mc³ controller - merrick-inc.com manual 2496g.pdf · mc³ controller operation and maintenance...

R:\MANUALS\ENGLISH\MC3\2496ex_g\2496_G1.doc 08/14/01 3:57 PM/LDD

MC³ ControllerOperation and Maintenance

Manualfor the

24.96.EX.G Belt Feeder

Merrick Industries, Inc.10 Arthur DriveLynn Haven, FL 32444(850) 265-3611

Revisions

0.30B June 1996

0.30D July 1996 Added and updated texts, bitmaps and drawings.

Sep 1996 Added and updated texts, bitmaps and drawings.

1.0 Nov 1996 Added and updated texts, bitmaps and drawings for batch mode.

Jan 1997 Corrected text.

D August 1998 Added and updated text and bitmaps.

G August 2001 Updated version

PROPRIETARY NOTE

The information in this manual, including technical data and copies of drawings, embodiesinformation proprietary to Merrick Industries, Incorporated. This manual is provided to the user ofequipment purchased from Merrick Industries, Inc. for use only in operation or maintenance ofsuch equipment. Such information in this manual is not to be used, disclosed, copied, orreproduced in whole or part for any use other than that indicated above, or for any other purposedetrimental to the interests of Merrick Industries, Inc. Patents owned by Merrick Industries, Inc.have been issued or are pending on at least some of the information in this manual, andunauthorized use of this subject matter of such patents is a violation of such patents and isprohibited

MC³ 24.96.EX O&M Manual Page i 08/14/01 4:34 PM

INTRODUCTION ...........................................................................................................................................1SAFETY.....................................................................................................................................................1

In General..............................................................................................................................................1Electrical Precautions............................................................................................................................1

MANUAL CONVENTIONS........................................................................................................................1Buttons ..................................................................................................................................................1Screens .................................................................................................................................................2

SOLVING PROBLEMS .............................................................................................................................2Help Button............................................................................................................................................2Technical Support .................................................................................................................................2

SYSTEM CONCEPTS...................................................................................................................................3HARDWARE .............................................................................................................................................3

Enclosure ..............................................................................................................................................3Backplane Board ..............................................................................................................................4

Card Stack Assembly............................................................................................................................4CPU Board........................................................................................................................................4PCAD Board .....................................................................................................................................4PCIO Board ......................................................................................................................................4LTI Board ..........................................................................................................................................4

Power Supply Assembly........................................................................................................................4Display Assembly ..................................................................................................................................5

LCD Board ........................................................................................................................................5LCD Display......................................................................................................................................5Touch Keypad...................................................................................................................................5

SOFTWARE..............................................................................................................................................5Application Software..............................................................................................................................5BIOS......................................................................................................................................................5Register Database ................................................................................................................................5

GETTING STARTED.....................................................................................................................................6INSTALLATION.........................................................................................................................................6

Panel Mount ..........................................................................................................................................6Installation.........................................................................................................................................6

Wall Mount ............................................................................................................................................6Installation.........................................................................................................................................6

STARTING THE CONTROLLER ..............................................................................................................6PASSWORD PROTECTION.....................................................................................................................7MAIN SCREENS .......................................................................................................................................7

Changing Main Screens........................................................................................................................7Feeder Screen ......................................................................................................................................7Graph Screen........................................................................................................................................8Numerical Display .................................................................................................................................9

ENTERING NEW VALUES .......................................................................................................................9Numeric Entry Screen ...........................................................................................................................9Sub Menus ..........................................................................................................................................10Common Displays in Main Screens ....................................................................................................10

Speed..............................................................................................................................................10Setpoint...........................................................................................................................................10Feedrate .........................................................................................................................................10Belt Load.........................................................................................................................................10Sub-Total ........................................................................................................................................10Total ................................................................................................................................................10Date and Time ................................................................................................................................10Pulses .............................................................................................................................................10Output .............................................................................................................................................10Deviation .........................................................................................................................................10Blank Button ...................................................................................................................................11

MC³ 24.96.EX O&M Manual Page ii 08/14/01 4:34 PM

Setpoint ...............................................................................................................................................11LOGO..................................................................................................................................................11Start, Stop, Clear Batch.......................................................................................................................11Indicators ( on Feeder Screen) ...........................................................................................................11General Alarms ...................................................................................................................................12

Belt Load Over Limit .......................................................................................................................13Belt Load Under Limit .....................................................................................................................13PCAD Near Zero.............................................................................................................................13PCAD Near Full ..............................................................................................................................13Z Track Out Of Range ....................................................................................................................13PCAD Discrepancy .........................................................................................................................13Tachos Do Not Comply...................................................................................................................13Communications Lost .....................................................................................................................13Setpoint Out Of Range ...................................................................................................................13No Speed Detected ........................................................................................................................14Anain Out Of Range .......................................................................................................................14LCD Not Responding......................................................................................................................14No Data From PCAD ......................................................................................................................14

CONTROLLER MODES..........................................................................................................................14SETPOINT ..............................................................................................................................................15

Setpoint Screens.................................................................................................................................15Batch setpoint......................................................................................................................................15

Local ...............................................................................................................................................15Remote Serial .................................................................................................................................15Setpoint...........................................................................................................................................15Batch Parameters ...........................................................................................................................15Feedrate .........................................................................................................................................16

Feedrate setpoint ................................................................................................................................16Manual Speed.................................................................................................................................16Local ...............................................................................................................................................17Remote Analog Input ......................................................................................................................17Remote Analog Ratio......................................................................................................................17Remote Serial .................................................................................................................................17Snap Button ....................................................................................................................................17Setpoint Button ...............................................................................................................................17

Fallback Setpoint.................................................................................................................................18Common Setpoint buttons...................................................................................................................18

Accept Button .................................................................................................................................18Arrow Buttons .................................................................................................................................18Return Button..................................................................................................................................18

ACTIONS ................................................................................................................................................18Cal .......................................................................................................................................................18Reset Total ..........................................................................................................................................18Sub-Total.............................................................................................................................................19Clean Screen.......................................................................................................................................19Diagnostics..........................................................................................................................................19Alarms .................................................................................................................................................19Print .....................................................................................................................................................19Print Line Editing and Printout Selection .............................................................................................19

PF buttons. .....................................................................................................................................20

SETTING UP YOUR CONTROLLER ..........................................................................................................21SETUP ....................................................................................................................................................21CHAIN EZ SETUP...................................................................................................................................21WEIGHT EZ SETUP ...............................................................................................................................22CUSTOM SETUP....................................................................................................................................23SETUP SCREEN 1 .................................................................................................................................24

Units Select .........................................................................................................................................24

MC³ 24.96.EX O&M Manual Page iii 08/14/01 4:34 PM

List of Unit String Combinations .....................................................................................................24Decimal Points ....................................................................................................................................25Design Capacities ...............................................................................................................................25PID Parameters & Output Dynamic Protection ...................................................................................25

Gain ................................................................................................................................................26Integral ............................................................................................................................................26Derivative ........................................................................................................................................26SCR Accel %/s and SCR Decel %/s...............................................................................................26Start Speed.....................................................................................................................................26

Limit Switches .....................................................................................................................................26FeedRate HI/LO..............................................................................................................................27Feedrate Rel Dev............................................................................................................................27Feedrate Setpoint Deviation ...........................................................................................................27Numeric Parameters.......................................................................................................................27

Belt Parameters ..................................................................................................................................28Pulses / Rev....................................................................................................................................28Length.............................................................................................................................................28# Proc Revs ....................................................................................................................................28# Speed Revs .................................................................................................................................28Nominal Speed ...............................................................................................................................28Alarm Delay ....................................................................................................................................28

Zero Tracking Parameters ..................................................................................................................28Wait Time .......................................................................................................................................29Max Load ........................................................................................................................................29Max Step Alwd ................................................................................................................................29Max Z Track....................................................................................................................................29

Tachometer Parameters .....................................................................................................................29Type................................................................................................................................................29Mode...............................................................................................................................................30Speed Sensing Operational Mode..................................................................................................30Numeric Parameters.......................................................................................................................31

Setpoint ...............................................................................................................................................31Totalizer Cut-Off..................................................................................................................................31Calibration Parameters .......................................................................................................................31

Calibration Weight ..........................................................................................................................31E-Cal Liveload.................................................................................................................................31Weigh Span ....................................................................................................................................31Chain Load......................................................................................................................................31Calibration Speed ...........................................................................................................................31

Display Dampening .............................................................................................................................32SETUP SCREEN 2 .................................................................................................................................33

Analog Inputs ......................................................................................................................................33IN1 Zero Level / IN2 Zero Level......................................................................................................33IN1 100% Level / IN2 100% Level ..................................................................................................33IN1 Scaling / IN2 Scaling ................................................................................................................33

Analog Outputs....................................................................................................................................33Mode...............................................................................................................................................34Type................................................................................................................................................34

Digital I/O Mapping..............................................................................................................................34Mapping inputs................................................................................................................................35Mapping outputs .............................................................................................................................35Inverting inputs and outputs............................................................................................................35Forcing inputs and outputs .............................................................................................................35Available logical I/O points..............................................................................................................36External physical I/O points ............................................................................................................36Digital Inputs Setup.........................................................................................................................36TAB.................................................................................................................................................36INV (button) / RV (indication) ..........................................................................................................37

MC³ 24.96.EX O&M Manual Page iv 08/14/01 4:34 PM

FRC (button) / FC (indication).........................................................................................................37List of Logical Inputs .......................................................................................................................37List of Physical Inputs .....................................................................................................................38Default Input Mapping.....................................................................................................................39Digital Outputs ................................................................................................................................40INV (button) / RV (indication) ..........................................................................................................40FRC (button) / FC (indication).........................................................................................................40TAB.................................................................................................................................................40List of Logical Outputs ....................................................................................................................41List of Physical Outputs ..................................................................................................................42List of Default Output Settings ........................................................................................................43

Sample Rate .......................................................................................................................................43Internal Sample Rate Parameters ..................................................................................................43External Sample Rate Parameters .................................................................................................44

External Totalizer Parameters.............................................................................................................44Divide Value....................................................................................................................................44Pulse Length...................................................................................................................................44

Communications .................................................................................................................................44Baud Rate.......................................................................................................................................44Data Bits .........................................................................................................................................45Stop Bits..........................................................................................................................................45Parity...............................................................................................................................................45

Numeric Parameters ...........................................................................................................................45Controller Number ..........................................................................................................................45Comp Start Code ............................................................................................................................45Comp End Code .............................................................................................................................45Communication Time-out ...............................................................................................................45

Set Date and Time ..............................................................................................................................46PCAD Settings ....................................................................................................................................46

CAL.................................................................................................................................................46ZERO..............................................................................................................................................46GAIN ...............................................................................................................................................46Set Status .......................................................................................................................................46Number of PCAD’s .........................................................................................................................46Allowed Difference..........................................................................................................................46

Display Parameters.............................................................................................................................47

CALIBRATING YOUR CONTROLLER........................................................................................................48INITIAL CALIBRATION CHECKLIST ......................................................................................................48CALIBRATION MENU.............................................................................................................................48

Speed Calibration................................................................................................................................49Zeroing Procedure ..............................................................................................................................50Material Calibration .............................................................................................................................51

Scale Totalized ...............................................................................................................................51Actual Total .....................................................................................................................................51

Chain Procedure .................................................................................................................................52Chain Factor Procedure ......................................................................................................................53Weight Procedure ...............................................................................................................................53Weight Factor Procedure ....................................................................................................................54Electronic Calibration ..........................................................................................................................54E-Cal Factor Procedure ......................................................................................................................55Grab Sample Calibration.....................................................................................................................56Analog Input Setup and Calibration.....................................................................................................56

DIAGNOSING PROBLEMS.........................................................................................................................58DIAGNOSTIC MENUS............................................................................................................................58

PCAD Diagnostics...............................................................................................................................58Ld....................................................................................................................................................58Out %..............................................................................................................................................58

MC³ 24.96.EX O&M Manual Page v 08/14/01 4:34 PM

PCAD1 and PCAD2........................................................................................................................58LL....................................................................................................................................................58Abs..................................................................................................................................................58Cnts ................................................................................................................................................59Z Ld.................................................................................................................................................59Settings ...........................................................................................................................................59Scale Factor....................................................................................................................................59

Communication Diagnostics................................................................................................................59Rx Buffer.........................................................................................................................................59Tx Buffer .........................................................................................................................................59Error Counters ................................................................................................................................59IIR - .................................................................................................................................................60LSR -...............................................................................................................................................60TX - .................................................................................................................................................60RX -.................................................................................................................................................61Communication Parameters ...........................................................................................................61

Tacho Diagnostics...............................................................................................................................61EMT PULS......................................................................................................................................61PT ...................................................................................................................................................61TST .................................................................................................................................................61Blt Trvl.............................................................................................................................................61Curr ratio.........................................................................................................................................61Diff % ..............................................................................................................................................61

Analog I/O Diagnostics........................................................................................................................62Digital I/O Diagnostics.........................................................................................................................62Register Monitor ..................................................................................................................................62Register Editor.....................................................................................................................................63Advanced Setup..................................................................................................................................63Quick Setup.........................................................................................................................................63

SOLVING PROBLEMS ...........................................................................................................................64Unit does not power up .......................................................................................................................64Controller Fails to Boot Up ..................................................................................................................64LCD Display too dark or too light.........................................................................................................65No load, or bad Load Reading ............................................................................................................65Tacho not counting pulses, or no speed indication ............................................................................65No analog Input ...................................................................................................................................65External Totalizer problems ................................................................................................................65General Alarms ...................................................................................................................................65No Serial Communications..................................................................................................................66Hang Message Appears......................................................................................................................66

HARDWARE CALIBRATION AND TESTING.........................................................................................66Analog Outputs....................................................................................................................................66Analog Inputs ......................................................................................................................................66PCAD ..................................................................................................................................................67Simulator .............................................................................................................................................67

WORKING WITH INPUTS AND OUTPUTS ...............................................................................................68LTI BOARD .............................................................................................................................................68

EMT.....................................................................................................................................................68Tacho ..................................................................................................................................................68Serial Communications .......................................................................................................................68

PCIO BOARD..........................................................................................................................................69Digital I/O.............................................................................................................................................69

Digital Inputs ...................................................................................................................................69Digital Outputs ................................................................................................................................69

Analog I/O ...........................................................................................................................................69Analog Inputs ..................................................................................................................................69Analog Outputs ...............................................................................................................................70

MC³ 24.96.EX O&M Manual Page vi 08/14/01 4:34 PM

PCAD BOARD.........................................................................................................................................70KEYBOARD LOCATION CODES ...........................................................................................................70PRINTER PORT......................................................................................................................................70

STORAGE ...................................................................................................................................................71STORAGE ON RECEIPT FROM FACTORY..........................................................................................71

Storage Longer than 6 Months............................................................................................................71Storage up to 6 Months .......................................................................................................................71

STORAGE FOLLOWING USE................................................................................................................71OPERATION AFTER STORAGE............................................................................................................71

SPARE PART LIST .....................................................................................................................................72MC³ CONTROLLER SPARE PARTS LIST .............................................................................................72ACCESSORIES FOR THE MC³ CONTROLLER ....................................................................................72

I/O System...........................................................................................................................................72Spare I/O Plugs ...................................................................................................................................72Miscellaneous......................................................................................................................................72Feeder Connection..............................................................................................................................73

APPENDIX A ...............................................................................................................................................74MC³ PANEL MOUNT - DIMENSIONS.....................................................................................................74WALL MOUNT - DIMENSIONS .............................................................................................................75

MC³ 24.96.EX O&M Manual Page 1 08/14/01 4:34 PM/LDD

INTRODUCTION

SAFETYThe Merrick MC³ Controller is used for the monitoring and control of process weighing equipment.To insure personnel safety please read the following instructions and precautions carefully.

In General1. Observe all standard precautions that pertain to moving machinery.

2. Observe all standard precautions that pertain to electrical drives and electrical controls.

3. Pay particular attentions to special notes and precautions that appear throughout thismanual.

4. Please read and familiarize yourself with this entire manual before attempting service orrepair of the Merrick MC³ Controller. If you have any questions or problems please callthe Merrick Service Department for assistance.

Electrical Precautions1. Before undertaking work on the electrical system, the drives, or the Controller, open

main disconnect switches and lock boxes. Work should never be performed on theController with power on the unit. It is recommended to disconnect the power cord fromthe panel mount style controller or switch off the main power in a wall mount beforeattempting any service procedure.

2. Verify that all grounds that are called for on the wiring diagrams are in place and aresecurely connected. Proper grounding not only helps insure your personal safety, butalso is necessary for the proper operation of the controller.

