How it Works
Emerson
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DL8000
User manual
330 pgs6.22 Mb0
Table of contents
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Emerson DL8000 User manual

Part Number D301244X012
April 2020
DL8000 Preset Controller Instruction Manual
Remote Au tomation Solutions
ii Revised April 2020
Contents
Chapter 1 – Overview 1-1
1.1 DL8000 Overview ............................................................................................................. 1-1
1.2 Hardware .......................................................................................................................... 1-3
1.2.1 Housing ................................................................................................................. 1-3
1.2.2 Electronics ............................................................................................................. 1-5
1.3 Security Gateway .............................................................................................................. 1-6
1.4 Additional Technical Specifications .................................................................................. 1-6
Chapter 2 – Installation and Use 2-1
2.1 Housing ............................................................................................................................. 2-1
2.1.1 Class I Zone 1 Housing ......................................................................................... 2-2
2.1.2 Securing the Cover to the Class I Zone I Case ..................................................... 2-4
2.1.3 Class I Div 2 Housing ............................................................................................ 2-5
2.2 Card Cage ........................................................................................................................ 2-6
2.2.1 Backplane .............................................................................................................. 2-7
2.3 Central Processor Unit (CPU) .......................................................................................... 2-8
2.3.1 Installing and Removing Wire Channel Covers................................................... 2-10
2.3.2 Removing and Installing Module Covers ............................................................. 2-11
2.3.3 Removing the CPU Module ................................................................................. 2-11
2.3.4 Installing the CPU Module ................................................................................... 2-12
2.4 License Keys .................................................................................................................. 2-12
2.4.1 Installing a License Key ....................................................................................... 2-13
2.4.2 Removing a License Key ..................................................................................... 2-14
2.5 Installation Planning ........................................................................................................ 2-15
2.6 Mechanical Installation ................................................................................................... 2-15
2.6.1 Planning Considerations ..................................................................................... 2-16
2.7 Electrical Installation ....................................................................................................... 2-18
2.7.1 General Considerations ....................................................................................... 2-18
2.7.2 Field Wiring Installation Guidelines: .................................................................... 2-18
2.7.3 Electrical Wire and Cable Selection and Installation ........................................... 2-19
2.7.4 Input/Output Field Signal Wiring.......................................................................... 2-20
2.7.5 Electrical Grounds ............................................................................................... 2-20
2.7.6 Wire Conduit Selection and Installation .............................................................. 2-22
2.8 Operator Interface ........................................................................................................... 2-23
2.8.1 Keypad ................................................................................................................ 2-24
2.8.2 LED Status Indicators .......................................................................................... 2-25
Chapter 3 – Modules 3-1
3.1 Power Input Module .......................................................................................................... 3-1
3.1.1 12 Volt DC Power Input Module ............................................................................ 3-2
3.2 Input/Output Modules ....................................................................................................... 3-3
3.2.1 General Installation ............................................................................................... 3-5
3.2.2 Installing an I/O Module ......................................................................................... 3-6
3.2.3 Removing an I/O Module ....................................................................................... 3-7
3.2.4 Wiring I/O Modules ................................................................................................ 3-7
3.2.5 Analog Input (AI) Modules ..................................................................................... 3-7
3.2.6 Analog Output (AO) Modules ................................................................................ 3-9
3.2.7 Discrete Input (DI) Modules ................................................................................. 3-10
Revised March 2020 Contents iii
3.2.8 Pulse Input (PI) Modules ..................................................................................... 3-12
3.2.9 Discrete Output (DO) Modules ............................................................................ 3-14
3.2.10 Discrete Output Relay (DOR) Modules ............................................................. 3-15
3.2.11 Resistance Temperature Detector (RTD) Input Modules .................................. 3-17
3.2.12 Alternating Current Input/Output (AC I/O) Module ............................................ 3-18
3.2.13 Advance Pulse Module (APM) ........................................................................... 3-23
3.2.14 Thermocouple (TC) Input Module...................................................................... 3-27
3.2.15 Highway Addressable Remote Transducer (HART
3.3 Communication Modules a nd Ports................................................................................ 3-32
3.3.1 Wiring Communications ...................................................................................... 3-34
3.3.2 Local Operator Interface (LOI – Local Port) ........................................................ 3-35
3.3.3 Using the LOI ...................................................................................................... 3-36
3.3.4 Ethernet Communications ................................................................................... 3-36
3.3.5 EIA-232 (RS-232) Serial Communications.......................................................... 3-38
3.3.6 EIA-422/485 (RS-422/485) Serial Communications Module .............................. 3-39
3.3.7 EIA-422/485 (RS-422/485) Jumpers and Termination Resistors ....................... 3-40
3.3.8 Dial-up Modem Communications Module ........................................................... 3-41
3.4 Additional Technical Information .................................................................................... 3-43
Appendix A – Glossary A-1
Appendix B – Modbus Communications B-1
®
) Module ........................... 3-30
B.1 Modbus Communications ................................................................................................ B-1
B.2 Modbus Configuration ..................................................................................................... B-2
B.2.1 Modbus Configuration General Tab .................................................................... B-3
B.2.2 Modbus Configuration Scale Values Tab ............................................................ B-5
B.3 Modbus History ................................................................................................................ B-7
B.3.1 Modbus Configuration History Table Tab ............................................................ B-8
B.4 Modbus Events & Alarms Functionality ......................................................................... B-11
B.4.1 Reading Events & Alarms Register ................................................................... B-11
B.4.2 Acknowledging Events & Alarms ....................................................................... B-11
B.5 Modbus Registers .......................................................................................................... B-12
B.5.1 Modbus Configuration Registers Tab ................................................................ B-14
B.5.2 Modbus Conversion ........................................................................................... B-17
B.6 Modbus Master Table .................................................................................................... B-19
B.6.1 Modbus Configuration Master Table Tab .......................................................... B-20
B.7 Modbus Master Modem ................................................................................................. B-22
B.7.1 Modbus Configuration Master Modem Tab ....................................................... B-22
B.8 HMI Information ............................................................................................................. B-24
