLoad 6000 software version number is displayed during the startup

sequence after power is applied to the instrument.

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.

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

DanLoad 6000 _____________________________________________________

1 - 2 __________________________________________________ Introduction

Information applicable to system operation 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, and Appendix B before installing the instrument.

# Section 3 - Setup

This section contains information on the initial setup (functional configuration), script language

activities 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, and Appendix B before installing the instrument.

_____________________________________________________ DanLoad 6000

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 - Installation Worksheets

This appendix contains several worksheets that aid in designing and implementing the system

interconnections and field wiring. These worksheets are described in Section 2 - Installation.

# Appendix B - Program Code Configuration

This appendix contains a list of all parameters and their default values.

DanLoad 6000 _____________________________________________________

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), multi-stage solenoid controlled 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 multiple 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 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

Introduction _________________________________________________ 1 - 5

DanLoad 6000 _____________________________________________________

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 simultaneously.

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. The actual implementation of the various possible

process operations are covered in detail in other sections of this manual.

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Daniel DanLoad 6000 Script Language Owner's manual

Daniel DanLoad 6000 Script Language Owner's manual

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