3. If it is necessary that you must work in or near areas of live high voltage always keepone hand clear of the machine, the cabinet, or any other conductors to avoid thepossibility of electrical shock traveling across your chest. NEVER undertake anyelectrical work in areas with wet or flooded standing areas.

4. NEVER impair or disable the function of a fuse.

IF YOU ARE IN DOUBT ABOUT ANY PROCEDURE, CONTACT THE MERRICK SERVICEDEPARTMENT. SEE Technical Support ON PAGE 2

MANUAL CONVENTIONSNOTE: Any additional information that may be useful follows the note marker.

CAUTION: Be careful, certain settings may cause problems.

WARNING: Follow the directions prescribed in the warning. Serious problems can occur if therecommendations are not followed.

ButtonsButton graphics will be shown to the left of the corresponding information regarding thefunction for the button.


Screens

A graphic of this size and type will show the functions available and/or information available indiagnostic screens and special display screens.

SOLVING PROBLEMSSeveral methods are available for use to assist in solving problems. The application contains helpbuttons for giving text explanations of the current selected function or parameter. Also included inthis manual is a troubleshooting section to assist in solving technical problems (DiagnosingProblems, page 58).

Help ButtonIf you do not understand a procedure or parameter this button is available to give someguidance.

Technical SupportMerrick provides customer technical and spare part support 24 hours a day, seven days a week.Our normal business hours are Monday through Friday 7:30 AM until 4:30 PM Central StandardTime. During normal hours call 1-888 MERRICK ( 637-7425) extension 7811.

After normal hours and on holidays and week-ends, technical assistance is available by calling 1-888 MERRICK extension 7878. Follow the instructions and be sure to enter the area code and thephone extension where you can be reached. Someone will return your call as soon as possible.

When you call Merrick for Technical Support, please have your machine serial number or acontroller serial number. This information will better help us to serve you.


SYSTEM CONCEPTS

HARDWARE

MC 3 Controller Unit

TouchScreen

LCDInterface

Board

LCDDisplay

LTIPCIO

Inputsand

Outputs

PCADLoadCell

Interface

CPU

Display Assembly

Ribbon Cable

Card Stack

PowerSupply

PowerRecepticle

Power System

Load Cells

BackplaneBoard

PC-104 Bus2nd PCAD 2nd PCIO

IBM PC orCompatible

ASCII Serial Printer

EMT (AC or DC)Electromechanical

Totalizer

I

O

SCR MotorController

I

O

I

O

Speed Encoder

Speed Encoder

Alarms

Infeed Gate forBatching

Optional Feeder Connection Board

LCD TachoInput

The MC³ Controller has been designed to control many different types of feeding, weighing andmetering equipment. This allows for easier maintenance and simplified training.The Standard Merrick MC³ 24.96.EX Controller consists of an Enclosure, an LCD Display, CardStack and a Power Supply.

EnclosurePanel MountThe panel mount enclosure consists of a rectangular box with a hinged door on the rear coveringthe I/O connections, a removable top cover, a system grounding bar and a sliding tray. The slidetray allows the Card Stack Assembly to be slid out of the back of the enclosure for easiermaintenance while the controller is mounted into a panel. The Display assembly is mounted on thefront bezel. The top cover may be removed for easier access to the boards. Access to theterminal blocks for interconnection with other equipment is obtained by unscrewing the rear cover.Wall MountThe wall mount enclosure is available in NEMA-4 or NEMA-12 boxes. NEMA-4 box includesgaskets and a window kit over the touch screen to provide extra protection.


Backplane BoardMost of the Digital I/O connections to the MC³ will be made through the Backplane Board. TheBackplane mounts vertically in the rear access cover on the Panel mount type enclosure. On theWall mount enclosure, the boards are mounted directly below the Card stack assembly. Theboards can also be mounted onto a DIN rail away from the controller. The Backplane Board has 7output relays and 4 input connectors and allows connection to one I/O rack on the PCIO card. Thisboard connects to the PCIO card via a ribbon cable.Additional Backplane boards may be connected using a DIN rail as the mounting for the boards.Up to four Backplane boards may be connected to the MC³ Controller when two PCIO boards arein the card stack assembly.

Card Stack AssemblyThe Card Stack assembly consists of a CPU Board, one or two PCAD boards, one or two PCIOboards and an LTI board. The Card Stack Assembly in the panel mount enclosure is mounted tothe slide tray and is kept in place by a pair of guides that are permanently mounted onto theenclosure and catch screws on the back of the enclosure. In the wall mount enclosure the CardStack Assembly is securely attached to the mounting plate. All boards are connected electronicallyby way of an industry standard PC-104 interface bus.

CPU BoardThe CPU Board contains the Intel 386EX Microprocessor. It also contains associated supportcircuitry for a bus interface, serial interface and memory support. The CPU board is the bottomboard of the card stack.

PCAD BoardThe Load Cell Transducer A/D Board (PCAD) contains the circuitry needed to process an inputfrom load cells into digital data. The Analog to Digital Converter used on the PCAD Board is a 20bit converter. This allows the Analog Load Cell signal to be resolved into approximately 1,000,000digital counts. As an option, the 2496EX Controller has the ability to utilize two PCAD boards.There are no switches on the PCAD Board for setting parameters such as Gain, Zero Offset orElectronic Calibration. The PCAD Board contains specialized circuitry for dynamically adjustingthese parameters through software. There is one set of jumpers to select Zener Barrier Protectionand Normal Operation of the PCAD.

PCIO BoardThe PCIO Board provides the circuitry for two isolated analog outputs, one isolated analog input,16 digital outputs and 8 digital inputs. The standard MC³ 2496EX Controller comes with one PCIOboard. One additional PCIO Board is available as an option giving the controller a capability ofhaving four isolated Analog Outputs, two isolated Analog Inputs, 32 Digital outputs and 16 Digitalinputs. There are two racks of inputs and outputs per PCIO board. Each rack consists of 7outputs and 4 inputs. Each rack is connected to a Backplane board via a ribbon cable.

LTI BoardThe LTI (LCD Tachometer Input) Board contains the circuitry required to process incoming speedpulses from one or two Tachos, outputs for an AC and DC Electromechanical Totalizer (EMT), anisolated RS-485 Serial Port and an interface to the Display assembly.The RS-485 Serial Communications port is a feature which provides the circuitry necessary for theMC³ Controller to communicate with other serial devices such as a SuperBridge or PersonalComputer. For more information on MC³ Serial Communications see [1] This specification listssome hardware options and interconnection examples and also describes the MerrickCommunications Protocol in detail.

Power Supply AssemblyThe Power Supply Board provides the proper voltages to the MC³ for operation. The PowerAssembly consists of the Power Supply, Power Receptacle and an AC and DC power cables. ThePower Supply is mounted on the front of the slide tray.


Display AssemblyThe Display Assembly consists of a Touch Keypad, an LCD Board and an LCD Display.

LCD BoardThis board is used to interface the LCD Display and the Touch Keypad to the LTI Board andprovides the proper voltage for the back light of the LCD Display. There is a potentiometer foradjusting the contrast of the LCD Display. Also on specific LCD Boards containing an LS220 typeinverter there is a Brightness Adjust potentiometer.

LCD DisplayThe LCD Display is a 240 horizontal by 128 vertical pixel resolution monochrome graphical display.The display works in conjunction with the Touch Screen to provide a Graphical User Interface.

Touch KeypadThe Touch Keypad is mounted directly to the bezel of the MC³ Controller. It consists of a four rowby eight column touch cell array. The Touch Keypad works with the LCD Display to provide a wayfor you to interface with the controller.

SOFTWAREThe MC³ software consists of three primary parts: The BIOS (Basic Input / Output System), aregister database, and the actual application software. The application and database is specific forthe 24.96.EX controller. The BIOS is common for many different applications.

Application SoftwareApplication Software is written for each specific type of “job” that the controller is to perform.

This software will allow you to turn on and off different modes of operation which allows you toconfigure the software for your specific process

There are four modes of operation of this software package:

Belt Scale – Basic model measuring the belt load and speed and calculates the feedrateand totalizes.

Batching Belt Scale – Allows you to batch out predefined lots of material across the belt.

Feeder – The MC³ controls the speed of the belt or pre-feeding device to follow a feedratesetpoint.

Batching Feeder – Allows you to batch out material at specific feedrates controlled by theMC³. There is a feedrate setpoint and a batch setpoint.

BIOSThe BIOS is the portion of the software which directly manipulates the hardware. It is the interfacebetween the application and the hardware.

Register DatabaseThe Register Database is a set of variables used in the software application. It is provided to allowstructured access through Serial Communications to variables used in the MC³. A numeric listingof registers for each application is available from Merrick. Procedures for using SerialCommunications to access the register list are also provided in [1].


GETTING STARTED

INSTALLATIONPlease refer to your wiring diagrams to insure proper installation of the controller. If you need tochange the wiring from the supplied wiring diagrams, Merrick must first be consulted to insure safeand proper operation of the controller. See Technical Support on page 2 for contacting the MerrickTechnical Service department.

Panel MountThe Merrick MC³ Panel Mount Controller is designed for mounting in the control panel. It issuitable for use in environments that are generally clean, and within the temperature range of 32oto 122o F (0o to 50o C). It must be protected from water and dust.

Installation1. Carefully unpack the controller and inspect it for obvious damage as a result of shipping

or handling. If the unit has been stored for a long period (greater than one month), amore thorough inspection of the unit is recommended. If the unit appears to bedamaged in any way, contact the Merrick Service Department for assistance.

2. Mount the controller in your panel, following the instructions on the drawing in “MC³Panel Mount - DIMENSIONS” on page 74. Make sure there is adequate clearancearound the unit for maintenance and ventilation.

3. Insure that the Power Cord is disconnected from the Power Receptacle at the rear ofthe controller. Make the wiring connections to the controller, following the instructionson your electrical connection diagram.

4. Verify all wiring connections before re-installing the Power Cord and applying power tothe unit.

Wall MountThe Merrick MC³ Wall Mount Controller is designed to be weatherproof, and can generally bemounted anywhere where the temperature range is within -10o to 40o C. Merrick recommendsthat it be located out of direct sunlight and away from dripping water.

Installation1. Carefully unpack the controller and inspect it for obvious damage as a result of shipping

or handling. If the unit has been stored for a long period (greater than one month),inspect the unit for rust or corrosion. If the unit appears to be damaged in any way,contact the Merrick Service Department for assistance.

2. Mount the controller on a vertical surface. Make sure there is adequate clearancearound the unit for swinging open the door and for maintenance.

3. Make the wiring connections to the controller. In order to maintain the weatherproofintegrity of the Wall Mount enclosure, you must use liquid-tight conduit and conduitconnectors when running your wires. It is recommended to penetrate the enclosurefrom the bottom.

4. Verify all wiring connections before applying power to the unit.

STARTING THE CONTROLLERThe following is an overview of the actions necessary for proper installation of the MC³ controller.Each step should be completed before the controller is placed in operation. Steps 3 through 7 maybe substituted by performing either Chain EZ Setup (page 21) or Weight EZ Setup (page 22)procedure.


1. Check all your wiring. At least the load cell(s) and power have to be connected for thecontroller to work. Normally, a connection diagram is supplied. Read more about inputsand outputs in the “Working With INPUTS AND OUTPUTS” on page 68.

2. Power up your controller. During power up several start up operations are beingperformed. This sequence takes approximately twenty seconds. The start up screencounts down the time remaining during the start up sequence. Check for any errormessages during the power-up sequence.

3. Check the Calibration settings. Normally, a specification sheet is supplied. Read moreabout how to set the Calibration parameters in the “Setting UP Your Controller” sectionon page 21.

4. Run a Speed Calibration procedure. Refer to “Speed Calibration“ on page 49 for moreinformation.

5. Run a Zero procedure. See “Zeroing Procedure” on page 50.

6. Run either a Chain, Weight or an Electrical Calibration. See “Chain Procedure” (page52), “Weight Procedure“ (page 53) or “Electronic Calibration” (page 54) for the methodfor performing the calibration procedures.

7. Set the Limit Switch values for the application. See Limit Switches on page 26.

8. Program the Setpoint method to be used by your application. See “Setpoint” on page15.

9. Record all essential parameters for your reference. Use a copy of the specificationsheet.

10. Change the Calibration, Diagnostic and Setup passwords to protect your settings.

PASSWORD PROTECTIONThe Password Entry screen is used to provide protection of the settings in the Calibration, Setup,and Diagnostic screens MC³ controller. The password is a four digit number, and can be differentfor each of the three screens. The default password for access to the Calibration Screen is 1234.The default password for the Setup screen is 5678. The default Diagnostic Screen password is1030. The Password Edit Screen is used to select the passwords that allow specific users accessto the Screens. To change the existing passwords, or to turn off password protection, navigate tothe Password Edit screen (press ACT, DIAG, and then PASSWORD), and enter a new four-digitpassword for the screen. Entering a ‘0’ in the password field will turn off password protection forthe screen.

MAIN SCREENS

Changing Main Screens

The is used to change between the Feeder Screen, Graph Screen and a Numerical Display.

Feeder ScreenThe first main screen in the 24.96.EX Controller is the Feeder Screen. This screen is setup toshow you the current running status of the controller. It also allows you to enter into sub menus forsetting the controller parameters, calibration and other functions.


Feeder Screen

Graph ScreenA Graph screen is available to show trend information. This screen also displays the currentrunning status of the controller.

Graph Screen


Numerical DisplayA large font screen is also available to display the current running status of the controller in a largertypeface for easier viewing from a distance.

Numerical Display

There are several common elements to the screens which are described below.

ENTERING NEW VALUES

Numeric Entry Screen

Numeric Screen Example

Most values are entered into the Controller via a numeric entry screen (see the above example).This screen shows the name of the parameter, the current value, units and the minimum andmaximum allowed values for the parameter. If there are three or more related parameters, thecontroller displays three at a time, otherwise the controller will only show one parameter. Theactive parameter is enclosed in a rectangle. This is the value that any button entry will act upon.First find the value by using the Up or Down arrow buttons to scroll to the parameter to bechanged.Enter the new value for the selected parameter using the numeric buttons. The display will showthe value area as they are entered.If the value is correct press the [ENT] button to save this value. The controller tests the number toinsure that it is a valid entry. If the number is within the minimum and maximum values a messagewill appear under the parameter list:

“Parameter Accepted”

If the value is incorrect, there are two ways to correct the number. One is to press the [CLR] buttonand re-enter the value. You may also use the Back arrow button to move back to the incorrectdigit. If the value is not within accepted limits, the following message will appear:

“Value is Out of Range”

NOTE: The unit will be shown for the parameter being displayed.


Sub Menus

The button allows access to the setup menu system which includes the EZ Setup functionsand the Custom Setup menus (see Setting UP Your Controller on page 21 for more information).

The button (page 18) allows access to the calibration, total and subtotal reset and diagnosticmenus. A password will need to be entered to allow access to the menus if Password protection isenabled. See PASSWORD PROTECTION on page 7.

Graph Update Time

In the Graph screen the and buttons change the update time of the graph. The updatetime ranges from 1 to 60 seconds in one second increments and is displayed above the graph.

Common Displays in Main Screens

SpeedThis is the current belt speed value in the current engineering units for speed. (SPD:) See UnitsSelect on page 24.

SetpointThis is the value of the current setpoint in units based on the type of setpoint method selected. IfBatch mode and PID mode are enabled or Batch mode only is enabled the current batch setpointwill be displayed. If PID mode only is enabled the feedrate setpoint method and value will bedisplayed. If both Batch and PID are disabled neither setpoint will be displayed. More informationon Setpoint, see page 15.

FeedrateThis is the Current Feedrate in current units for feedrate. (FR:)

Belt LoadThis is the current belt load value in the engineering units for load. (LD:)

Sub-TotalThis is the sub-total value for the feeder. See Page 19 for instructions on the procedure to reset theSub-Total. (Sub-T:)

TotalThis is the master total for the feeder. The Master Total may be reset from the Reset Total buttonin the Actions menu. See Page 19 for instructions on the procedure to reset the Master Total.

Date and TimeThe Date and Time is available on all of the main screens.

PulsesThis value is the number of pulses accumulated in the controller for Tacho 1. This value isavailable only in the Numeric Display.

OutputThis is the current control output (belt speed demand) value in percentage. This value is availableonly in the Large Font Display.

DeviationThis is the percentage of difference between setpoint and feedrate. This value is available only inthe Numeric Display.


Blank ButtonThis button places a empty line on the screen.

SetpointBased on the mode of the controller this button will allow you to enter the Batch or Feedratesetpoint. If the mode is Batching Feeder both Batch and Feedrate setpoint methods are availablefrom this button. See Setpoint on page 15 for more information.