B.8.1 Sequentia l Ble nd ing ........................................................................................... B-24
B.8.2 Ratio Blending ................................................................................................... B-25
Appendix C – Wiring Diagrams C-1
C.1 Daniel Senior Sonic Meter to PI Module ......................................................................... C-1
C.2 Daniel 1818A and 1838 Turbine Pre-Amp to PI Module ................................................. C-2
C.3 Mi cro Motion RFT9739 & 2400S Transmitters to PI Module ........................................... C-3
C.4 Mi cro Motion RFT9739 & 2400S Transmitters to APM Module ...................................... C-4
C.5 3- and 4-Wire RTD to RTD Module ................................................................................. C-5
C.6 Daniel Senior Sonic Meter to APM Module ..................................................................... C-6
C.7 Daniel 1818A and 1838 Dual Turbine Pre-Amp to APM Module .................................... C-7
C.8 Daniel 1818A and 1838 Turbine Pre-Amp to APM Module ............................................. C-8
C.9 Two-Stage Valve with Two Limit Switches to APM Module ............................................ C-9
C.10 Micro Motion 1700 & 2700 T r ansmitter to PI Module ................................................... C-10
Appendix D – Communications Protocols D-1
D.1 Introduction ...................................................................................................................... D-1
iv Contents Revised March 2020
D.1.1 Communication Channels ................................................................................... D-2
D.1.2 Communications Failure ...................................................................................... D-2
D.1.3 Supported Protocols ............................................................................................ D-3
D.1.4 Configuration ....................................................................................................... D-5
D.1.5 Commands .......................................................................................................... D-6
D.1.6 Status Flags ......................................................................................................... D-7
D.2 Batch Control in Auto Mode ............................................................................................. D-8
D.2.1 Steps for Authorizing a Transaction .................................................................... D-8
D.2.2 Steps for Authorizing a Batch ............................................................................ D-11
D.2.3 Stop/End of Batch .............................................................................................. D-12
D.2.4 End of Transaction............................................................................................. D-13
D.2.5 Batching Status States ...................................................................................... D-14
D.3 Communications Commands ........................................................................................ D-15
D.3.1 Modbus Commands........................................................................................... D-15
D.3.2 DanLoad 6000 Protoco l Com m ands ................................................................. D-30
D.4 Mapping Modbus Registers ........................................................................................... D-73
D.5 DanLoad 6000 Protocol Frame ..................................................................................... D-76
D.6 BCC Calculation ............................................................................................................ D-77
D.7 CRC-16 Checksum Table .............................................................................................. D-78
D.8 Status Flags Description [63,0,119] ............................................................................... D-80
D.9 Exception Codes ............................................................................................................ D-85
D.10 New/Unused DanLoad 6000 Exception Codes ............................................................ D-87
D.11 Alarm Logs .................................................................................................................... D-88
D.12 Error Codes ................................................................................................................... D-90
Appendix E – DL8000 Keypad Display E-1
E.1 Keypad Display Components .......................................................................................... E-1
E.1.1 Keypad ................................................................................................................. E-2
E.1.2 LED Status Indicators .......................................................................................... E-4
E.1.3 Liquid Crystal Display (LCD) ................................................................................ E-5
E.1.4 Power Failure ....................................................................................................... E-5
E.1.5 Operational Modes ............................................................................................... E-6
E.2 Loading Mode .................................................................................................................. E-6
E.2.1 Recipe Selection .................................................................................................. E-6
E.2.2 Invalid Recipe Selection ....................................................................................... E-7
E.2.3 Additive Selection ................................................................................................. E-7
E.2.4 Data Item Prompt ................................................................................................. E-7
E.2.5 Preset Quantity .................................................................................................... E-8
E.2.6 Invalid Preset ....................................................................................................... E-8
E.2.7 Loading ................................................................................................................ E-8
E.2.8 Transaction End Prompt .................................................................................... E-10
E.2.9 Conditional String Display for Temperature Correction String ........................... E-10
E.3 Program Mode ............................................................................................................... E-12
E.3.1 ROCLINK 800 Configuration .............................................................................. E-12
E.3.2 Log In ................................................................................................................. E-14
E.3.3 Initial Menu ......................................................................................................... E-14
E.3.4 Clear Alarms ...................................................................................................... E-15
E.3.5 Select Language ................................................................................................ E-15
E.3.6 Print Record ....................................................................................................... E-15
E.3.7 Display Setting ................................................................................................... E-16
E.3.8 Current Status .................................................................................................... E-16
E.3.9 Setup/ Configuration .......................................................................................... E-22
E.3.10 Generic TLP for Setup and Status ................................................................... E-45
E.3.11 Online Help ....................................................................................................... E-47
E.4 Calibration ...................................................................................................................... E-49
E.4.1 Calibrating Additive Meters ................................................................................ E-50
E.4.2 Calibrating Analog Input ..................................................................................... E-53
E.4.3 Calibrating RTDs ................................................................................................ E-55
Revised March 2020 Contents v
E.4.4 Calibrating Product Meters ................................................................................ E-59
E.5 Diagnostics .................................................................................................................... E-75
E.5.1 Diagnosing Digital Outputs (DO) ....................................................................... E-75
E.5.2 Diagnosing Digital Inputs (DI) ............................................................................ E-76
E.5.3 Diagnosing Analog Outputs (AO) ...................................................................... E-81
E.5.4 Diagnosing Analog Inputs (AI) ........................................................................... E-85
E.5.5 Diagnosing AC Input/Outputs (AC I/O) .............................................................. E-89
E.5.6 Diagnosing RS-232 Communication Ports ........................................................ E-93
E.5.7 Diagnosing RS-485 Communication Ports ........................................................ E-97
E.5.8 Error Messages ................................................................................................ E-100
E.5.9 Translated Alarm and Status Messages .......................................................... E-101
Index I-1
vi Contents Revised March 2020

Chapter 1 – Overview

Chapter 1
Provides an overview of the functions and hard w ar e
Chapter 3
Provides information on the Power Input, Provides information on using the DL8000 keypad
This manual, the DL8000 Preset Controller Instruction Manual (part D301244X012), provides operational information for the DL8000, and contains the following chapters:

1.1 DL8000 Overview

General Information Chapter 2
Installation and Use
Modules
Appendix A Provides a comprehensive glossary of terms. Appendix B Provides information on Modbus communications. Appendix C
Appendix D
Appendix E
Index Provides a topical index to the manual.
for the DL8000. Provides installation and usage information on the
components of the DL8000, including the housing, card cage, and CPU. This chapter also addresses installation issues.
Input/Output (I/O), and communication modules available for the DL8000.
Provides sample wiring diagrams for several Emerson devices.
Provides information of alternative communications protocols.
display.
The DL8000 can be operated in an independent, stand-alone mode with the operator controlling and monitoring batch delivery operations from the control panel located on the front of the unit.
Note: Although the DL8000 can also function as a slave unit in a
The DL8000 accepts process input signals from and provides process control signals to the common instruments and devices used in liquid batch delivery systems. These instruments and devices include:
Liquid flow meters (volumetric or mass inputs from a turbine,
Coriolis, ultrasonic, or other flow measurement devices using single or linearized meter factors).
Solenoid-controlled digital flow control valves (both digital and 2-
stage).
Additive injectors. Security devices for verifying electrical ground connections and
compartment overfills.
Revised April 2020 Overview 1-1
terminal automation system (TAS) network, this manual only discusses local operation of the DL8000 in the stand-alone mode.
1: Pump Control Output
6. Temperature Probe
2
7
3
8
4
9
5. Meter Pulse Output
Electric motor driven pumps. Motor operated block valves.
You can easily configure the DL8000 to deliver single component liquids or to blend up to four liquid components in precise ratios, with or without additive injection. Operator-selectable predefined delivery control procedures (“recipes”) control the DL8000’s various possible delivery and blending functions. Additive injection is controlled by manual selection, recipe selection, or automatic selection from a terminal automation system. These features allow one DL8000 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 DL8000 application is to function as an on-site controller for delivering refined liquid hydrocarbon products from loading terminal storage tanks to mobile tanks (such as tanker trucks, rail cars, or barges). Other applications include liquid component blending and / or additive injection in refinery or chemical plant processes. In addition, liquid components (with or without additive injection) can be blended into flowing pipelines or into storage tanks. Figure 1-1 shows a typical load rack installation with a DL8000 and associated equipment.
1-2 Overview Revised April 2020
. Density Transmitter . Pressure Transmitter . Additive Injection Output(s)
. Valve Control . DL8000 . Permissive Contacts
Figure 1-1. Typical DL8000 Load Rack
this product.
Factory Default
The DL8000 is factory-configured with a basic set of communication
Logical Functions
The flow measurement and logical functions listed below are available
Warning
Configuration
Overfill protection is critica lly important to your site. If your site DOES NOT have overfill protection hardware installed, DO NOT set the Overrun Limit Quantity value (defined on the Alarm Setup tab of the Preset Setup screen in the Batching program) to zero. Setting that field to zero DISABLES overfill protection. Remote Automation Solutions is not responsible for damage resulting from disabling this critical safety feature.
Additionally, you MUST have a redundant safe ty system (such as Ground fault, Overfill) in place and operational. Otherwise, DO NOT use
and I/O modules to accommodate process I/O signals. The default I/O module load—as well as any optional modules—is
determined during initial purchase. However, the I/O modules and communications modules mix is field-reconfigurable, within the limits of the DL8000’s central processing unit (CPU). The hardware configuration determines the DL8000’s capacities for I/O signal handling and the data logging/data communications.
in all hardware configurations of the DL8000. However, each unique installation requires a specific complement of I/O modules, based on the actual devices the DL8000 monitors and controls.