LOGOThis screen displays the address and phone number for Merrick.

It also shows the revision and build date for the software that is currently in operation. The versionand build date are important when you need service on your controller.

Start, Stop, Clear BatchThese buttons allow you to start, stop, or clear a batch. The buttons will only be visible

when Batch Controls is enabled. See Digital Inputs Setup on page 36. The batch will run until thebatch total has reached the batch setpoint, and the load has dropped below 3% of the design load.

Start batch starts a batch process. It will turn on the Discharge Gate logical output.When the batch total has reached the batch setpoint minus the Preact value has beenreached, the Discharge Gate logical output will turn off. (see Batch Parameters on page15 for more information).

Stop batch pauses a batch process. It will turn off the Discharge Gate logical output.The batch may be restarted by touching the start batch button. The batch may also becleared by touching the clear batch button.

Clear Batch stops the current batch process clears the batch total and turns off theDischarge gate logical output.

Indicators ( on Feeder Screen)There are indicators which are used by the software to provide you with a visualindication that the controller is operating properly. The operator can insure that thecontroller is in the correct mode and accomplishing its set tasks by being aware of whichvisual indicators are (ON) or (OFF).

HI High Feedrate - This indicator is on when a high feedrate condition exists.The type and value of High Limit Switch is determined by the operator. Whenthis indicator is off the feedrate is not above the parameters set in Limit


Switches (page 26).

GOOD Good. This indicator is on when all of the following conditions have been met. If anyone of the conditions are not met this indicator will not activate.

1. The setpoint method is not Manual Speed.

2. The Feeder Block input is OFF (see Digital Inputs Setup on page 36).

3. The Run Permission input is ON (see Digital Inputs Setup on page 36).

4. The controller is in Gravimetric Mode (see Digital Inputs Setup on page 36).

5. No Calibration procedures are running.

6. The controller is not in its power up sequence.

7. Feeder Run output is ON.

8. The PID controller algorithm output is in its active domain.

9. There are no General Alarms.

10. The Feedrate has not exceed the Hi Feedrate Limit or Low Feedrate Limit.

LO Low Feedrate - This indicator is on when a low feedrate condition exists. The type andvalue of Low Limit Switch is determined by the operator. When this indicator is off thefeedrate is not below the value set in Limit Switches (page 26).

RMT Remote - This indicator is on when the keypad has been locked through serialcommunications. For more information on MC³ Serial Communications see [1]. Theremote device may be SuperBridge or another MC³. This indicator is off during normalkeypad operation.

AUTO Auto - When this indicator is on, the controller is in the Automatic Setpoint ControlMode. This is active when a Setpoint mode other than Manual Speed is active. If thecontroller is in Manual Setpoint the indicator will be off. See Page 15 for a completeexplanation of the Setpoint modes

RPER Run Permission - This indicator will be on when the Logical Input Run Permission isON. Run Permission clamps the speed demand output from the controller to Zerowhen OFF. With this input ON the controller is able to control the process (see DigitalInputs Setup on page 36).

GRAV Gravimetric ON - This indicator follows the Logical Input Gravimetric ON. (see DigitalInputs Setup on page 36).

ZTRK Zero Tracking - This indicator will be on when Zero Tracking is turned on and theprocedure is currently running. See Zero Tracking Parameters on page 28 for moreinformation.

FBLK Feeder Block - This indication follows the Logical Input ‘Feeder Block’. See DigitalInputs Setup on page 36 for more information.

General AlarmsThe general alarm button is used to indicate that a problem may exist. This button willremain on until the conditions that caused the alarm have been removed and the alarmacknowledged. To view the condition (or conditions) which has caused a General Alarm,

touch the alarm button. All alarms will be displayed with an indicator to the left of the text ( = ON = OFF). You may still access this screen from the action menu.


Alarm Screen

Belt Load Over LimitIf the load on the belt exceeds the Overload Limit set in the Limit Switches on page 26, a GeneralAlarm of this value will occur.

Belt Load Under LimitIf the belt load ever drops below the value Underload Limit this General Alarm will be set. See LimitSwitches on page 26 for more information.

PCAD Near ZeroThis error message indicates that a Raw (Gross) A/D reading less than 10 occurred. This could becaused by the belt being lifted off of the weigh deck.

NOTE: This alarm is an indication of a serious problem. If this alarm is observed damage may haveoccurred to the load cell or the suspension.

PCAD Near FullThis error message indicates that a Raw (Gross) A/D reading greater than 1,000,000 occurred.This could be caused by too high a load on the belt.

NOTE: This alarm is an indication of a serious problem. If this alarm is observed damage may haveoccurred to the load cell or the suspension.

Z Track Out Of RangeThis alarm indicates that after attempting to complete a Zero Tracking calibration, the calculatedzero change was larger than the maximum specified by the operator. See Page 28 for anexplanation of Zero Tracking Parameters.

PCAD DiscrepancyIf there is a discrepancy between two load cell channels (PCADs) greater that the alloweddifference this alarm will be displayed. There are several ways for this error to occur. For example,if there is only one PCAD on the card stack but the number of PCAD’s is set to two or if the loadhas shifted significantly to one side of the belt this error can occur.

Tachos Do Not ComplyThis error can occur if a belt slippage condition exists. When using two tachos, the controller looksfor a specific ratio and allowed difference between the tachos. If a discrepancy occurs this alarmwill be set. If you are using only one tacho but the number of tachos is set to two this error willoccur.

Communications LostThis error message indicates that no communications message has been received for a timeperiod exceeding the maximum time allowed. See the Merrick communications SpecificationManual for a complete explanation of this error.

Setpoint Out Of RangeIf the feedrate setpoint is less than zero or is greater than the design feedrate this alarm will occur.This alarm will also be enabled if the batch setpoint exceeds 10,000,000 engineering units.


No Speed DetectedThis error occurs when the controller expects a belt speed and none exists after 10 seconds.

Anain Out Of RangeThis alarm will occur if the allowed range for the analog inputs have been exceeded.

LCD Not RespondingThis error message indicates that an error occurred while the CPU was testing the status of theLCD Display. This error can occur if the ribbon cable connecting the LCD Display to the LTI Boardis removed then replaced.

No Data From PCADThis condition can occur if the PCAD Board fails to develop an A/D Reading or if the CPU Boardfails to handle the reading. Normally, if the condition remains it indicates an PCAD or CPU Boardmalfunction.

Use and to move the selection box to the alarm you want to acknowledge. is

used to acknowledge an alarm selected by moving the selection box around the alarm. isused to reset all alarms. If an error that caused an alarm has not been corrected the alarm buttonwill continued to be displayed on one of the main screens and the alarm will continue to beindicated on this screen.

CONTROLLER MODESThe four modes of operation for MC³ 24.96 are:

There are four modes of operation of this software package:

Belt Scale – Basic model measuring the belt load and speed and calculates the feedrateand totalizes.

Batching Belt Scale – Allows you to batch out predefined lots of material across the belt.

Feeder – The MC³ controls the speed of the belt or pre-feeding device to follow a feedratesetpoint.

Batching Feeder – Allows you to batch out material at specific feedrates controlled by theMC³. There is a feedrate setpoint and a batch setpoint.

Operating mode selection is made by setting the Batch Controls and PID Controls Logical Inputs to“on” or “off” according to the following table. See Digital Inputs Setup on page 36 for informationon Logical Inputs.

Mode PID Controls Setting Batch ControlsSetting

Belt Scale Off Off

Feeder On Off

Batching Belt Scale Off On

Batching Feeder On On


SETPOINTVarious screens may be displayed based on the mode of your controller.

Setpoint Screens

These are the screens you will see when batching and PID logical inputs are turned on. You are

able to toggle between the two screens by touching the or buttons.

Batch setpointIf the PID is turned off and Batching is enabled this is the setpoint screen you will see.

There are two Batch setpoint methods available in this controller.Local

Remote Serial

LocalWhen this mode is selected, the batch setpoint is entered by the operator at thecontroller. This setpoint is in engineering units for total.

Remote SerialThis setpoint mode allows the MC³ Controller to receive a batch setpoint from a remotedevice through the serial port such as a computer or a PLC/SuperBridge Controller.This method requires that the remote device is connected to the controller via the RS-

485 serial port.NOTE: When the controller is to be used in SuperBridge or any other system which transmits setpoint

information using Serial Communications, the Remote Serial mode must be selected. The rules andformat of the data exchange is described in [1].

SetpointThis button allows you to directly edit the batch setpoint using a numeric edit screen.

Batch ParametersThis button allows you to edit the batch parameters.LC-Head Length This parameter is the length from weigh idler to the head pulley (where materialdrops off the end of the belt).


Maximum Error - this value is the maximum error allowed before the batch error logical output isenabled.Maximum Time - The maximum allowed time for a batch process to occur before the logical output“Batch Error” goes on. See List of Logical Outputs (page 41).Preact - is used to turn off the output to the discharge gate ahead of time, allowing the batchsetpoint to be reached with a minimum of error. The preact is updated automatically after the batchis complete, end is expressed in the units for total.Preact Absolute - the maximum value that the Preact may achieve.Preact Delta - the maximum change in the Preact per batch.Preact Adaptation % - the percentage of the last batch error to be added to the Preact, per batch.

Batch Setpoint

Preact

Close Discharge Gate(Setpoint + [-Preact])

Open Discharge Gate

Batch Running End Run

BeltLoad

Time

FeedrateThis button is displayed when the PID option is enabled. This allows you to go to the Feedratesetpoint screen.

Feedrate setpoint

With the Batch disabled and the PID enabled this is the screen you will see.There are currently five Feedrate Setpoint methods available in the MC³ Controller.

Manual Speed

Local

Remote Analog Input

Remote Analog Ratio

Remote Serial

To choose the desired Setpoint mode, rotate the selection to the desired type of

setpoint and touch the button. To enter a setpoint value, follow the directions forentering numeric values found on page 9.

Manual SpeedThis is the first Setpoint Mode Available in the MC³ Feeder Controller. This mode isused to provide output to the SCR on a scale from 0.0% to 100.0% of the maximumcapacity of the SCR and drive motor on the feeder. The output may be voltage or


current depending on jumper setting on the PCIO board (see Analog Outputs on page 70 for moreinformation).

LocalWhen this mode is selected, a Feedrate setpoint can be entered by the operator. Thissetpoint is in engineering units for rate. This mode allows the operator entered setpointto be used by the controller in conjunction with the current feedrate to develop closed-loop control of the feeder.

Remote Analog InputThis Setpoint mode allows the setpoint value to be input through the Analog Input inrelation to the IN1 Scaling parameter, see IN1 Scaling / IN2 Scaling (page 33). DefaultIN1 Scaling is the Design Feedrate Capacity. See Design Capacities (page 25).

Remote Analog RatioThis mode scales the External Feedrate setpoint as a percentage of the incominganalog input signal. Scaling is the same as Remote Analog. This allows multiple feedersto be connected to a single signal with each feeder assigned a particular percentage of

the signal as a setpoint.For example, three feeders are to be used set up to provide material to a process using one analoginput for control. Feeder number one provides 25%, feeder number 2 provides 35% and feedernumber 3 provides 40% of the material needed for the total process. When the setpoint changesfor the process all three feeders will properly scale the outputs for the new setpoint.

Remote SerialThis setpoint mode allows the MC³ Controller to receive a setpoint from a remote device throughthe serial port such as a computer or a PLC/SuperBridge Controller. This method requires that theremote device is connected to the controller via the RS-485 serial port.

NOTE: When the controller is to be used in SuperBridge or any other system which transmits setpointinformation using Serial Communications, the Remote Serial mode must be selected. The rules andformat of the data exchange is described in [1].

When the logical input Serial Setpoint is enabled and there is no communications time-out, thesetpoint screen will display a Fall back Setpoint menu allowing you to enter a method and value forthe controller to default to when serial communications are interrupted.

Snap ButtonThe Snap button is used only in the Manual Speed and Local setpoint methods. Thisfunction is used to ‘capture’ the current feedrate to the setpoint. The current feedrate isdisplayed in this button.

If this button is not available for a method, the current feedrate will be displayed.

Setpoint ButtonThis button allows numeric editing of the setpoint. This button is only available for theManual Speed, Local, and Remote Analog Ratio methods.

If this button is not displayed, the current setpoint for the method selected is displayed


Fallback Setpoint

This screen will be displayed when the Logical input Serial Setpoint is enabled and there is acommunications failure. This will allow you to set a feedrate value which to default to in the case ofcommunication failure. This setpoint will be enabled after the communications time out hasoccurred.

Common Setpoint buttons

Accept ButtonIn the setpoint menu system, no changes will occur until the accept button has beentouched. Once the button has been touched the new setpoint will be accepted and youpress return to exit to the screen you entered from.

Arrow ButtonsThe Arrow buttons are used to quickly adjust the setpoint by adding or subtracting apercentage of the span. Specifically 0.5% of the span for batch and 5% of the span for

Feedrate. For example, if the design feedrate is 10 TN/h, touching one of the arrow keys will addor subtract 0.5 TN/h to the current value of the setpoint.

Return ButtonThis button will allow you to exit out of the Setpoint menu. If you do this without firsttouching the Accept button, no changes you did will take effect.

ACTIONS

CalThis button takes you to the Calibration menu. See Calibration on page 48 for furtherexplanation of the Calibration menu.

Reset TotalWhen this button is selected you will be asked to enter the calibration password toconfirm that you actually want to clear the Master Total. Enter the password to clear theTotal or touch the ESC button in the password screen to escape to the action screen

without clearing the Master Total.


Sub-TotalThis button clears the Sub-Total and any remaining pulses for the external counter.

Clean ScreenIf the touch screen gets smeared or very dirty it may be necessary to clean the screen.This function gives you 60 seconds to clean the screen without affecting the controller.

DiagnosticsThis selection takes you to the Diagnostic menu. See Diagnosing Problems on page 58for further explanation on the Diagnostic menu system.

AlarmsThis selection allows you to view the status of all alarms at any time. For more

information on alarms see General Alarms on page 12.

PrintTouch this selection to enter the Print Line Editing and Printout Selection screens (see page 19 formore information).

Print Line Editing and Printout SelectionThis menu allows you to edit or to print one of the four available print strings. Print strings are linesof characters that convey information to a printer for permanent record.

Touching on of these buttons will send the selected print string to the printer.

This selection allows editing of the strings. The string to edit is selected in thefunction.


These allow you to move character by character in the selected print string.

Touching these buttons will allow you to rotate through the character selection screens.

This is the shift button. This allows you to select uppercase or non-alphanumericcharacters on the buttons. If a button has two lines displayed the upper set is selectedby pressing this button (SHIFT will appear under the string) then pressing theappropriate button.

This allows you to enter specific ASCII values that are not supported with a button.

Also enter the print counter and increment values.

Un-shifted this is used to place a space character in your string. When the shift isenabled, it places a null (0) value at that character position.

In the un-shifted mode this button places a linefeed character in the string. Whenshifted, it places a carriage return at the current character position.

This button toggles through the four available print strings.

FF - Form feed

HT - Horizontal tab

PF buttons.The PF buttons embeds function codes into print string.

Button Function DescriptionPF1 ASCII CODE DO NOT USEPF2 Total Prints the totalPF3 Sub-total Prints the subtotalPF4 Date Prints the MC³ date.PF5 Time Prints the MC³ time.PF6 Clear Sub-total Clears the Sub-totalPF7 Counter Prints the value of the print counterPF8 Increment counter Increment the counterPF9 Belt load Prints the current belt loadPF10 Feedrate Prints the current feedrate.PF11 Setpoint Prints the current setpointPF12 Register value Prints the value of a registerPF13 Load unit Prints the Load units.PF14 Feedrate unit Prints the Feedrate units.PF15 Total unit Prints the Total unitsPF16 NOT EMBEDDED Clear currently selected print string


SETTING UP YOUR CONTROLLER

SETUP

Pressing the button on the Main screen or Large Font screen will display a Password Entryscreen (if password is enabled), and once the proper password is entered, the Setup screen will bedisplayed. See PASSWORD PROTECTION on page 7.

There are three selections from the Setup menu. Chain and Weigh EZ Setup allow for an easyand quick setup of your controller. Custom Setup allows customization of the parameters of thecontroller to allow optimum efficiency for your control application. The Custom Setup button maynot be visible. See Advanced Setup, page 63.

CHAIN EZ SETUPThis procedure assumes:

1. All Electrical connections and wirings are correct.

2. Acceptance of factory default settings.

3. Belt Length, Maximum Feedrate and the Test Chain load values are known.

4. You have a test chain available for the procedure.

The Calibration Speed (page 31), number of speed calibration revolutions (# Speed Revs page 28)and the number of calibration procedure revolutions (# Proc Revs page 28) may be adjusted foryour specific application by entering the custom setup menu and changing the value. See EnteringNew Values on page 9 for the proper method to enter values into Numeric Entry Screens.