1.2 Hardware

1.2.1 Housing
The DL8000 can simultaneously monitor and control operation of up to three flow meters, up to three flow control valves, and deliver up to four products. The minimum configuration consists of one flow meter measuring one component (liquid product), one control valve, one pump start, and one permissive input. Product deliveries and component blending deliveries are selected by up to 30 configurable recipes (batch delivery/blending control procedures). The actual implementation of the various possible process operations are covered in detail in other sections of this manual.
The DL8000 has two primary physical components: the external housing and the internal electronics. Refer to Chapter 2, Installation and Use, for details on installation.
The DL8000 uses either of two external housings: A cast aluminum casing with stainless steel front cover bolts. It is
flame-proof (in accordance with Class I, Zone 1, Group IIB) and weatherproof (in accordance with IP66).
A 14-gauge stainless steel box with 12-gauge stainless steel
mounting flanges, CSA-rated as a Type 4 enclosure. The door is
Revised April 2020 Overview 1-3
B
D
B
D
Note: For specific details, refer to the technical specification DL8000
made of 0.090 inch thick aluminum secured to the box with a stainless steel piano hinge and two stainless steel spring latches.
Preset (part D301255X012), available at www.EmersonProcess.com/Remote.
A Front cover bolts
Display
C Status LEDs
Weights & Measures switch
E Operator keypad
Figure 1-2. DL8000 (in Class I, Zone 1 Enclosure)
Sixteen stainless steel front cover bolts (M10 – 1.5 metric) secure the lid to the housing. Two of the front bolts are longer and drilled close to the threaded ends, allowing placement of Weight & Measures seal wires to prevent undetected access to the electronics.
Bolt holes are tapped to 13 mm (0.50 inches); require an 8 mm (5/16­inch) Allen wrench, and torque to 24 to 29 Newton/meters (18 to 21 foot/pounds) of force.
The operator keypad provides 18 rugged, Hall-Effect pushkeys which are impervious to chemicals commonly associated with petroleum applications. A sealable Weights & Measures switch provides security to flow measurement parameters.
Secured behind non-glare glass, the liquid crystal display (LCD) provides an 8-line by 40-column message area for operator interface. The display uses a photo sensor and temperature sensor which can be
1-4 Overview Revised April 2020
set to automatically adjust contrast and backlighting for optimal viewing.
Light-emitting diodes (LEDs) displaying the status of alarms, operating mode, and permissive powers are located to the right of the display.
With the front cover bolts removed, the lid hinges down to reveal the electronic compartmen t.
1.2.2 Electronics
The DL8000’s CPU sits inside the cast aluminum enclosure. The DL8000 uses a highly innovative and versatile CPU with a backplane to which the CPU, Power Input module, input/output (I/O) modules, and communication modules connect. The DL8000 unit has nine module slots, three of which (slots 1, 2, and 3) can house communication modules.
The DL8000 uses a 12 volt dc Power Input module to convert 120 to 250 V ac external input power to the voltage levels required by the unit’s electronics and to monitor voltage levels to ensure proper operation. For more information on the Power Input module, refer to Chapter 3, Modules.
The DL8000 supports a number of I/O modules, which can satisfy a wide variety of field I/O requirements (refer to Chapter 3, Modules). I/ O modules include:
Analog Inputs (AI). Analog Outputs (AO). Discrete Inputs (DI). Discrete Outputs (DO). Digital Output Relay (DOR). Alternating Current Input/Output (ACIO). Advance Pulse Module (APM). Pulse Inputs (PI) – High/Low Speed. Resistance Temperature Detector Inputs (RTD).Thermocouple (TC) HART®
In addition to the built-in serial interface (the Local Operator Interface, or LOI) and an Ethernet connection, the DL8000 also supports the following communications modules:
EIA-232 Serial Communications. EIA-422/485 Serial Communications. Dial-up Modem.
Revised April 2020 Overview 1-5

1.3 Security Gateway

For enhanced data security when using an IP/Ethernet connection, Remote Automation Solutions recommends adding an industrial router with VPN and firewall security. Recommended solutions include the MOXA EDR-810, the Hirschman Eagle One, or the Phoenix mGuard rs4000 (or equivalents). An example of how to install one of these devices to the RTU/flow computer can be found in the Remote Automation Solutions MOXA® Industrial Secure Router Installation Guide (part number D301766X012). For further information, contact your Local Business Partner or the individual vendor’s website.

1.4 Additional Technical Specifications

For further technical information on the DL8000, refer to the technical specification DL8000 Preset (part D301255X012), available at www.EmersonProcess.com/Remote.
1-6 Overview Revised April 2020
Chapter 2 – 0BInstallation and Use
In This Chapter
2.1 Housing.………………………………………………………………………. 2-1
2.1.1 Class I Zone 1 Housing .............................................................. 2-2
2.1.2 Securing the Cover to the Class I Zone I Case .......................... 2-4
2.1.3 Class I Div 2 Housing ................................................................. 2-5
2.2 Card Cage.…………………………………………………………………… 2-6
2.2.1 Backplane ................................................................................... 2-7
2.3 Central Processor Unit (CPU)………………………………………………. 2-8
2.3.1 BInstalling and Removing Wire Channel Covers...................... 2-10
2.3.2 Removing and Installing Module Covers .................................. 2-11
2.3.3 Rem oving the CPU Mo dul e ...................................................... 2-11
2.3.4 Installing the CPU Module ........................................................ 2-12
2.4 License Keys ……………………………………………………………….. 2-12
2.4.1 Installing a License Key ............................................................ 2-13
2.4.2 Rem oving a Licens e Key .......................................................... 2-14
2.5 Installation Planning ……………………………………………………….. 2-15
2.6 Mechanical Installation ……………………………………………………. 2-15
2.6.1 Planning Considerations ........................................................... 2-16
2.7 Electrical Installation ………………………………………………………. 2-18
2.7.1 General Considerations ............................................................ 2-18
2.7.2 Field Wiring Installation Guidelines: ......................................... 2-18
2.7.3 Electrical Wire and Cable Selection and Installation ................ 2-19
2.7.4 Input/Output Field Signal Wiring ............................................... 2-20
2.7.5 Electrical Grounds .................................................................... 2-20
2.7.6 Wire Conduit Selection and Installation .................................... 2-22
2.8 Operator Interface …………………………………………………………. 2-23
2.8.1 Keypad ...................................................................................... 2-24
2.8.2 LED Status Indicators ............................................................... 2-25
This chapter describes the DL8000’s external housing, its internal electronic components (the ROC800-Series CPU), and the specifics of mechanical and electrical installation.

2.1 1BHousing

The DL8000 uses either of two external housings: A cast aluminum casing with stainless steel front cover bolts. It is
flame-proof (in accordance with Class I, Zone 1, Group IIB) and weatherproof (in accordance with IP66).
A 14-gauge stainless steel box with 12-gauge stainless steel
mounting flanges, CSA-rated as a Type 4 enclosure. The door is made of 0.090 inch thick aluminum secured to the box with a stainless steel piano hinge and two stainless steel spring latches.
Revised April 2020 Installation and Use 2-1
2.1.1 9BClass I Zone 1 Housing
The DL8000 Class I Zone 1 housing is cast aluminum that, when appropriately sealed, provides a flame-proof enclosure. Sixteen threaded stainless steel fasteners secure the lower portion of the housing to the hinged lid, which contains the display panel, operator keypad, and LED status display. See Figures 2-1 and 2-2.
Figure 2-1. Standard DL8000 Enclosure
2-2 Installation and Use Revised April 2020
Figure 2-2. Standard DL8000 Enclosure
Note: The four mounting holes on the bottom and back of the DL8000
case accept 10M (10mm) bolts.
The DL8000’s design makes it highly adaptable to a wide variety of installations. Consequently, this manual cannot cover all possible installation scenarios. Contact your local sales representative if you require information concerning a specific installation not described in this manual.
Revised April 2020 Installation and Use 2-3
clean and free of damage.
Planning is essential to a good installation. Because installation requirements depend on many factors (such as the application, location, ground conditions, climate, and accessibility), this document only provides generalized guidelines.
2.1.2 10BSecuring the Cover to the Class I Zone I Case
The DL8000 ships from the factory with the cover secured to the case with one stainless steel fastener (“bolt”). The remaining bolts are bagged and included with the DL8000. You must install all bolts.
Warning
Caution
Failure to install ALL cover bolts will compromise the flame-proof characteristics of the enclosure.
The flanges between the case and the cover create a flameproof joint. Before you secure the cover to the case, make sure the surfaces are
To secure the DL8000 cover:
Caution
Notes:
You must use a torque wrench for this procedure. The bolt in position 9 (see Figure 2-3) is factory-installed. Be sure
that the bolts you install in positions 12 and 8 are the two longer bolts with pre-drilled holes (for the Weights & Measures seal wires).
1. Swing the DL8000 cover up against the case.
2. Insert a bolt in position 1 (refer to Figure 2-3) and finger-tighten the
bolt until you feel resistance.
3. Insert a bolt in position 2 (refer to Figure 2-3) and finger-tighten the
bolt until you feel resistance.
4. Repeat step 3 for bolts in positions 3 through 16.
5. Using a torque wrench, tighten the bolt in position 1 to
specifications (24 to 29 Newton/meters or 18 to 21 foot/pounds of force).
6. Tighten bolts in positions 2 through 16 to specifications.
Tighten the bolts in the numeric order shown in Figure 3-3 to prevent deforming the cover and risking the integr ity of the seal between cover and case. You must install all the bolts.
2-4 Installation and Use Revised April 2020
Figure 2-3. Bolt Tightening Sequence
8
2
11
15
1
5
9
13 7 12
16 3 6
10
14
2.1.3 11BClass I Div 2 Housing
The Class I, Division 2 housing includes a 14-gauge stainless steel box with 12-gauge stainless steel mounting flanges. The door is made of .090 inch thick aluminum and is secured to the box via a stainless steel piano hinge and two stainless steel spring latches. The latches include features for padlocking or installing wire seals. The assembly includes a door stop that locks the door in position at approximately 120 degrees from the closed position. The viewing window in the enclosure door is made from scratch / UV resistant polycarbonate/acrylic blend (PC/PMMA). The keypad bezel is mounted to the front of the door and is made from UV resistant polycarbonate. The assembly is rated by CSA as a Type 4 enclosure, and can be either pole-mounted or flush­mounted.
Revised April 2020 Installation and Use 2-5

2.2 2BCard Cage

Figure 2-4. Class I Division 2 DL8000 Housing
The DL8000 uses electronic modules which fit into a card cage. The card cage rests inside the cast housing. See Figure 2-5 for a view of the card cage as it would appear when the housing is opened.
The card cage provides a backplane with sockets for installing a main processor board, a DC power supply, up to nine process I/O boards, and up to three communications cards. The card cage (see Figure 2-5) supports a total of nine boards, in addition to the power supply and the CPU.
Note: Board placement is critical for I/O assignments during startup.
Refer to Chapter 3, Modules, for further information.
2-6 Installation and Use Revised April 2020
A
B
C
C
A
B
D
2.2.1 12BBackplane
The backplane has connectors for the CPU, the power input module, and all the I/O and communication modules. When a module is completely inserted into the module slot, the connector on the module fits into one of the connectors on the backplane. The backplane does not require any wiring, and there are no jumpers associated with the backplane.
Removing the backplane from the housing is not recommended, as there are no field-serviceable parts. If the backplane requires maintenance, please contact your local sales representative.
CPU Power module Module cover
D Wire channel covers (removed)
Figure 2-5. Card Cage (with modules)
Revised April 2020 Installation and Use 2-7
A
Securing screw
B
C
E
Ethernet port
F
B C D
E
F
A
A
A A B
C
D E F

2.3 3BCentral Processor Unit (CPU)