Touch to enter the Units Select menu. Scroll to the unit selection that is correct for your

application. Touch to set the units.

Touch to enter the numeric entry screen for the “EZ Setup” parameters. You will needto know the design feedrate for the feeder, the length of the belt and the test chain load. SeeEntering New Values on page 9 for the proper method to enter values into Numeric Entry Screens.

When complete, touch to exit the numeric entry screen and return to EZ Setup procedure.

The next series of tests will determine the type and mode of the Tacho attached, the number oftacho pulses for one revolution of the belt and the design speed of the feeder.

WARNING: THE BELT WILL START MOVING TO COMPLETE THESE TESTS.


Five seconds are allotted to allow the belt to start to spin up for the tacho type and directiondetection. Next the speed calibration procedure is performed. This procedure determines thenumber of tacho pulses per belt revolution.

NOTE: The belt must cycle the number of revolutions that is indicated on the speed calibration screen.

Touch when you are ready for the test to be performed. Allow the number of revolutions

specified by # Speed Revs (page 28) to accumulate then touch . If value is reasonable,

touch . The speed will automatically increase to determine the design speed of thefeeder. When this speed is found, the controller will stop the feeder.

WARNING: THE BELT WILL START MOVING TO COMPLETE THIS TEST.

Next the zero procedure will be run to determine the zero load value for your feeder. After touching

the controller will take 5 seconds to allow the feeder to spin up for the test. Touch

to begin the procedure. This will zero the controller when there is no load on the feeder.

Touch to accept results.


Next the chain calibration procedure will be performed. You must put the test chain on thecontroller. The controller will run 30 seconds to allow the load to stabilize before allowing the

procedure to be run. Touch to start the procedure. Touch to accept results.

Touch to accept results and quit EZ Setup.

WEIGHT EZ SETUPThis procedure assumes:

1. All Electrical connections and wirings are correct.

2. Acceptance of factory default settings.

3. Belt Length, Maximum Feedrate and the Static Calibration Weight values are known.

4. You have test weights available for the procedure.

The Calibration Speed (page 31), number of speed calibration revolutions (# Speed Revs page 28)and the number of calibration procedure revolutions (# Proc Revs page 28) may be adjusted foryour specific application by entering the custom setup menu and changing the value. See EnteringNew Values on page 9 for the proper method to enter values into Numeric Entry Screens.

Touch to enter the Units Select menu. Scroll to the array of units that is correct for your

application. Touch to set the units.

Touch to enter the numeric entry screen for the “EZ Setup” parameters. You will needto know the maximum feedrate for the feeder, the length of the belt and the calibration weight. See


Entering New Values on page 9 for the proper method to enter values into Numeric Entry Screens.

When complete, touch to exit the numeric entry screen and return to EZ Setup procedure.

The next series of tests will determine the type and mode of the Tacho attached, the number ofpulses per revolution of the belt and the design speed of the feeder.

WARNING: THE BELT WILL START MOVING TO COMPLETE THESE TESTS.

Five seconds are allotted to allow the belt to start to spin up for the tacho type and directiondetection. Next the speed calibration procedure is performed. This procedure determines thepulses per belt revolution.

NOTE: The belt must cycle the number of revolutions that is indicated on the speed calibration screen.

Touch when you are ready for the test to be performed. Allow the number of revolutions

specified by # Speed Revs (page 28) to accumulate then touch . If value is reasonable,

touch . The speed will automatically increase to determine the design speed of thefeeder. When this speed is found, the controller will stop the feeder.


Next the zero procedure will be run to determine the zero load value for your feeder. After touching

the controller will take 5 seconds to allow the feeder to spin up for the test. Touch

to begin the procedure. This will zero the controller when there is no load on the feeder.

Touch to accept results.


Next the calibration procedure will be performed. You must put the calibration weights on thefeeder suspension. The controller will run 30 seconds to allow the weight to stabilize before

allowing the procedure to be run. Touch to start the procedure. Touch to

accept results. Touch to accept results and quit EZ Setup.

CUSTOM SETUPThere are two screens in the Custom Setup menu. These functions allow you to customize thecontroller for a specific feeder and process.


SETUP SCREEN 1

Setup Screen 1

Units SelectTo enter the Units Select Menu, press the button from the Setup Screen 1.

Use the Up or Down arrow buttons to scroll through the list of units until the combination appears in

the center box that is correct for your application. Touch to set your selection and returnto Setup Screen 1.

List of Unit String Combinations

Speed Load Total Length Feedrateft/s lb/ft lb ft lb/minft/s lb/ft lb ft lb/hft/s lb/ft TN ft lb/minft/s lb/ft TN ft lb/hft/s lb/ft TN ft TN/h

ft/min lb/ft lb ft lb/minft/min lb/ft lb ft lb/hft/min lb/ft TN ft lb/minft/min lb/ft TN ft lb/hft/min lb/ft TN ft TN/hm/s kg/m kg m kg/minm/s kg/m kg m kg/hm/s kg/m t m kg/minm/s kg/m t m kg/hm/s kg/m t m t/h

m/min kg/m kg m kg/minm/min kg/m kg m kg/hm/min kg/m t m kg/minm/min kg/m t m kg/hm/min kg/m t m t/h

NOTE: It may be necessary, after selecting the units, to update the decimal point selection values. SeePage 25 for instructions concerning the decimal point selection. Even if no changes to the decimal


points are necessary, you should at least look at each decimal point option to insure the properdisplay of values.

Decimal PointsInternally the MC³ Controller uses floating point numbers. Any changes to the decimalpoint settings affects only the display of the values which will be rounded appropriately.To enter the Decimal Points Menu, press the Decimal Points button while in the first

Setup Screen menu. The display will be a Numeric Entry Screen. Use the directions on page 9 tochange the value of the parameter.

Parameter Min Max

Belt Load 0 4

Total 0 4

Belt Speed 0 4

Belt Length 0 4

Feedrate 0 4

NOTE: Please note that the maximum number of decimal places is four.

Design CapacitiesTo enter the Design Capacities Menu, press the button from the first Setup Screen menu. Thedisplay will be a Numeric Entry Screen. Use the directions on page 9 to change the value of theparameter.

Parameter Min Max

Design Load 1 30000

Design Feedrate 0.01 30000

Design Speed 0.5 30000

PID Parameters & Output Dynamic ProtectionThe MC³ Controller, when in control mode, uses a PID (Proportional (Gain), Integral,Derivative) control algorithm. To tune this algorithm to a particular feeder, changes canbe made to these parameters.

When the MC³ is in control, it is the MC³’s job to maintain a feedrate setpoint. This is done bycontrolling the belt speed to a point where the difference between the setpoint and the actualfeedrate is minimal. In the MC³, error is defined as (error) = (actual feedrate) - (setpoint). The PIDalgorithm uses this error term to adjust the speed of the feeder belt. For example: If the error isslightly positive (the actual feedrate is larger than the setpoint), the MC³ will slow down the beltspeed.The advantage of a PID algorithm is that it is an industry standard and many books and articleshave been written on how to tune a PID controller. Several of these methods require littleknowledge about the actual dynamics of the system to be tuned. If possible, Merrick will tune thePID controller before the feeder is shipped to you. Otherwise, we recommend you use whatevertuning method you are most familiar with.To enter the PID Parameters, press the button from the first Setup Screen menu The display willbe a Numeric Entry Screen. Use the directions on page 9 to change the value of the parameter.


GainThis is the amount of gain associated with the PID algorithm. In the MC³, gain is expressed as apercentage. The higher the gain, the more aggressive controller behavior. A purely proportionalcontroller (with no integral and derivative action) would result in constant error. Too much gain cancause the controller to go unstable.

IntegralIntegral action adjusts the belt speed using the accumulated (integral of) the error. The integralterm is expressed in units of 1/sec. Since a purely proportional controller will result in a constanterror, the integral term eliminates this error. As with gain, too much integral action can result in anunstable controller.

DerivativeDerivative action adds dampening to the controller. The derivative term is expressed in units ofseconds. The derivative term acts against changes in the error. This has the effect of minimizingovershooting the setpoint.

SCR Accel %/s and SCR Decel %/sThere are also two other parameters that provide Output Dynamic Protection. The two parametersare available to limit the acceleration and deceleration of the controlled device. Their purpose is toeliminate damage to the motor drive circuit, motor, drive mechanism and belt. For some materials,it is also necessary to limit acceleration and deceleration of the belt to prevent material frombouncing around on the belt or falling off the belt. The parameters are expressed as percent persecond.

Start SpeedThis is a feature that, when enabled, makes the belt sped quickly jump to a pre-calculated speed atfeeder start-up. This is useful in blending applications or when a quick start is required. Thecontroller calculates the required belt speed for the current setpoint based on the current belt load,and generates an output signal for the belt drive that will produce this speed, based on thecontroller’s experience. Enter a value of 1 to enable this feature.

Limit Switches

Three feedrate alarm indicators located on the Main Screen, and nine feedrate alarm LogicalOutputs are affected by the controller operating mode selected. The operating modes may bechanged during the normal operation of the feeder as required. (See Controller modes page 14.)The Logical Outputs can be mapped to physical outputs for external indication and alarming. (SeeDigital I/O Mapping on page 34.) The nine feedrate Logical Outputs will only be active when all thefollowing conditions have been met:

1. Feedrate Mode is selected.2. Not in Manual Speed setpoint.3. The logical inputs Run Permission and Gravimetric are on.


The feedrate Logical Output alarms are delayed by settable time parameters, “High Delay” and“Low Delay” to prevent frequent cycling. In addition, there is a “Startup Delay” that is active whenthe feeder is starting up, from either a blocked state or a zero setpoint. The Main Screen displaysare not delayed. See List of Logical Outputs on page 41 for more information on the specificoutputs affected.The mode determines the kind if deviation that is controlling the Hi Rate and Lo Rate alarms andthe indicators on the main screen. There are three feedrate limit switch operating modes:

FeedRate HI/LOWhen this mode is selected, the feedrate must be between the values entered into theLimit Switch numeric parameters for High Feedrate and Low Feedrate.

Feedrate Rel DevThis mode activates the logical outputs when the feedrate deviates from the setpoint by a

percentage of the current setpoint. The limits are entered into the parameters HighRelative Deviation and Low Relative Deviation. As an example, if High RelativeDeviation is set to 10 %, Low Relative Deviation is 5 % and the current setpoint is at 10lb/min, the rate alarm outputs would be active when the feedrate is above 11.00 lb/min

and below 9.5 lb/min. If the setpoint changed to 5.00 lb/min, the outputs would be active above5.5 lb/min and below 4.75 lb/min.

Feedrate Setpoint DeviationIn Feedrate Setpoint Deviation, the logical outputs will turn on if the feedrate deviates from thesetpoint by fixed values, set in High Rate and Low Rate deviation. For example, if the parameters

High Feedrate Deviation is set to 2.00 lb/min and Low Feedrate Deviation 1.00 lb/minand the setpoint is 10.00 lb/min, the High Rate Alarm output would turn on when thefeedrate exceeds 12.00 lb/min and the Low Rate Alarm output would turn on when the

feedrate falls below the 9.00 lb/min.

The Overload and Underload limits are limits on the Belt Load set to cause a General Alarm if theboundaries are exceeded for any reason. These boundaries are set to inform operators of acondition that may have caused serious damage to the feeder.

There are also two delays involved with the rate alarm outputs. This is the high delay time and thelow delay time. These are the times from which the pertinent alarm first occurs and when you wishfor the alarm l outputs to come on.There are upper and lower limits for each of these modes which are called HI or LO. The valuesfor each set of limits are located in the numeric section of the menu.

Numeric Parameters

To enter numeric values for the Limit Switches, touch . The display will be a NumericEntry Screen. Use the directions on page 9 to change the value of the parameter.

Parameter Default Min Max

High Feedrate 90% of DesignFeedrate

0 150% of Design Feedrate

Low Feedrate 10% of DesignFeedrate

0 150% of Design Feedrate

High Relative Deviation 10% 0 % 100 %

Low Relative Deviation 10% 0 % 100 %

High FeedrateDeviation

10% of DesignFeedrate

0 Design Feedrate

Low Feedrate Deviation -10% of DesignFeedrate

0 Design Feedrate


Parameter Default Min Max

High Delay 10 seconds 0 3600 seconds (1 hour)

Low Delay 10 seconds 0 3600 seconds (1 hour)

Startup Delay 0 seconds 0 3600 seconds (1 hour)

Overload Limit Design Load 1 150% of Design Load

Underload Limit - 10% of DesignLoad

- DesignLoad

Design Load

High Speed Design Speed 0 150% of Design Speed

Low Speed 0 0 Design Speed

High Speed Delay 10 seconds 0 3600 seconds (1 hour)

Low Speed Delay 10 seconds 0 3600 seconds (1 hour)

Belt ParametersTo enter numeric values for the Belt parameters, touch the Belt Parameter button fromthe first Setup Screen menu. The display will be a Numeric Entry Screen. Use thedirections on page 9 to change the value of the parameter.

Pulses / RevThe Pulses/Belt Rev variable represents the number of pulses from Tacho #1 for one revolution ofthe feeder’s belt. Limits are minimum of 1 and maximum of 1,000,000. This value is normally setby the using the Speed Calibration procedure, see page 49.

LengthThe belt length variable represents the belt length in the currently selected units (feet or meter).Limits are minimum of 1 and maximum of 50,000.

# Proc RevsThe “Number of Calibration Procedure Revolutions” variable represents the number of beltrevolutions to perform for calibration procedures with the exception of the Speed Calibration.Limits are minimum of 1 and maximum of 100.

# Speed RevsThis parameter is used to determine the number of revolutions to use for the Speed Calibration(page 49). Limits are minimum of 1 and maximum of 100.

Nominal SpeedThis is the speed of the belt when no tacho is used on the belt pulleys and the belt will run at aconstant speed. This is normally used for a belt scale application. Limits are minimum of 0 andmaximum of the Design Speed.

Alarm DelayThis is the delay time for the No Speed Detected General Alarm. Tacho pulses must be detectedwithin this time frame when the feeder is started.

Zero Tracking ParametersThe Zero Tracking function is used to automatically zero the feeder load value when thebelt is empty and is running. The logical input Zero Tracking must be ON for this functionto be active.


Belt Load

Load Limit(Instant)

AbsoluteLimitZero

Load

Wait Time Test Revolution

IncrementLimit

Wait Time Wait Time

TestDiscarded

Test Revolution

Value aboveIncrement Limit,

no change

Wait TimeThe “Time Delay” value is the time that the controller will wait after all conditions have been metbefore actually starting a Zero Tracking procedure. This means that the belt must be empty andrunning for this amount of time before the process will begin. In addition, this delay time is requiredto elapse before another procedure will begin after completion of a previous. Limits are minimumof 0 and maximum of 3600.

Max LoadThis value is used to determine whether or not the belt is empty. For example, if this value is 2.00lb/ft, then the belt would be considered empty if the load on the scale drops below this value. If thisvalue is exceeded anytime during the wait test than the current Zero Track test is abandoned andthe wait time is started for a new test. Limits are minimum of 0 and maximum equal to the DesignLoad.

Max Step AlwdThis parameter is the maximum allowable Zero Tracking step change. If the new calculated ZeroLoad differs from the old more than this parameter then no change is made. Limits are minimumof 0 and maximum of 20% of the Design Load.

Max Z TrackThe “Maximum Zero Tracking” parameter is the maximum zero tracking compensation that will beused. If this value is reached, with a legal step change, no change is made and the General AlarmBad Zero Tracking will occur. Limits are minimum of 0 and maximum of 10% of the Design Load.

Tachometer ParametersThis set of parameters allows you to set up the Tachometer interface. To select the typeand direction of the tachometer, press the appropriate button and cycle through thepossible choices. To edit the numeric parameters, use the directions found in Numeric

Entry Screen on page 9.

TypeThe following are the four types of tachometers that can be used with the MC³:

Optical 5 Volt digital encoder, either signal channel or quadrature.

Mag/F-25 Merrick F-25 Encoder or a 2 wire current loop magnetic style encoder.


Stepper Brushless pulse generator.

Frequency Frequency generator.

ModeMode determines if direction detection is to be utilized. For direction detection, a quadratureencoder must be connected to the MC³, channel A and/or B. A quadrature encoder allows the MC³to determine when the belt is moving and will only generate a speed signal if the belt is moving in aforward direction. This is useful for when the belt is stopped and vibration at the tacho can causepulses to be sent to the controller. If only one tacho line is to be used, then the signal must beattached to the channel A input (see Tacho on page 68) and the mode must be set to NODIRECTION.