The CPU contains the microprocessor, the firmware, connectors to the backplane, three built-in communication ports (two with LEDs), a LED low power wakeup button, a RESET button, the application license key connectors, a STATUS LED indicating system integrity, and the main processor. See Figure 2-6.
The 32-bit microprocessor is based on a Motorola® MPC862 Quad Integrated Communications Controller (PowerQUICC™) PowerPC® processor running at 65 MHz (in the Series 2 CPU module) or 50 MHz (in the Series 1 CPU module).
The internal Sanyo 3 volt CR2430 lithium backup battery provides backup of the data and the Real-Time Clock when the main power is not connected.
Series 1 CPU Faceplate
(Gray)
Series 2 CPU Faceplate
(Black)
2-8 Installation and Use Revised April 2020
LED button LOI – EIA-232 (RS-232D)
D Status LED
EIA0232 (RS0232C)
Figure 2-6. CPU Front View (Series 1 and Series 2 CPU Modules)
A
C
D
E
G
CPU Number
Series 1
Series 2
J1
Backplane connector
Backplane connector
J2
Backplane connector
Backplane connector
J3
Not Used
Battery Backup
J4
Battery Backup
Not Used
P2
LOI Port RJ-45
License Key Terminal
P3
Ethernet RJ-45
License Key Terminal
P4
License Key Terminal
RS-232
P5
Not Used
LOI Port RJ-45
P6
License Key Terminal
Ethernet RJ-45
SW1
LED Button
RESET Button
SW2
RESET Button
LED Button
A
B
D
E
C
H
H
F
G
Series 1 CPU (Green) Series 2 CPU (Black)
Battery
B LED Button
RJ-45 port License keys RESET button
F RJ-45 port
RS-232 port
H Microprocessor
Figure 2-7. CPU Connectors
Table 2-1. CPU Connector Locations
Revised April 2020 Installation and Use 2-9
Status LED
Color
Definitions
Solution
Continually Lit
Green
DL8000 functioning normally.
N/A
Low Battery Voltage alert.
Charge battery.
System AI (Point number 1) LoLo Alarm.
Apply DC voltage source.
Flashing
Green
Firmware invalid.
Update firmware.
Green-Green to Red-Red
Flashing
Green to Red
Firmware update is flashing image.
Do not restart the DL8000.
The CPU contains a microprocessor supervisory circuit. This device monitors the battery voltage, resets the processor, and disables the SRAM chip if the voltage goes out of tolerance. The CPU has an internal Analog to Digital Converter (A/D). The A/D monitors the supply voltage and board temperature. The CPU has two buttons (see Figure 2-7):
LED – Press to turn on the LEDs on the CPU module, I/O modules,
RESET – Press to reset the DL8000 system to defaults.
The STATUS LED indicates the integrity of the DL8000. Refer to Table 2-2.
Continually Lit Red
and communication modules when the DL8000 has timed out.
Table 2-2. STATUS LED Functions
Flashing
Firmware update in decompr ess ion. Do not restart the DL8000.
As a power-saving feature, you can enable or disable the LEDs on the DL8000 (with the exception of the LED on the power module). You can also use the ROCLINK™ 800 software to configure how long the LEDs remains on after the LED button on the CPU module is pressed. For instance, with the default setting of five minutes, all LEDs go off after five minutes. If you press the LED button, LEDs become active again for five minutes. If you enter a 0 (zero) setting, they always stay active.
2.3.1 13BInstalling and Re m ovi ng Wire Channel Covers
The DL8000 includes wire channel covers (see Figure 2-5) you install over the wiring channels once you complete wiring the terminal blocks on the modules.
To install a wire channel cover:
1. Align the wire channel cover over the wire channel, allowing
unobstructed wire access.
2-10 Installation and Use Revised April 2020
2. Press the wire channel cover into place until it snaps. Note: The tabs on the top side of the wire channel cover should rest in
the slots on the top edge of the channel.
To remove a wire channel cover:
1. Grasp the wire channel cover at both the left and right ends.
2. Start at the left or right and pull the wire channel cover out of the
wire channel.
2.3.2 14BRemoving and Installi ng Module Covers
Before you insert an I/O or communications module, remove the module cover (see Figure 2-5) over the empty module slots in which you intend to install the modules. Although you are not required to remove the power to the DL8000 to perform this procedure, caution is always advisable when working with a powered DL8000.
Caution
To avoid circuit damage when working inside the unit, use appropriate electrostatic discharge precautions (such as wearing a grounded wrist strap).
When working on units located in a hazardous area (where explosive gases may be present), make sure the area is in a non-hazardous state before performing procedures. Performing these procedures in a hazardous area could result in personal i n jury or property damage.
To remove a module cover:
1. Remove the wire channel cover.
2. Unscrew the two captive screws on the face of the cover.
3. Using the tab at the top side of the module cover, lift the module
cover from the DL8000.
Note: If you remove a module for an extended period, install a module
cover over the empty module slot to keep dust and other matter from getting into the DL8000.
To install a module cover:
1. Place the module cover over the module slot.
2. Tighten the two captive screws on the face of the cover.
3. Replace the wire channel cover.
2.3.3 15BRemoving the CPU Module
To remove the CPU module:
Caution
Failure to exercise proper electrostatic discharge precautions (such as wearing a grounded wrist strap) may reset the processor or damage electronic components, resulting in interrupted operations.
When working on units located in a hazardous area (where explosive gases may be present), make sure the area is in a non-hazardous state before performing procedures. Performing these procedures in a hazardous area could result in personal i n jury or property damage.
1. Back up critical data.
Revised April 2020 Installation and Use 2-11
hazardous area could result in personal i n jury or property damage.
Note: “Critical” data may include your device configuration file,
2. Remove power from the DL8000.
3. Remove the wire channel cover.
4. Unscrew the two captive screws on the front of the CPU module and
5. Place a small screwdriver under the ejector clip at the left or right of
6. Remove the CPU module carefully. Make sure not to pull on any
2.3.4 16BInstalling the CPU Module
To install the CPU module:
Caution
Failure to exercise proper electrostatic discharge precautions (such as wearing a grounded wrist strap) may reset the processor or damage electronic components, resulting in interrupted operations.
When working on units located in a hazardous area (where explosive gases may be present), make sure the area is in a non-hazardous state before performing procedures. Performing these procedures in a
device alarms and events history, or displays.
remove the faceplate.
the CPU module and lightly pry the CPU module out of its socket. You may find it easiest to carefully pry on the left ejector clip a little, and then carefully pry the right ejector. You will feel and hear the CPU as it detaches from the backplane.
cables attached to the CPU module.