If direction detection is needed and you are not sure if your encoder is right hand or left hand, runthe feeder and switch between right and left hand detection until a speed signal is present.

NO-DIRECTION - Direction of tacho is undetermined. The MC³ will use pulses from channel Aonly to determine the speed signal.

R-HAND - The MC³ will only generate a speed signal if a right hand rotational direction is detected.The MC³ determines right hand rotation as channel A leading channel B (see diagrambelow.)

L-HAND - The MC³ will only generate a speed signal if a left hand rotational direction is detected.The MC³ determines left hand rotation as channel B leading channel A (see diagrambelow.)

A Leads B - R HAND

A

B

BB Leads A - L HAND

A

Speed Sensing Operational ModeThe lower left button is used to toggle between different operational modes of the belt spedsensing. The following operational modes are available:

NONE No tacho is used at all. The speed is set in the Nominal Speed parameter in the BeltParameters (page 28) screen. The logical Input “Belt Running” determines the speedused by the controller. If the input is OFF, the speed is zero. If it is on, then the“Nominal Speed” is used.

FIRST One tacho is used to measure the speed. It is connected to the Tacho inputs 1A and1B. See LTI on page 68.

SECOND One tacho is used to measure the speed. It is connected to the Tacho inputs 2A and2B. See LTI Board on page 68. This setting is normally used in a dual tachoinstallation when the first tacho is not working.

BOTH Two tachos are used. The first determines the speed, and the second is used todetect belt slippage. If a discrepancy between the two tachos is detected, theGeneral Alarm “Tacos Do Not Comply” is set and the logical output “Belt Slippage”is turned on. Tacho 1 is still used for determining the speed.

AUTO BYP This mode is similar to BOTH. If there is a discrepancy between the two tachos, thespeed sensing mode is changed to SIMULATOR, and remains there until theGeneral Alarm “Belt Slippage” has been cleared. This allows for the controller tokeep the feeder operational.


SIMULATOR The belt speed is calculated from the output to the belt drive (SCR OUTPUT), andthe relation detected between the output and the actual speed with fully operationaltachos, initially set to 100 %.

Numeric ParametersNominal Ratio - This value is the ratio between the two tachos. The ratio of Tacho 2 to Tacho 1 is

used for comparison. For example, if Tacho 2 runs at 1000 pulses/rev and Tacho 1runs at 100 pulses/rev the ratio would be 10.0000. Limits are minimum of 0.0100 andmaximum of 10000.0000.

Allowed Diff - This is the difference between the measured ratio and the Nominal Ratio betweenthe two tachos. If the difference is larger than this percentage than the General Alarm“Tacos Do Not Comply” will be issued. Limits are minimum of 0 and maximum of 100.

Minimum Number of Pulses - This parameter is the minimum number of pulses to accumulatefrom any of the tachos before the controller compares the pulses from two tachos.Limits are minimum of 0 and maximum of 1,000,000.

SetpointThis screen is described in Setpoint on page 15.

Totalizer Cut-OffWhen the belt load drops below this value, the totalizers will stop. The totalization is bi-directional, meaning that it is possible to subtract from the total. This is desirable if thereis a large variation of zero load along the belt. Limits are minimum of -30% of the Design

Load and a maximum of the Design Load.

Calibration ParametersThe following parameters are used during the calibration procedures to set the proper scaling forthe feeder.

Calibration WeightThis value is the sum of the weights you will be using when you are performing the WeightProcedure (page 53). Limits are minimum 0 and a maximum of the Design Load multiplied by theWeigh Span.

E-Cal LiveloadThis is the live load relative output, in mV/V, from the load cell for the design load. The value canbe calculated, and used in an Electronic Calibration procedure (page 54). Limits are minimum of 0and a maximum of 4.000 mV/V. Performing a E-Cal Factor Procedure (page 55) will adjust thisvalue.

Weigh SpanThe weigh span is the gravimetric length of the weigh bridge. Performing a Weight FactorProcedure (page 54) will adjust this value. Limits are minimum of 0.1 and a maximum of 10000.

Chain LoadThis is the test chain load to be used on the feeder during a Chain Procedure (page 52). The chainload is normally available on the chain label. Limits are minimum of 0 and a maximum of theDesign Load. Performing a Chain Factor Procedure (page 53) will change this value.

Calibration SpeedThis parameter is used to set the belt speed used during the EZ Setup procedures. The defaultspeed is 80%. Limits are minimum of 0 and a maximum of 100.


Display DampeningThese factors are used to dampen the displayed values for the feedrate and speed. Increasing thevalue will cause more dampening of the displayed feedrate or speed. Note that the Speed Factor iscritical for the dynamics of the controller, and the Feedrate Factor is not. Set the Speed Factor for alow belt speed. You have to tune the PID controller after changing the Speed Factor dampening.See PID Parameters & Output Dynamic Protection on page 25.

Parameter Min Max

Feedrate Factor 0 99

Speed Factor 0 99


SETUP SCREEN 2

Setup Screen 2

Analog InputsThe Analog Input #1 is used for the Feedrate setpoint, when Remote Analog Input orRemote Analog Ratio is used. See page 17. The input signal is converted into a unipolar20 bit number 0..1048575. A two point conversion is used to translate the raw input

counts to a usable value, expressed in engineering units for feedrate. Three parameters areinvolved, as described below. The parameters are normally set using the Analog Input Setup andCalibration procedure (page 56), but they can also be manually edited here.

A similar set of parameters are available for analog input #2. Although this input is unused in theapplication, the analog input can be “borrowed” by supervisory system, such as the SuperBridgePLC interface.

IN1 Zero Level / IN2 Zero LevelThis value is the counts representing the zero value of the incoming signal. When the input signalis set to 4 -20 mA or 2..10 V input then this value should be around 200,000 counts. If the input isset to 0 - 20 mV then the zero level should be close to 0 counts. Limits are minimum of 0 and amaximum of 1,040,000.

IN1 100% Level / IN2 100% LevelThis value is the representation of the 100% value of the incoming signal. Normally this value willbe 1,000,000 counts representing 20 mA or 10 V (100% ) of the incoming signal. Limits areminimum of 1 and a maximum of 1,040,000.

IN1 Scaling / IN2 ScalingThis is the value representing the full scale value used for scaling the input. Normally, this is theDesign Feedrate, but there are applications where other values can be used, especially if RemoteRatio is used. Limits are minimum of 1 and a maximum of 100,000.

Analog OutputsThe purpose of this section is to configure the Analog Outputs. Each analog output maybe 0-20 V, 4-20 mA, 0-10 V or 2-10V. Note that the selection between voltage andcurrent is made with straps on the PCIO boards, while the output at zero is selected

here. The type of output may be for Feeder Control, Feedrate or Belt Load, Speed or the currentsetpoint. To change the settings for any of the outputs, just press on the button to cycle throughthe choices for type and output rating.


Analog Output Setup Screen

ModeSCR OUTPUT Control signal for the belt motor drive, controlling the belt speed. This is the

output from the PID controller. Scaling is 0..100%.

Feedrate Follows the actual feedrate. Full output represents design feedrate.

Belt Load Follows the belt load as measured by the weigh suspension. Full outputrepresents design belt load.

Belt Speed Follows the belt speed, normally as measured by tacho #1. Full outputrepresents design belt speed.

Setpoint Follows the actual setpoint, regardless of setpoint mode. Full output representsdesign feedrate.

Available This mode is unused by the application. It makes it possible for a supervisorysystem, such as the SuperBridge PLC interface to “borrow” the analog output.

Type0-20 mA - The mode selected is scaled between 0 and 20 mA or 0 and 10 V.

4-20 mA The mode selected is scaled between 4 and 20 mA or 2 and 10V.

Digital I/O MappingThe MC³ allows you to configure the digital inputs and outputs to your system’s requirements. Byallowing mapping of the I/O, the MC³ gives you flexibility in design of your system.

I/O mapping requires a layered approach to the design process. In the MC³ there are two layers,physical and logical. The physical layer is connected to the outside world, for example relays andswitches. The inputs and outputs have names like “Rack 1 Input 3”. The logical layer is what theMC³ application acts on. The inputs and outputs have names like “Run Permission” or “BeltSlippage”

CAUTION: Changes you make, using the I/O mapping screens take effect immediately, as you make themThis function must be used with extreme care. For most applications, the default valuesshould be used.


PHYSICALINPUTS(WORLD)

PHYSICALOUTPUTS(WORLD)

LOGICALINPUTS

(MC³)

LOGICALOUTPUTS

(MC³)

1 TO MANYLI1LI2LI3LI4LI5LI6LI7LI8LI9LI10

PI1PI2PI3PI4PI5PI6PI7PI8PI9PI10

LO1LO2LO3LO4LO5LO6LO7LO8LO9LO10

PO1PO2PO3PO4PO5PO6PO7PO8PO9PO10

MANY TO 11. Physical output map stores address of logic out assigned to it.2. Logical Input map stores the address of the Physical In assigned to it.3. Reversing and Force Properties are mapped to the Physical layer.

PI7

PI4PI5

PI6PI7

PI4

LO1LO3LO6

LO3LO7

LO6

MAP

MAP

XXX

10

X

FC0

0

00

RM001

00

0

RV

0

0

00

0

RM

0

XX1X

FC

0100

RV

4. Remote Property is mapped to the Logical layer.

Mapping inputsThe physical input layer is mapped to the logical input layer. This allows one physical input tocontrol several logical inputs. For example, one physical input can control both access to thecustom setup menus and to the ability to accept calibration changes. There are two specialphysical inputs, called “Always On” and “Always Off”. Logical inputs that are not used in yourapplication are normally mapped to one of these two inputs.

Mapping outputsThe logical output layer is mapped to the physical output layer. This allows you to use severalphysical outputs mapped to one logical output. For example, some action may need to take placedue to a low feedrate condition, and you also would like an indication that the feedrate went low inthe control room. The MC³ can map the Low Feedrate logical output to two different physicaloutputs allowing the action to be taken and giving an indication in the control room without usingextra hardware.

Inverting inputs and outputsYou can invert the function of the physical inputs and outputs. For example, you can have onelogical output controlling two physical outputs with one output normally closed and one normallyopen.

Forcing inputs and outputsThe MC³ also allows you to force the physical inputs and outputs On or Off. Forcing simulates theaction of switches (inputs) or relays (outputs) for an easier way to troubleshoot your system. Forexample, by forcing on the Load simulator On, and setting the tacho operational mode to“Simulator”, you can simulate a running feeder for troubleshooting purposes. Or if you want toverify the General Alarm indication in your control room, you can force the General Alarm output


On at the MC³. When you have forces in effect, there is an indication in the Main Feeder screen“FORCE(S)”.

Available logical I/O pointsThere are eight logical inputs and outputs called “Available I/O 1” - “Available I/O 8”. These logicalI/O points are both inputs and outputs, and are not used by the application. This allows you toborrow unused physical inputs and outputs from the controller to accommodate local specificneeds. For example, you may have a local emergency stop loop, and you want a indictor light forthe stopped condition. You can connect the “Not Stopped” condition to an unused physical input,map it to “Available I/O 1” and then map “Available I/O 1” to an unused physical inverted output.

External physical I/O pointsThere are 16 external physical inputs and 16 external physical outputs. They are not present in thecontroller, but are rather controlled by serial communications. This makes it possible, via asupervisory system, such as SuperBridge, to locate inputs and outputs inside a controlling PLC.The Ladder Program can have direct control over the feeder.

Digital Inputs SetupYou reach the Digital Inputs screen from Setup Screen 2. See page 33. The screenallows you to change the mapping for the Digital Inputs. The Physical inputs are mappedto the Logical inputs. The logical inputs appear to the left, and the physical inputs appear

to the right. When you enter the screen, the list of Logical Inputs is marked.

Digital Inputs setup screen

Use the up and down arrow key the select the logical input you want to work with. Map unusedlogical inputs to either “Always On” or “Always Off”. The black dot to the right of the Logical Inputname indicates the state of the Logical Input. (ON) or (OFF) The black dot to the right of thePhysical Input name indicates the state of the Logical Input. In the IV (inverted) property column, a“0” means “Not Inverted” and a “1” means “Inverted”. In the FC (forced) property column, a “0”means “Forced OFF”, a “1” means “Forced ON” and an “X” means “Not Forced”. The “RM”property column has no meaning and is not used.

TABThis button switches the marking between the Logical and Physical columns. Touchingthe TAB button makes the screen look like this:

Digital Inputs setup screen, Physical list marked.


The INV and FRC buttons become visible. Use the up and down arrow key to change the mappingfor the logical input.

CAUTION: As you move through the physical inputs with the up and down arrow keys, the logical input willimmediately change state, following the state of the physical input.

Touching the TAB button again restores the marking to the Logical column.

INV (button) / RV (indication)This button inverts the Physical Input. The character the “IV” column will toggle between“0” (not inverted) and “1” (inverted). The changes take effect immediately.

FRC (button) / FC (indication)This button controls forcing of the Physical Input. The character in the “FC” column willcycle between “X” (not forced), “0” (forced OFF) and “1” (forced ON). The changes take

effect immediately. The physical inputs “Always On” and “Always off” can not be forced.

List of Logical InputsThere are many logical inputs. You normally only use a few of them. Unused Logical Inputs mustbe mapped to either “Always On” or “Always Off”.

Logical Input Description

Feeder Block This input is used to unconditionally stop the feeder. When on,the SCR OUTPUT Analog Output goes to its zero value andthe Logical Output Feeder Running goes off.

Run Permission This input is used to start and stop the feeder in continuous,automatic mode. The feeder will run when the input is on. If theFeedrate Setpoint Mode is set to “Manual Speed”, this input isignored, and the feeder will run regardless of the state of theinput. See Feedrate setpoint on page 16.

Gravimetric This input allows the controller adjust the belt speed, using thePID control algorithm. If this is turned off the SCR OUTPUTAnalog Output value will freeze. If the Feedrate Setpoint Modeis set to “Manual Speed”, this input is ignored. See Feedratesetpoint on page 16.

Print Sends the selected print string to the printer serial port. SeePrint on page 19.

Extended Access Allows access to calibration constants in the register editor andvia communications. See Register Editor on page 63.

Load Simulator Turns on or off the belt load simulator. See Simulator on page67.

Advanced Set Allows access to the custom setup menus. Mapping this inputto Always Off, and then exiting the Digital Input screen makesit impossible to get back in again. To get around this potentialproblem, refer to Advanced Setup on page 63.

Calibr. Access Allows calibration procedures to run to completion. You canstill run calibration procedures, but you can not accept theresults.

Pulse Block This input blocks all incoming pulses from both tachos. It isuseful when performing Speed Calibration (page 49). See alsoTachometer Parameters on page 29.

Sim Load Up Increase the simulated belt load. The simulated belt loadincreases as long as the input is on, until the design belt load is


Logical Input Descriptionreached.

Sim Load Down Decrease the simulated belt load. The simulated belt loaddecreases as long as the input is on, until the zero load isreached.

Belt Running Indicates to the MC³ that the belt is running. This input isnormally connected to an auxiliary contact on the belt motorstarter when the belt runs at a constant speed, and there areno tachos attached. See Tachometer Parameters on page 29.

Register Access Allows access to the Register Editor. See page 63.

NTEP Mode This is used for certified scales to restrict access to portions ofthe menu system. It also has the same effect as turning theCalibr. Access input off.

Serial Setpoint This input forces the Feedrate Setpoint mode to RemoteSerial, page 15. See also Fallback Setpoint on page 18.

PID Controls This input turns on the PID controller feature. See Controllermodes on page 14.

Batch Controls This input turns on the Batch controller feature. See Controllermodes on page 14.

Start a Batch Starts a batch. This input has the same effect as touching theStart Batch button in the Feeder Screen (page 7).

Stop the Batch Pauses the current batch. This input has the same effect astouching the Stop Batch button in the Feeder Screen (page 7).

Clear the Batch Clears and resets the batch. This input has the same effect astouching the Clear Batch button in the Feeder Screen (page 7).

Diverter Valve Position of the grab sample diverter valve. See Grab SampleCalibration on page 56.

EMT Enabled When off, the pulses going to External ElectromechanicalTotalizer (EMT) are disabled. See External TotalizerParameters on page 44.

Total Enabled Enables the main Totalizer. When Off, the main total does notincrement.

Sub-Total Enabl Enables Sub Totalizer. When Off, the sub total does notincrement.

Zero Tracking Enables the Zero Tracking feature. See Zero TrackingParameters on page 28.

Available I/O 1 - 8 See Available logical I/O points on page 36.

List of Physical Inputs

Physical Input Description

Always Off Always returns an OFF state.

Always On Always return an ON state.

Stable Weight Unused. Unpredictable state.

Keyboard Locked Unused. Unpredictable state.


Physical Input Description

Acc Switch 1 Allows access to calibration constants in the registereditor and via communications. See Register Editor onpage 63.

Acc Switch 2 - 4 Unused. Unpredictable state.

Keyboard A1 - H4 Returns the state of a touchpad on the touch screen.A1 is upper left pad, B1 is the second pad from the leftin the upper row etc. The lower right pad is H4.

Rack 1 Input 1 through 4 Inputs on I/O rack 1, normally mounted inside thecontroller.

Rack 2 Input 1 through 4 Inputs on I/O rack 2, if present. Normally mountedoutside the controller.

Rack 3 Input 1 through 4 Inputs on I/O rack 3, if present. Normally mountedoutside the controller. The MC³ must have 2 PCIOboards to support a third I/O rack.

Rack 4 Input 1 through 4 Inputs on I/O rack 4, if present. Normally mountedoutside the controller. The MC³ must have 2 PCIOboards to support a fourth I/O rack.

Extern input 1 - 16 Inputs controlled by communications. See Externalphysical I/O points on page 36.

Acc Switch 1 through 8 Accessory Switches

Internal I/O 1 through 24 Internal I/O points

Default Input MappingAfter a RAM Reset, the inputs will be mapped according to the following setting.

Logical Input Physical Input

Feeder Block Always Off

Run Permission Rack 1 Input 1

Gravimetric Rack 1 Input 2

Print Always Off

Extended Access Always Off

Load Simulator Always Off

Advanced Set Always Off

Calibr. Access Always On

Pulse Block Rack 1 Input 4

Sim Load Up Keyboard G1

Sim Load Down Keyboard G2

Belt Running Always Off

Register Access Always Off

NTEP Mode Rack 2 Input 4

Serial Setpoint Always Off

PID Controls Always On

Batch Controls Always Off


Logical Input Physical Input

Start a Batch Rack 2 Input 1

Stop the Batch Rack 2 Input 2

Clear the Batch Rack 2 Input 3

Diverter Valve Rack 1 Input 3

EMT Enabled Always On

Total Enabled Always On

Sub Total Enabl Always On

Zero Tracking Always On

Available I/O 1-8 Always Off

Digital OutputsYou reach the Digital Outputs screen from Setup Screen 2. See page 33. The screenallows you to change the mapping for the Digital Outputs. The Logical Outputs aremapped to the Physical Outputs. The Physical Outputs appear to the left, and theLogical Outputs appear to the right. When you enter the screen, the list of Physical

Outputs is marked.

Digital Outputs setup screen

Use the up and down arrow key the select the physical output you want to work with. Map unusedphysical outputs to either “Always On” or “Always Off”. The black dot to the right of the PhysicalOutput name indicates the state of the Physical Output. (ON) or (OFF). The black dot to theright of the Logical Output name indicates the state of the Logical Output. In the IV (inverted)property column, a “0” means “Not Inverted” and a “1” means “Inverted”. In the FC (forced)property column, a “0” means “Forced OFF”, a “1” means “Forced ON” and an “X” means “NotForced”. The “RM” property column has no meaning and is not used.

INV (button) / RV (indication)This button inverts the Physical Output. The character the “IV” column will togglebetween “0” (not inverted) and “1” (inverted). The changes take effect immediately.

FRC (button) / FC (indication)This button controls forcing of the Physical Output. The character in the “FC” columnwill cycle between “X” (not forced), “0” (forced OFF) and “1” (forced ON). The changes

take effect immediately. The physical inputs “Always On” and “Always off” can not be forced.

TABThis button switches the marking between the Physical and Logical columns. Touchingthe TAB button makes the screen look like this:


Digital Outputs setup screen, Logical list marked

The INV and FRC buttons become invisible. Use the up and down arrow key to change themapping for the Physical Output.

CAUTION: As you move through the Logical Outputs with the up and down arrow keys, the PhysicalOutput will immediately change state, following the state of the selected Logical Output.

Touching the TAB button again restores the marking to the Physical column.

List of Logical OutputsThere are many logical outputs. You normally only use a few of them.

Logical Output Description

High Rate Alarm High Feedrate Alarm. The function depends on the LimitSwitch Mode setting. See Limit Switches on page 26. Action isdelayed according to the High Delay parameter.

Low Rate Alarm Low Feedrate Alarm. The function depends on the Limit SwitchMode setting. See Limit Switches on page 26. Action isdelayed according to the Low Delay parameter.

High Feedrate Feedrate is above High Feedrate. See Limit Switches on page26. Not delayed.

Low Feedrate Feedrate is below Low Feedrate. See Limit Switches on page26. Not delayed.

High Belt Load Belt Load is above Overload Limit. See Limit Switches on page26. Not delayed.

Low Belt Load Belt Load is below Underload Limit. See Limit Switches onpage 26. Not delayed.

Good Feedrate This output follows the GOOD indicator in the Main Screen. Itis normally used as a startup sealing contact. See Indicators (on Feeder Screen) on page 11.

In Control The controller is running in automatic mode, and no calibrationroutines (with the exeption of the Grab Sample routine) areactive.

Feeder Running This output is intended for the belt motor starter. Theapplication will turn this output on whenever the Feeder Beltshould be running.

General Alarm There is at least one General Alarm condition. See GeneralAlarms on page 12.

Analog Setpoint The Feedrate Setpoint Mode is either “Rem Ana” or “RemRatio”. See Feedrate setpoint on page 16.


Logical Output Description

Manual Setpoint The Feedrate Setpoint Mode is “Man Spd”. See Feedratesetpoint on page 16.

Z Tracking High The Zero Tracking load has stepped out of the load limit. SeeZero Tracking Parameters on page 28.

PID off Limits The output from the PID controller algorithm is greater than99.995% or is less than .005%. See PID Parameters & OutputDynamic Protection on page 25.

Master Com Lost Communications has timed out. See Communication Time-outon page 45.

Belt Slippage The two tachos do not comply. See Tachometer Parameterson page 29.

Always On Output is always ON ( closed ).

Always Off Output is always OFF ( open ).

Restr. Access Indicates restricted access to registers for communicationsand the register editor. See also the “Extended Access” logicalinput in List of Logical Inputs on page 37.

In Menu System The controller is in one of the SET or ACT menus.

High Speed Limit The belt speed is above the High Speed limit. See LimitSwitches on page 26. Action is delayed according to the HighSpeed Delay parameter.

Low Speed Limit The belt speed is below the Low Speed limit. See LimitSwitches on page 26. Action is delayed according to the LowSpeed Delay parameter.

Discharge Gate This output is used to control the discharge, ahead of thefeeder, gate for batching.

Batch Running On when a batch in running.

Batch Pause On when the batch has been paused.

Batch Complete On when the batch has been completed.

Batch Error On when there has been an error in the batch process, either atime-out or a batch under- or overweight. See BatchParameters on page 15

Serial Setpoint The Feedrate Setpoint Mode is “RM Serial”. See Feedratesetpoint on page 16.

AIN1 High Alarm No useful function. Do not use.

AIN1 Low Alarm No useful function. Do not use.

AIN2 High Alarm No useful function. Do not use.

AIN2 Low Alarm No useful function. Do not use.

Inferred Speed The speed used by the controller is inferred, either becausethe tacho mode is set to Simulator, or Auto-Bypass mode andthere is a tacho discrepancy condition. See TachometerParameters on page 29.

List of Physical Outputs

Physical Output Description


Physical Output Description

Rack 1 Output 1 through 8 PCIO #1 1st bank.

Rack 2 Output 1 through 8 PCIO #1 2nd bank.

Rack 3 Output 1 through 8 PCIO #2 1st bank.

Rack 4 Output 1 through 8 PCIO #2 2nd bank.

Vol Switch 1 through 8 Volatile Switches

Acc Switch 1 through 8 Accessory Switches

Internal I/O 1 through 24 Internal I/O Points

List of Default Output Settings

Physical Output Logical Output

Rack 1 Output 1 High Rate Alarm

Rack 1 Output 2 Low Rate Alarm

Rack 1 Output 3 Good Feedrate

Rack 1 Output 4 In Control

Rack 1 Output 5 Feeder Running

Rack 1 Output 6 Discharge Gate

Rack 1 Output 7 General Alarm

Rack 1 Output 8 Z Tracking High

Rack 2 Output 1 High Feedrate

Rack 2 Output 2 Low Feedrate

Rack 2 Output 3 High Belt Load

Rack 2 Output 4 Low Belt Load

Rack 2 Output 5 Manual Setpoint

Rack 2 Output 6 PID Off Limits

Rack 2 Output 7 Belt Slippage

Rack 2 Output 8 Unused

Sample RateThere are two modes of sample rates in the MC³ 24.96.EX Controller, Internal and External.Internal mode is almost always used. In external mode, the sampling is triggered by tacho 1, usingthe parameters described below.

Internal Sample Rate ParametersThe Sample Time is the interval, in seconds, between samples read from the Load Cell A/Dconverter. Limits are minimum of 0.10 and a maximum of 5.0. Default is 0.33.


External Sample Rate ParametersThe Pulse Divisor parameter is the actual number of pulses required to generate a PCAD sample.For example, if this parameter is set to 10, it would take 10 pulses from tacho 1 for every A/Dsample. Limits are minimum of 1 and a maximum of 1000.

The Min Sample Time is the shortest sample time the A/D will sync to. The default value is 0.1seconds which allows 10 samples per second. Limits are minimum of 0.10 and a maximum of 5.0.

The Max Sample Time is the longest sample time the A/D will sync to. The default value is 5.00seconds which allows 1 samples every 5 seconds. Limits are minimum of 0.10 and a maximum of5.0.

NOTE: If the incoming pulse period would generate a sample time that is higher or lower than the Max andMin sample times, the sample rate will default to the Max or Min sample times, respectively.

External Totalizer Parameters

Divide ValueThis is the value used to scale the pulse train to the EMT (External Mechanical Totalizer)output. For every lb or kg that is totalized there is a pulse if the EMT Divide Value is set

to one (1). If EMT Divide Value is set to 100, there must be 100 pounds or kilograms totalizedbefore a pulse is sent to the external totalizer. Limits are minimum 1 and a maximum of 100,000.

Pulse LengthThis value is the length in seconds for the pulse which is sent to the EMT. A mechanical totalizerwill require a longer pulse than a electronic. The pulse output from the controller is buffered, inorder to allow slow EMT’s to “catch up” and be accurate. The recommended value for amechanical totalizer is 0.10, and 0.01 for an electronic totalizer. Limits are minimum of 0.01 and amaximum of 5.0. The duty cycle should be 50% at the full pulse rate.

CommunicationsSerial Communications provides the means to exchange information between the MC³Controller and another device. For example, data in the MC³ Controller can beexchanged with devices such as SuperBridge, for PLC connectivity. The rules and

format of the data exchange is described in [1].Communications port 1 is used for communication with another intelligent device such asSuperBridge, for PLC connectivity. Port 2 is used to send strings to a serial printer.

NOTE: Failure to program communications correctly can result in the operational failure of serialcommunications.

For Baud Rate, Data Bits, Stop bits and Parity parameters, simply pressing the button for thecorresponding parameter will toggle through the list of available settings. For numeric parameters,follow the direction given in the Numeric Entry Screen section found on page 9.

Baud RateThe Baud Rate is the speed at which data is transmitted across the serial communications lines.Available baud rates are:

300


600

1200

2400

4800

9600

19200

Default is 19200 baud.

Data BitsThe number of data bits value indicates how many bits represent each character transmitted orreceived on the serial communications lines. There are only two options available, 7 or 8. Therecommended value, and default, is 8.

Stop BitsThis value is used to number of stop bits added to the end of a character transmission unit andmay be set to 1 or 2. The recommended value, and default, is 1.

ParityParity is a method of error checking during serial communications. Available selections:

NO

ODD

EVEN

MARK

SPACE

The recommended value, and default, is 8.

Numeric ParametersAn ASCII Begin Code and End Code must be designated for each message sent to and from theserial port on the MC³ Controller. Since not all computers and protocols have the same Begin andEnd Codes, an operator may wish to change them in order to attempt to communicate with non-Merrick equipment. A specific controller number is used to identify each controller on the network.

Controller NumberThis number is used to identify the numeric address of the controller when utilizing serialcommunications on a multi-drop line. No controllers connected to the same communication lineshould have the same controller number. Limits are minimum of 1 and a maximum of 64.

Comp Start CodeThis value is always sent at the beginning of a communications message. This default value is 10,for an ASCII representation of a Line Feed. To enter new values for this variable, use the arrowkeys to select you choice. Limits are minimum of 1 and a maximum of 127.

Comp End CodeThis value is always sent at the end of a communications message. This default value is 13, for anASCII representation of a Carriage Return. Limits are minimum of 1 and a maximum of 127.

Communication Time-outThis parameter is the allowed limit of no communications activity on the serial port. If this value isexceeded, there will be a Communications Lost General Alarm (page 13). Limits are minimum of 0(turns off alarm) and a maximum of 1,000,000. When communications is lost, the controller takessome automatic actions:1. Remote analog inputs are set to OFF. See External physical I/O points on page 36.


2. If the Serial Setpoint logical input is on, the controller reverts to using the Fallback Setpoint.See page 18.

NOTE: It is very important that no two controllers on the same serial line have the same controller address!This would result in both responding to a message at the same time. The results would usually beunusable data.

Set Date and TimeFor setting the date and time parameters, follow the direction given the Numeric EntryScreen section found on page 9. The application and controller hardware has beentested for the millennium shift, with regards to operation across the shift and the year

2000 being a leap year. There are no known problems. The controller is “Y2K compliant”.

PCAD Settings

WARNING: The following values are set at the factory and should never be changed.

CALThis value is used by the PCAD Converter to control an amount of positive offset added to the loadcell signal. It is used to simulate load on the load cell during an Electronic Calibration, an isnormally zero. In the rare occasion of negative dead load, a positive value can be present. Theactual offset signal is added is 0.2 mV/V times the Cal Set number.

ZEROThis value is used by the PCAD Converter to control an amount of negative offset added to theload cell signal. It is used to electronically remove dead load from the load cell signal. This allowsthe PCAD to operate at a higher gain and achieve better resolution when measuring the load cellsignal. The actual offset signal is added is -0.2 mV/V times the Zero Set number

GAINThis value is used by the PCAD Converter to control the Gain setting of the PCAD Converter. Theamount of Gain depends on how much dead load and live load there will be on the scale. Theactual Gain of the controller decreases as the PCAD Gain Value is increased. This value isnormally set to 15.

Set StatusThis value is the hardware calibration setting and is preset at the factory. This value should not bechanged.

WARNING: This number should not be changed from it’s setting of 2. DO NOT CHANGE THIS NUMBER!

CAL 0

ZERO 0

GAIN 15

Set Status 2

Number of PCAD’sIf your application requires two PCAD’s this number must be set to two to insure proper operationof the application software.

Allowed DifferenceThis parameter is the allowed difference in counts between two installed PCAD’s. If this value isexceeded the General Alarm PCAD Discrepancy will activate.


Display ParametersSome properties of the graphical display can be set here. This screen is shown when entering thedisplay setup

Touching the [INVERT DISPLAY] button makes the display operate in reversed mode. This can beused when difficult light conditions exist. The only numerical parameter that can be set is thebacklight turn-off time in seconds. Default is 3600, that is, one hour.


CALIBRATING YOUR CONTROLLERThere are four basic feeder parameters involved with calibration.

1. Belt Length. This value is simply entered into the controller, after the belt length has beenmeasured. See Length, on page 28.

2. Number of pulses for one belt revolution. This is set by the Speed Calibration procedure, page49. Together with the belt length, this value is used to determine the belt speed, belt travel andthe duration of calibration procedures. See also Pulses / Rev on page 28.

3. Zero Load. This is the load presented to the load cell or load cells by the belt and weighsuspension. It is set by the Zeroing Procedure, page 50. For this procedure to work properly,the number of pulses for one belt revolution must be correct.

4. Load Scale Factor. This is a multipliers used to convert the data from the Load Cell A/Dconverter to lb/ft or kg/m. The Material Calibration, page 51, Chain Procedure, page 52,Weight Procedure, page 53, Electronic Calibration, page 54 and Grab Sample Calibration,page 56 are all used to set the Load Scale Factor. They all require that the Zero Load is setproperly. All but the Material Calibration require accurate values for Belt Length and Number ofpulses for one belt revolution.