2.4 4BLicense Keys

1. Slide the CPU module into the slot.
2. Press the CPU firmly into the slot, ensuring the ejector clips rest on
the module rail guides. The connectors at the back of the CPU module fit securely into the connectors on the backplane.
3. Place the CPU faceplate on the CPU.
4. Tighten the two captive screws on the faceplate of the CPU module
firmly.
5. Replace the wire channel cover.
6. Return power to the DL8000.
License keys with valid license codes grant access to applications or, in some cases, allow optional firmware functionality to execute. In some situations, a license key may also be required before you can run the application. Examples of licensed applications include DS800 Development Suite software, meter run calculations, and various User C programs (such as LiquidCalcs in this application). You can then
2-12 Installation and Use Revised April 2020
Failure to exercise proper electrostatic discharge precautions (such as
hazardous area could result in personal i n jury or property damage.
configure these applications using ROCLINK 800 or the DS800 Development Suite software.
The term “license key” refers to the physical piece of hardware (see Figure 2-8 and Figure 2-9) that can contain up to seven different licenses. Each DL8000 can have none, one, or two installed license keys. If you remove a license key after enabling an application, the firmware disables the task from running. This prevents unauthorized execution of protected applications in a DL8000.
Figure 2-8. License Key
2.4.1 17BInstalling a License Ke y
Note: For the DL8000, license keys are a factory-installed option.
Under normal operation, you should not need to install, remove, or replace a license key.
To install a license key:
Caution
wearing a grounded wrist strap) may reset the processor or damage electronic components, resulting in interrupted operations.
When working on units located in a hazardous area (where explosive gases may be present), make sure the area is in a non-hazardous state before performing procedures. Performing these procedures in a
1. Back up critical data. Note: “Critical” data may include your device configuration file,
device alarms and events history, or displays. Refer to Saving and Retrieving Configurations in the ROCLINK 800 Configuration Software User Manual (for DL8000) (part
D301259X012) for further information.
2. Remove power from the DL8000.
3. Remove the wire channel cover.
Revised April 2020 Installation and Use 2-13
4. Unscrew the captive screws from the CPU faceplate and remove it.
hazardous area could result in personal i n jury or property damage.
5. Place the license key in the appropriate terminal slot in the CPU (see
Figure 2-9. License Key Installation
6. Press the license key into the terminal until it is firmly seated (refer
7. Reattach the CPU faceplate and tighten the two captive screws.
8. Replace the wire channel cover.
Figure 2-7).
Note: If you are installing a single license key, place it in the
uppermost slot (closest to the LOI port).
to Figure 2-9).
9. Restore power to the DL8000.
2.4.2 18BRemoving a License Key
To remove a license key:
Caution
Failure to exercise proper electrostatic discharge precautions (such as wearing a grounded wrist strap) may reset the processor or damage electronic components, resulting in interrupted operations.
When working on units located in a hazardous area (where explosive gases may be present), make sure the area is in a non-hazardous state before performing procedures. Performing these procedures in a
1. Back up critical data. Note: “Critical” data may include your device configuration file,
device alarms and events history, or displays. Refer to Saving and Retrieving Configurations in the ROCLINK 800 Configuration Software User Manual (for DL8000) (part
D301259X012) for further information.
2. Remove power from the DL8000.
3. Remove the wire channel cover.
4. Unscrew the two captive screws on the CPU faceplate and remove
it.
5. Remove the license key from the appropriate terminal slot in the
CPU (see Figure 2-9).
6. Reattach the CPU faceplate and tighten the two captive screws.
2-14 Installation and Use Revised April 2020
7. Replace the wire channel cover.
8. Restore power to the DL8000.

2.5 5BInstallation Planning

Installation planning is very important due to the DL8000’s physical and functional reconfigurable capabilities. Installation planning consists of the following three major tasks.
Assure that the DL8000 contains the required number and type of
Determine the functions the DL8000 will perform. You selectively
Design the mechanical/electrical installation with special
process I/O boards to monitor and control the other devices in the product delivery system.
enable these functions during the DL8000’s configuration procedure.
consideration for both the operator’s safety and ease-of-use and the maintenance technicians’ safety and ease-of-access to instruments and devices.