Before attempting to calibrate the feeder, insure that all values and parameters from theSpecification Sheet have been entered into the controller correctly. Improper entry of some valuesin the controller can cause inaccurate calibration of the feeder. Below is a checklist with the orderin which calibration tests should be accomplished. The first time a controller is installed all of theCalibration Routines listed below should be completed for proper operation. After the initialcalibration is complete, it is normal to re-calibrate the feeder periodically by completing a ZeroingProcedure and then a Calibration Procedure.

INITIAL CALIBRATION CHECKLISTThe following numbered list specifies the order that the calibration tests should be performed.

1. Measure and enter the Belt Length. See Pulses / Rev on page 28

2. Run a Speed Calibration procedure, page 49

3. Run a Zeroing Procedure, page 50.

4. If you can, run a Material Calibration, page 51, followed by a Chain Factor Procedure, page53, a Weight Factor Procedure, page 54 and an E-Cal Factor Procedure, page 55.

5. If you can’t run a Material Calibration, run a Chain Procedure, page 52, followed by aWeight Factor Procedure, page 54 and an E-Cal Factor Procedure, page 55.

6. If you can’t run a Material Calibration or a Chain Procedure, run a Weight Procedure, page53, followed by an E-Cal Factor Procedure, page 55.

7. If you can’t run a Material Calibration, Chain Procedure or Weight Procedure, run aElectronic Calibration, page 54.

8. As the last resort, use the Grab Sample Calibration method. See page 56.

CALIBRATION MENU

To enter the Calibration Menu, press the button while in the Action Menu.


Calibration Menu

The display will show the password entry screen. A four digit numeric password must be enteredat this time. The Calibration Password may be modified by selecting the “Passwords” Menu Optionfrom the Diagnostics Menu. See PASSWORD PROTECTION on page 7 for complete instructionson changing the Calibrate Password. The default (unmodified) value of the Calibrate Password is1234. While entering the password an asterisk (*) will appear for each digit entered. If the correctpassword has not been entered you will be prompted again for the Calibration Password. If thecorrect password has been entered the Calibration menu will be displayed.

NOTE: You may run any of the calibration procedures at any time, but if the logical input Calibr. Access isOFF you will not be able to accept and change any results. See List of Logical Inputs, on page 37.

Speed CalibrationThis procedure is used to set the pulses per revolution of the feeder belt for accurateindication of speed. The belt length must be measured and entered before you run thisprocedure. If there are two tachos attached to the feeder, this procedure will also set the

ratio between the two tachos.

The first screen to appear will show you the current setting of Pulses / Rev (page 28) and the #Speed Revs (page 28). See Belt Parameters on page 28 for information regarding changing thoseparameters. If two tachos are connected the ratio of tacho 2 to tacho 1 is also displayed.

If your feeder is equipped with an Feeder Connection Board (page 73) you may use the TachoPulses switch to turn the pulses on and off for this test. As an alternative, you can use the logicalinput Pulse Block. See List of Logical Inputs, on page 37. You should mark an index on the beltand on the feeder. This will make it easier to count the number of belt revolutions needed foraccurate results. When performing the test insure that you are able to see the belt and index forproper counting of belt revolutions.

1 Tacho 2 Tachos

If your feeder has a Feeder Connection Board turn off the Tacho Pulses switch. Press to start the test. Turn on the tacho pulses switch. Keep track of the number of revolutions of thebelt. As the test progresses, you will see the tacho counts accumulate on the screen.


1 Tacho 2 Tachos

When the number of revolutions is completed, turn off the Tacho Pulses switch, or hit stop and

then press the button to acknowledge the end of the test.

1 Tacho 2 Tachos

If the values are correct press to accept or to reject the results

Before proceeding with other calibration procedures or normal operation verify that pulses areturned back on to the controller.

Zeroing ProcedureThe purpose of the Zeroing Procedure is to zero the load value when the belt is empty.This procedure will measure the average load over the length and adjust the zero loadvalue accordingly. The Zeroing Procedure is accomplished by the controller recording

weight readings while the feeder is running empty. For a correct Zero Load value to be computedthe belt should be empty during the test. The controller will record load readings for a certainamount of belt revolutions. The number of belt revolutions for the test is determined by theparameter “# Proc Revs” (page 28). After the correct number of belt revolutions are reached, thecontroller will display a difference value computed for the change in the zero load value. You willthen have the option of accepting or rejecting the new zero load value.

If you do not wish to run the Zeroing Procedure, press the button to return to the

Calibration Menu. However, if you are ready to begin the Zeroing Procedure press . Thedisplay will show the percent of the test completed.


After the test is 100 percent complete the display will show the difference between the current andnew Zero Load values..

At this point the change in the zero load value as a percent of design load will be shown in the

display. If you wish to accept the new zero load value press . Otherwise, press

to abort the results of the test. Pressing either button will return you to the calibrationmenu:

Material CalibrationThe Material Calibration procedure requires that there is a way to measure the weight of thematerial fed, i.e. by collecting it and weighing it on a certified platform scale. Stop the feeder andZero the sub-total before starting the procedure. See Sub-Total on page 10. Feed the weighedmaterial over the feeder and stop it again. Then, enter the procedure by touching the MATERIALbutton.

Scale TotalizedThe MC³ Controller will suggest the current Sub Total. You may change or update the value.

Actual TotalThis is the amount of material that the MC³ Controller actually fed. This value should be accurateand verified by an external source.

Use Entering New Values on page 9 for instructions on entering values.


After entering the values press button.

The difference in percentage will be displayed.

If OK press to accept changes.

Chain ProcedureA chain that produces a known load is placed on the feeder. The controller will recordload readings for a certain amount of belt revolutions. The number of belt revolutions isdetermined by the parameter “# Proc Revs” (page 28). After the correct number of belt

revolutions is reached, the controller will display a difference between the measured load and thechain load stored in the controller. A new lads scale factor will be calculated. You will then havethe option of accepting or rejecting the new value.

NOTE: After running a Chain Factor Procedure, the Factored Chain value is used.

To begin the Chain Procedure press the button. The display will show:

If your chain has been installed and you are ready to begin the Chain Procedure press the

button. The display will show the percentage of test completed:

After the test is complete the display will show:


If the test is not accurate or if you do not wish to complete the Chain Procedure for any reason,

press the button to return to the Calibration Menu.

If you wish to accept the new values press . Otherwise, press to abort theresults of the test.

Chain Factor ProcedureThis procedure will adjust the Chain Load (page 31). The chain load is normally entered

using the value on the label on the chain. It could be adjusted to compensate for small inaccuraciesbetween the Material Calibration procedure and Chain Procedure Run this procedure onlyimmediately after an accurate Material Calibration procedure has been performed. See page 51.To run a Chain Factor Procedure, select this option from the Calibration menu. From this point onthe procedure is just like the Chain Procedure. See Page 52. After the procedure is complete thechain load will be updated. The load scale factor is not affected with this procedure.

Weight ProcedureThis test is used when a Material Calibration or Chain Procedure can’t be performed.The Weigh Span, page 31, must be accurately measured and entered for this procedureto work. A calibration weight is placed on the feeder, usually by hanging off the weigh

suspension The number of belt revolutions for the test is determined by the parameter “# ProcRevs” (page 28). After the correct number of belt revolutions is reached, the controller will display adifference between the measured weight and the weight stored in the controller. A new lads scalefactor will be calculated. You will then have the option of accepting or rejecting the new value.

To begin the Weight Procedure press the button. The display will show:

If your weight has been installed and you are ready to begin the procedure press the button. The display will show the percentage of test completed:


After the test is complete the display will show:

If the value is not accurate or if you do not wish to complete the procedure for any reason, press

the button to return to the Calibration Menu.

If you wish to accept the new values press . Otherwise, press to abort theresults of the test.

Weight Factor ProcedureThis procedure will adjust the Weigh Span (page 31). The weigh span is normally

entered by measuring the length of the weigh suspension. It could be adjusted to compensate forsmall inaccuracies between the Material Calibration or Chain Procedure and Weight ProcedureRun this procedure only immediately after an accurate Material Calibration or Chain Procedure hasbeen performed.To run a Weight Factor Procedure, select this option from the Calibration menu. From this point onthe procedure is just like the Weight Procedure. See Page 53. After the procedure is complete theweigh span will be updated. The load scale factor is not affected with this procedure.

Electronic CalibrationThe Electronic (E-Cal) Procedure is provided as a third method to calculate the internal Load ScaleFactor. The E-Cal Procedure is used when it is not convenient to run either a Material, Weight or aChain Procedure on the feeder. The E-Cal Procedure is made possible by the ability of the MC³PCAD Board to simulate a load on the load cell. For this procedure to be accurate, the E-Calliveload mV/V value must be correctly calculated and entered. See E-Cal Liveload, on page 31.Requirements for performing an E-Cal Test are as follows.If the calculated Live Load has changed from the specification sheet, “Load Cell Live Load” insection “Machine Data”, use the following formula to calculate the E-Cal Live Load mV/V:

ECal Load mV / V = Design Live Load * mV / V rating of Load Cell * Weigh Span

Capacity of Load Cell


To start the test press the button from the Calibration menu.

If the E-Cal Load mV/V is not accurate or if you do not wish to complete the E-Cal Procedure for

any reason, press the button to return to the Calibration menu.. If you are ready to

execute the E-Cal Procedure, press the button.

During the test, the percentage completed will be displayed on the controller.

After the test is complete the display will show the error percentage.

At this point the proposed change in the internal Scale Factor as a percent of design load will be

shown. If you wish to accept the new value press button , otherwise, press toabort the test.

E-Cal Factor ProcedureThis procedure will adjust the E-Cal Liveload (page 31). It could be adjusted tocompensate for small inaccuracies between the Material Calibration, Chain Procedure orWeight Procedure and Electronic Calibration Run this procedure only immediately after

an accurate Material Calibration, Chain Procedure or Weight Procedure has been performed.


To run a E-Cal Factor Procedure, select this option from the Calibration menu. From this point onthe procedure is just like the Electronic Calibration. See Page 54. After the procedure is completethe weigh span will be updated. The load scale factor is not affected with this procedure.

Grab Sample CalibrationUse this method only as a last resort. It sets the Load Scale Factor, while the feeder is running,using a diverter valve in the material flow, and a separate totalizer for the grab sample. A limitswitch on the diverter valve must be connected to the logical input Diverter Valve. See List ofLogical Inputs on page 37. After opening and closing the diverter valve, and then weighing thediverted sample, enter the GRAB SAMPLE screen.

Enter the weight of the diverted material by touching the Sample Weight button, then touchACCEPT.

You will be presented with the difference, new and old scale factor, and have the option to acceptor cancel the procedure.

Analog Input Setup and CalibrationThis procedure allows you to setup and calibrate your analog inputs.

Touch the number of the analog input to calibrate or touch the analog in alarms button to edit theanalog input alarm values.


Adjust the input for a zero level. The live counts will vary accordingly. When zero is reached touchthe snap zero button. The live value will snap to the new value column.

Adjust the input for full scale level. The live counts should follow the input. When the full level hasbeen reached touch the Snap full button. The live value will snap to the new Hi column.

If the values you selected are correct for your application, touch the accept button. You will beasked if you want to edit the values. This gives you the opportunity to perform fine adjustments tothe zero and full level values.

If you want to manually adjust the values, press the Yes button. The numeric entry screen foranalog inputs will be displayed (see Analog Inputs on page 33). When editing is completed thecontroller will return you to the analog input setup screen.


DIAGNOSING PROBLEMS

DIAGNOSTIC MENUSThe Diagnostic Menu for the MC³ Controller is provided to allow access to additional displays andvalues. It is not necessary to access this menu under normal operating conditions. It is provided asa troubleshooting tool and should be accessed only by knowledgeable personnel. The DiagnosticMenu has its own password.Access to the Register editor is only allowed if the logic input “Register Access” is ON. See List ofLogical Inputs on page 37. If the logical input is OFF, the button for the Register Editor will notappear on the diagnostic screen.

CAUTION: The values in this menu are very sensitive. Changing any of these values could adversely affect theoperation of the Feeder Controller.

PCAD Diagnostics

LdThis value is the belt load in engineering units.

Out %This value is the Feeder Control output with a range of 0 to 100%

PCAD1 and PCAD2A/D Counts are a digital representation of the analog load cell signal. These are the raw A/Dcounts developed from the Load Cell signal without any numeric adjustment or filtering.

LLThe Live Load mV/V is the relative output signal of the load cell, representing the live load of theweight as a Load Cell output signal.

AbsThe Absolute Load mV/V is the relative output signal of the load cell all load including supportstructure, zero load and material.


CntsThis display is the raw, digital representation of the total load as it is received directly from thePCAD. It is the same as PCAD #1 If one PCAD is used. It is the average of PCAD #1 and PCAD#2 if two PCAD’s are used.

Z LdThis is the Zero Load, as set by the Zeroing Procedure, page 50.

An example for which it might be necessary to change this value directly, would be to return a scaleto a known Zero Value after the system has been reset or damaged in some way. After a goodZero Calibration has been accomplished, it is a good idea to record this number for futurereference.

SettingsCAL, ZERO, GAIN, SET STAT.

A thorough discussion of the meanings of these setting is discussed in PCAD Settings on page 46.

Scale FactorThis number is the ‘Internal Scale Factor”. It is used to provide a relation between the PCADCounts (from the Load Cell signal) and the actual Belt Load in engineering units. It is set by variouscalibration procedures. See Calibrating Your Controller, on page 48.

It is important to remember that modifying this value affects calibration directly.

An example for which it might be necessary to change this value directly, would be to return a scaleto a known calibration after the system has been reset or damaged in some way. After a goodcalibration has been accomplished, it is a good idea to record this number for future reference.

Communication DiagnosticsThis display is useful when troubleshooting serial communications.

Rx BufferThis line displays the first 28 characters in the receiver buffer.

Tx BufferThis line displays the first 28 characters in the transmitter buffer.

NOTE: Not all characters can be displayed so some may appear as spaces.

Error Counters

Counter Description

A Receive Errors on the character level, such as parity error, etc.

B Number of characters received with a format error

C Input Buffer Overrun Errors. The incoming telegram was too long.Check the Start and End codes. See Numeric Parameters onpage 27


Counter Description

D Number of messages received with a bad message format.

E Number of Communication Interrupts. This counter increments forevery character received or transmitted.

F Last Serial Communications UART Status word with an error bitset. See LSR - on page 60.

IIR -This is the value in the UART Interrupt Identification Register. It is bit coded according to thefollowing table:

Bit Description

0 Modem status changed

1 No interrupt pending

2 Transmitter buffer empty


4 Receiver buffer full


6 Receiver buffer full and receive character error


LSR -This is the value in the UART Line Status Register. It is bit coded according to the following table:

Bit #r Description

Bit 7 Not used.

Bit 6 Transmitter Empty - holding register and shift register.

Bit 5 Transmitter holding register empty.

Bit 4 Break detected.

Bit 3 Framing Error

Bit 2 Parity Error

Bit 1 Overrun Error

Bit 0 RxRD Receive Data Ready

TX -This is the status of the message transmitter function.

Value Description

0 Transmitter passive

1 Transmitter active

2 The last byte of the telegram is being transmitted


RX -This is the status of the message receiver function.

Value Description

0 Waiting for start char

1 Waiting for controller address

2 Addressed, Buffering characters

3 Message received, not processed

Communication ParametersFor a thorough explanation of communication parameters see Communications on page 44.

Tacho DiagnosticsThe tacho diagnostics screen allows you to troubleshoot your tachos. See also TachometerParameters on page 29.

Two tachos One tachoThe screen looks different depending on the number of tachos used. The speed sensingoperational mode and tacho modes are show, along with current values.

EMT PULSThe number of buffered pulses for the EMT. The controller can buffer pulses for the EMT if a slowcounter is used. This is the number of EMT pulses not yet delivered to the EMT. See ExternalTotalizer Parameters on page 44.

PTPulse counter. Increments with incoming pulses.

TSTPulse counter for the ongoing discrepancy test run. These parameters are used to detect beltslippage or malfunctioning tachos.

Blt TrvlBelt travel, in m or ft, per PCAD sample. See also Sample Rate on page 43.

Curr ratioThe ratio of pulses between tacho 1 and tacho 2. This value is updated continuously during theongoing discrepancy test run.

Diff %The difference in ratio between the ongoing discrepancy test run and the set value from the SpeedCalibration. See page 49. This value is compared with the max. limit in Tachometer Parameters(page 29) to determine if a belt slippage exists.


Analog I/O Diagnostics

This diagnostic screen displays the current function and type for each of the Analog outputs. The“Actual” column in the output section displays the current value of function selected for theparticular output. The “EST-mA” column displays the estimated milliamp value for the output. SeeAnalog Outputs on page 33 for more information.