2.6 6BMechanical Installation

In planning the physical installation of the DL8000, consider ease of use of the instrument with the operator in a safe and comfortable position. Also consider how maintenance tasks may be performed without disrupting ongoing product delivery operations in close proximity. Drawing rough diagrams of normal operator actions during the different possible batch delivery related tasks may be helpful. Note especially the operator’s location in relation to the location of one or two tanker vehicles and their related loading arm and bottom loading hose connections.
Some location or position restrictions may be present when a DL8000 is retrofitted or upgraded into an existing installation. However, mechanical installation planning should still be performed. It may be possible to correct an existing inconvenient controller mounting location in a current loading rack installation when retrofitting a DL8000 at the installation.
Following are the major steps performed during installation.
1. Plan the installation.
2. Fabricate device supports and lay electrical conduit.
3. Mount the DL8000 and other load rack devices.
4. Run and connect all wiring.
5. Verify and tag each wire.
Revised April 2020 Installation and Use 2-15
6. Seal conduit within 50 mm (2 inches) of the DL8000.
7. Secure cases and covers of all devices.
8. Apply electrical power.
9. Configure (set up) the DL8000 and any other devices as required.
10. Disable product block valves and additive block valves to
11. Enable one product block valve at a time and one additive
12. Perform meter proves to determine DL8000 meter calibration.
2.6.1 19BPlanning Considerations
Note: Install certified conduit plugs in any unused entries.
prevent any product or additive flow. Then verify system monitor and control functions with dry piping.
injection system at a time. Then verify the piping integrity and system operation in increments for each product and each additive handling system.
Consider the following points during DL8000 mechanical installation planning:
Maintenance Access
The operator panel is hinged at the bottom side and opens down for maintenance access. Route all conduit to the rear, sides, or bottom of the unit. Do not locate any object under the DL8000 or in front of the conduit connections for a distance of approximately 533 mm (21 inches) below the instrument.
Mounting Height
Recommended mounting height is approximately 1.14 to 1.27 meters (45 to 50 inches) above grade to the bottom of the DL8000 case (see Figure 2-2). 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 operator in relation to one or two tanker vehicles present and connected at the loading island.
Mounting Fixtures
You must fabricate mounting fixtures for the DL8000. Each DL8000 comes with four M10-1.5 x 15 mm metric thread bolts for mounting. You can either rear-mount or bottom-mount the DL8000, although bottom-mounting is preferred due to the DL8000’s weight. The mounting attachment should be a 4 mm (0.16 inch) (minimum) thick mild steel member with four 11.5 mm (0.44 inch) diameter
2-16 Installation and Use Revised April 2020
holes that match the bolting pattern being used. The steel member may be sheet, angle, channel, or another shape.
Center the forward pair of mounting screw holes in bottom-mount fixtures no more than 19 mm (0.75 inch) from the edge. The case has a taper to the rear. The standard case may need a shim at the rear pair of screws to level the DL8000. Level the case to allow for the best conduit alignment.
Special Installation Considerations
The DL8000 is designed for installation in an outdoor environment. The instrument is weatherproof and explosion-proof in accordance with 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 or loading island area is covered, locate the
DL8000 so that the operator is protected or partially protected from direct rainfall.
• In tropical climates, place sunshades above the DL8000 and
other electronic instruments, such as process transmitters. Locate sunshades to prevent direct sunlight on the instruments during the hottest part of the day (10:00 to 15:00). Construct sunshades of metal, fiberglass, or other suitable materials. Sunshades should be rear-sloping to direct rain to the rear of the instrument and away from the operator. Avoid sharp edges or corners on sunshades to prevent injuries.
• In desert areas or areas of blowing sand, install a cover to
protect the operator control panel during idle time. Continuous blowing sand over an extended period of time can sandblast the display panel and pushkey legends, affecting readability. Fabricate a cover from raw materials or use a modified NEMA 4 weatherproof enclosure with a sealed rear cutout, placing it 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 DL8000. The operator panel is hinged to open in the down direction for maintenance access.
• In areas of continuous high humidity, place a 76.2mm x
76.2mm (3-inch x 3-inch) desiccant pack inside the DL8000 case. Place desiccant packs so that any expansion due to moisture absorption does not interfere with any of the equipment or wiring inside the case. Two sources of desiccant packs are:
o Waterguard® Desiccants
PO Box 1079 16023 I-10 East, Suite 30 Channelview, TX 77530
Revised April 2020 Installation and Use 2-17
Seal all cable entries within 50 mm (2 inches) of the enclosure with

2.7 7BElectrical Installation

Caution
Shut off all sources of AC and DC power to the loading island site before installing the DL8000.
2.7.1 20BGeneral Considerations
Use any of three cable entries located on the bottom of the housing for wiring access to the DL8000.
A threaded 25.4 mm (1-inch) female NPSM connection on the left
side of the unit (for AC power and control / status signals).
A spare threaded 25.4 mm (1-inch) female NPSM connection on the
right side of the unit (may be used for meter pulse wiring to segregate meter pulse wiring from all other signals).
o A+ Corporation
40462 Highway 42 Prarieville, LA 70769
A threaded 50 mm (2-inch) female NPSM connection for DC
cabling and low voltage level signals in the center.
Caution
suitable sealing or potting compound.
2.7.2 21BField Wiring Installation Guidelines:
Route external AC and DC wiring in separate conduits. Record cable and wire routing and interconnection information to
simplify the creation of as-built documentation for the system.
Provide remote circuit breakers and optional disconnect switches for
all AC and DC power input circuits.
Follow power and signal field wiring grounding standards. Use only stranded copper wire, equal to or of larger gauges as
indicated on the basic wiring diagrams located at the rear of this section. Take care not to cut or weaken wire strands during the removal of insulation.
Clearly mark all wire ends with slip-on wire tags or similar devices.
Preferably, color-code the wire tags to indicate the voltage level and mark tags with the specific signal name.
Cut power and signal wires with an additional length of
approximately 50 mm (2 inches) for service loops to allow terminal board and connector removal.
2-18 Installation and Use Revised April 2020
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