In the Input section the current analog counts, the percentage of the allowed range and the valuebased on the scaler for the particular input are displayed. See Analog Input on page 33 for moreinformation.

Digital I/O DiagnosticsThe button between the up and down arrows toggles between Digital Outputs and

Inputs. The up and down arrow buttons are used to page the digital I/O points.

For more information see Digital I/O Mapping on page 34.

= OFF = ON

ST - Current status of I/O point.

IV - Invert the I/O point.

0 The Physical I/O point is not inverted.

1 The Physical I/O point is inverted.

FC - Force the I/O point ON, OFF or Normal Operation.

0 I/O point is forced off.

1 I/O point is forced on.

X I/O point is under normal operation.

Register Monitor


This screen is used to monitor the values of specific registers. The display includes the registernumber, the value and the register name.

To setup the register pointers you must have access to the Register Editor and a register list.Determine the number of the register ‘ai_regptr0’. Enter this value into the register number field(R[ ]) in the register editor. Tab to the register value entry field. Clear and enter the number of theregister you wish to view in the monitor. You may enter up to eight different registers for viewingwith the register monitor.

Register EditorUse of the register editor is simple. The ‘>’ symbol is used to denote the active line.

The top line displays the current register number. The second line displays the register name andthe value that the register contains.

Before entering new values into the controller , you must clear the previous value bypressing the button.

The tab button is used to switch between the Register Number line and the RegisterName/Value line.

The left arrow is used a backspace key in the register editor.

The up and down arrow buttons are used to scroll up and down through the register list.This works when either the register number or register name is the current selection.

Advanced SetupThis function allows entry into the Custom Setup menus (page 23) if the logical input“Advanced Set“ has been switched off for any reason.

Quick SetupThis button can be used to quickly set up reasonable controller parameters based on basic designparameters (design speed, design load and design feedrate).

Parameter Quick Setup value

Load decimal points To produce five significant digits in the display

Total decimal points None for kg or lb, two for TN and t


Parameter Quick Setup value

Belt length decimal points Three

Feedrate decimal points To produce five significant digits in the display

Speed decimal points To produce four significant digits in the display

Totalizer cutoff Negative 10% of design load

Scaler for analog input 1 Design Feedrate

Low Feedrate 10% of design feedrate

High Feedrate 90% of design feedrate

Low and high absolutesetpoint deviation

10% of design feedrate

Overload Limit Design load

Underload Limit Negative 10% of design load

High Speed Design speed

Nominal speed (no tacho) Design speed

Max Zero Track Load 10% of design load

Max Zero Track Step 1% of design load

Max Zero Track 4% of design load

SOLVING PROBLEMSIf the following procedures do not assist in solving your problem, see Technical Support on page 2on obtaining factory support for your controller.

Unit does not power upWARNING: Only Qualified service technicians should work on the controller. When working with live voltages

insure all safety precautions are taken..

1. Check wiring harnesses, Power running to the controller

2. Verify that the fuses are good. There are two fuses in the controller. One is in the powerreceptacle and the other is on the power supply board.

3. Using a volt meter, verify that 110V is present at the power supply

4. Verify that the +5 volt and ±12 volts at the power supply are good.

Controller Fails to Boot Up1. If the message “Bad Register Checksum, Press OK to Continue” appears during boot-up, hit

OK and the controller should continue to initialize. After the controller has initialized, check allsettings carefully before operating the Feeder.

2. By pressing the upper left and right corners of the touch screen simultaneously duringinitialization, a screen will be displayed that will ask if you would like to reset the registers toreasonable values. This will set the feeder to the factory defaults, which will be different fromyour actual setup. You must re-enter all of your operating parameters and re-calibrate thefeeder before normal operation can resume.

WARNING: Make sure that you check all settings carefully before starting the feeder. Otherwise the feedercould operate in an unsafe mode.


LCD Display too dark or too light1. The contrast of the LCD display is affected by large temperature changes. You may need to

adjust it. The contrast adjustment (R3) is located inside the controller on the backside of thedisplay assembly in the upper right hand corner.

2. The LCD backlight may be burned out and need to be replaced. This can be verified byremoving the top of the controller and looking at the display assembly. With power applied youshould see light from the backlight coming from the bottom of the assembly.

No load, or bad Load Reading1. Check all wiring connections.

2. Has the scale been properly calibrated? If not, see Calibrating Your Controller (page 48) forproper setup procedures.

3. Inoperative PCAD, Counts = 0 or 16,777,215. If there is no response and you are using 5 wireLoad cell connections insure that the sense signal lines are connected to the excitation voltage.

4. Check and make sure the correct number of PCAD’s installed is entered in PCAD Settings(page 46).

Tacho not counting pulses, or no speed indication1. Check all wiring.

2. Verify Logical Input “Feeder Block” or “Pulse Block” is not set.

3. Make sure that the correct type of encoder is selected in the setup menu, and the Speedcalibration has been run.

4. In the ‘Large Font Display’ screen, select ‘PULSES’ for one of the displayed values. Verify thatyou are receiving pulses from the encoder.

5. Check to see that the correct mode (direction) is selected in Tachometer Parameters (page29). If R-Hand or L-Hand direction is selected, try setting the direction to “No Direction” andverify that pulses are detected.

6. Check that the proper number of Tachos installed is entered in Tachometer Parameters onpage 29. The MC³ can support 2 encoders but only channel 1 is used for speed detection.

7. If you are using a Feeder Connection board between the MC³ and the encoder, make sure theTacho Pulses switch is in the ‘ON’ position.

No analog Input1. Check all wiring, make sure that the polarity is correct.

2. If possible, place a current meter in series with the current loop and verify that current ispresent and the polarity is correct.

External Totalizer problems1. Check and verify all wiring and connections are correct.

2. If you are using a DC EMT, check the polarity of the connection between the EMT and thecontroller are correct.

3. Check the External Totalizer Parameters on page 44 and verify that the Divide Value andPulse Length values are correct for your installation.

General Alarms1. Refer to General Alarms (page 12) for specific information on each specific alarm condition.


No Serial Communications1. Check all cables and wire harness

2. Check the serial port settings in Communications on page 44 (baud rate, data bit, stop bits,parity.)

Hang Message AppearsThe hang screen message will appear if an error occurs within the control software that couldeffect the safe operation of the system. If the hang screen appears, write down the exact error thatis displayed on the screen and call customer support at Merrick Industries. Several types of errorsmay cause the controller to reset or reboot. If this occurs verify all parameters.

HARDWARE CALIBRATION AND TESTINGThe MC³ was calibrated and tested at the factory before it was shipped. The following procedurescan effect the accuracy of the controller and should only be performed with extreme caution.

WARNING: Always disconnect the MC³ from the feeder before attempting to test or calibrate hardware. Failureto do so could damage the feeder or cause personal injury.

Analog Outputs1. Attach a milliamp meter to the analog output to be adjusted.

2. In the Analog Output setup menu, select ‘Feeder Control’ and ‘0-20mA’ for the output that youare calibrating.

3. In the setpoint menu, select ‘Manual Spd’. Set the controller output to 0%.

4. If you are calibrating analog output 1, adjust the ‘A01 Z’ pot (R68) until the meter reads 0.0milliamps.If you are calibrating analog output 2, adjust the ‘A02 Z’ pot (R66) until the meter read 0.0milliamps.

5. In the setpoint menu, set the controller output to 100%.

6. If you are calibrating analog output 1, adjust the ‘A01 S’ pot (R67) until the meter reads 20.0milliamps.If you are calibrating analog output 2, adjust the ‘A02 S’ pot (R65) until the meter read 20.0milliamps.

7. Set the controller output to 50% and verify that 10 milliamps is read on the meter.

Analog InputsTypically, a current source is not available, so the easiest way to adjust the analog input is to feedthe analog outputs back into the analog input. This can be done by using jumpers from the analogoutput to the analog input. To calibrate the Analog Input using the 24.96.EX application you musthave access to the register editor. The following procedure assumes you are using analog output1.

1. Jumper from analog output 1 to the analog input, make sure the polarity is correct (positive topositive, negative to negative).

2. In the analog output menu, set analog output 1 to ‘Feeder Control’, ‘0-20mA’.

3. In the setpoint menu, select ‘Manual Spd’. Set the output to 0%.

4. Go to the register editor and select the al_aninst1 register (this is register 385 for version0.3A).

5. Adjust ‘AIN Z’ (R64) until the register just reads 0 (the best way to do this is approach zerofrom the positive side).

6. In the setpoint menu, set the output to 100%


7. Adjust ‘AIN S’ (R63) until the register reads 1,000,000 counts.

8. In the setpoint menu, set the output to 50%

9. Verify that the register reads 500,000 counts.

PCADTo calibrate the PCAD requires a precision load cell simulator and therefore can not be calibratedin the field. However, to gain some confidence that the PCAD is working correctly use the followingprocedure.

1. Create a dummy load cell by: shorting the Excite + to Sense + (pins 2 & 3), shorting the inputsignal (pins 4&5), short Excite - to Sense - (pins 6&7).

2. Attach the dummy load and turn on the controller (this is important that the dummy load cell beattached when the power is first turned on.)

3. In the diagnostic menu select the PCAD settings menu. Set the CAL setting to 3.

4. Go to the PCAD diagnostic menu and the PCAD1 counts should be around 200,000.

5. Return to the PCAD settings menu and return the CAL setting to 0.

Simulator1. A load and speed simulator is available for demonstration purposes and to assist in

troubleshooting problems. To invoke the simulator, map the ‘simulator load’ and/or ‘simulatorspeed’ logical inputs to the physical input ‘always on’ in the Digital Input setup menu (See thesection on I/O mapping). To disable the simulator, map the ‘simulator load’ and/or ‘simulatorspeed’ logical inputs to the physical input ‘always off’ in the Digital Input setup menu.

WARNING: Make sure the simulator functions are turned off before attempting to operate a feeder.


WORKING WITH INPUTS AND OUTPUTSThe MC³ is capable of processing many different types of inputs and outputs. Most of theconnections necessary for the inputs and outputs are located on the Backplane Board. Pleaserefer to the electrical connection diagram for the physical layout of all input and output connections.

Rear View (standard configuration)

LTI BOARD

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

TX+ TX- RX+ RX- GND 1A 1B 2A 2B +12VDC

+5VDC

10 11

AC EMT

-+TachoRS-485 DC EMT

A B

EMTThe EMT outputs are provided to you for connection to a remote totalizer. Both AC and DC pulseoutputs are available. See “External Totalizer Parameters” on page 44 for more information.

TachoIf only one tacho input is to be used it must be in the A position. The mode should be No -Direction.See Tachometer Parameters on page 29 for more information regarding tacho parameters.

Serial CommunicationsSerial Channel #1 is an RS-485 port. The baud rate, parity, stop bit settings and protocol of theports are setup in the software. For further information on configuring the Serial CommunicationsBoard and its interface to different types of serial equipment, see Communications on page 44.


PCIO BOARD

1 2 3 4 5 6

Digital I/O2 Digital I/O1AOUT 1 AOUT 2 AIN 1

+ + + --- 1

2

15

16

1

2

15

16

OUT4

OUT5

OUT6

OUT7

OUT8

OUT3

OUT2

OUT1

GND

+5VDC

GND

IN4

IN1

IN2

IN3

+5VDC

151 3 5 7 9 11 13

2 4 6 8 10 12 14 16

Digital I/O Pin Layout

Digital I/O

Digital InputsThe digital inputs are provided so that the customer may provide logical on/off signals to the MC³Controller. The default digital input is:

Digital OutputsThe digital outputs are provided so that the customer may use these outputs as status indicators.The default digital output map is:

Analog I/OLocated on the PCIO board are straps to convert the analog signals from current to voltage.

Strap top row for current outStrap bottom row for voltage out

Strap forCurrent Input

Ana Out 2 Ana Out 1

Analog IO ConnectorDigital Rack 2

This example is set for Current input and output.

Analog InputsOne analog input is available for changing the Setpoint. See “Analog Input” on page 33.

NOTE: If the analog signal is a current input then a jumper must be installed. If the input is a voltage, ajumper must be removed for proper conversion.


Analog OutputsIsolated Analog Outputs are provided with the PCIO Board. There is a maximum of two outputs perboard. With two PCIO, a maximum of four analog outputs can be used. See “Analog Outputs” onpage 33.

PCAD BOARDThe transducer (load cell) connections are on the PCAD Board. There is a strap on this board toswitch between normal operation and Zener Barrier operation.

1 2 3 4 5 6 7 8

+OUTPUT

-OUTPUT

+SENSE

-SENSE

-EXCITE

+EXCITE

SHIELD

NO

CONNECT

KEYBOARD LOCATION CODES

A1 B1 C1 D1 E1 F1 G1 H1

A2 B2 C2 D2 E2 F2 G2 H2

A3 B3 C3 D3 E3 F3 G3 H3

A4 B4 C4 D4 E4 F4 G4 H4

PRINTER PORTMC³ CPU board must be specifically configured for Printer operation. Call Merrick for details toverify your CPU board configuration.

Pin # Description

1 N/C

2 TX Data

3 N/C

4 N/C

5 Ground

6 N/C

7 Clear to send

8 N/C

9 N/C


STORAGE

STORAGE ON RECEIPT FROM FACTORY

Storage Longer than 6 MonthsOutside storage is NOT recommended. If at all possible, store electrical equipment in a heatedwarehouse, above freezing temperatures.The same precautions as above apply, plus the following:Operate all electrical and electronic equipment at least once a year for a minimum of two hours,preferably during a low humidity season. Operate all switches at least ten times and allow theequipment to obtain normal operating temperature before turning off. Allow units to cool beforerepackaging and returning to storage.If stored in a warehouse with temperatures below freezing, the above applies, plus the following:

Storage up to 6 MonthsKeep all equipment dry and well above the ground. If the equipment has been in transit for twomonths or longer, replace the factory supplied desiccant (if so equipped) before placing in storage.The use of evaporative corrosion inhibitors is recommended, but not mandatory.

STORAGE FOLLOWING USEA. Clean all equipment and enclosures thoroughly inside and out.

B. Remove rust as necessary. Touch up painted surfaces as necessary to protect baremetal surfaces. Protect electrical and electronic components from painting operations.

C. Place desiccant or evaporative corrosion inhibitors inside control enclosures.

D. Observe storage instructions as above for storage before use.

OPERATION AFTER STORAGEWhen electrical equipment has been stored at either high humidity or low temperature, do notapply power until the equipment has been allowed to stand at ambient conditions a minimum of 3hours.Remove all packing and/or protective materials. Remove all desiccants.Refer to Installation on page 6 for proper installation and start-up procedures.


SPARE PART LISTThis section contains a typical parts lists to assist you in identifying necessary parts, should aproblem develop with your MC³ Controller unit or a part become lost or damaged. Depending onthe options ordered with your unit, it is possible that not all parts shown will be present in your unit.If you need further assistance, or would like to place a parts order, please contact the MerrickSpare Parts Department.

MC³ CONTROLLER SPARE PARTS LIST

Description Part Number

Power Supply Assembly BMKM21912-1A

Fuse BMKQ-73

CPU Board BMKM21746-1A

HPAD Board #1 BMKM21701-1A

HPAD Board #2 BMKM21701-2A

PCIO Board #1 BMKM21735-1A

PCIO Board #2 BMKM21735-2A

LTI Board BMKM21689-1A

Display Assembly BMKM21729-2A

ACCESSORIES FOR THE MC³ CONTROLLER

I/O System


Backplane Board BMKM21882- 1

Cable - 9 inch BMKM20184- 6

Cable 12 inch BMKM20184- 5



Spare I/O Plugs


4 Pin BMK09-204-40401

6 Pin BMK09-204-40601

8 Pin BMK09-204-40801

11 Pin BMK09-204-41101

Miscellaneous


Grounding Bar BMKFE11887

Power Cord BMKFE11270


Feeder Connection

Name Part Number Description

Feeder Connection Board Only MKM21911-1 1 Load Cell

Feeder Connection Board Only MKM21911-4 4 Load Cells

FCB Assembly MKA31196-1 NEMA 4 SS Enclosure 1 Load Cell

FCB Assembly MKA31196-2 NEMA 4 SS Enclosure 4 Load Cell

FCB Assembly MKA31196-3 NEMA 4 Std Enclosure 1 Load Cell

FCB Assembly MKA31196-4 NEMA 4 Std Enclosure 4 Load Cell


APPENDIX A

MC³ PANEL MOUNT - DIMENSIONS

Front View

Top View


Side View

WALL MOUNT - DIMENSIONS

mc³ controller - merrick-inc.com manual 2496g.pdf · mc³ controller operation and maintenance...

Documents