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MERRICK MC3 35.00.EX Operation And Maintenance Manual Download Page 14

 

HARDWARE 

The MC³ Controller has been designed to control many different types of feeding, 
weighing and metering equipment.  This allows for easier maintenance and simplified 
training.  

The Standard Merrick MC³ 35.00.EX Controller consists of an Enclosure, an LCD 
Display, Card Stack and a Power Supply. Refer to MC³ Hardware manual for details. It is 
available for download from 

[MCT]

. 

The hardware manual describes the different enclosures, installation, wiring and 
hardware related configuration and troubleshooting. 

35.00.EX O&M Manual 

 

10 

Summary of Contents for MC3 35.00.EX

Page 1: ...C 35 00 EX Weigh Out Batch Controller Operation and Maintenance Manual Version C MERRICK INDUSTRIES INC 10 Arthur Drive Lynn Haven FL 32444 U S A Tel 1 850 265 3611 Fax 1 850 265 9768 www merrick inc com ...

Page 2: ...from Merrick Industries Inc for use only in operation or maintenance of such equipment Such information in this manual is not to be used disclosed copied or reproduced in whole or part for any use other than that indicated above or for any other purpose detrimental to the interests of Merrick Industries Inc Patents owned by Merrick Industries Inc have been issued or are pending on at least some of...

Page 3: ...llation 11 Stable Samples 28 Starting the controller 11 Calibrate Settings 28 Quick Setup 11 Cal Weight 28 Main Screens 12 E Cal Liveload 28 Main Screen 12 Zero Weight 28 Batch Statistics Screen 13 Scale Factor 28 Warnings 14 Quick Setup 28 Faults 15 Sample Rate 29 Setting the Setpoint 15 Display Parameters 29 Manual Setpoint Method 17 Backlite Off 30 Action Menu 17 Displayed FR 30 Batch Control B...

Page 4: ... The Crash Screen 54 Start Up Crash 54 Parameter Corruption 54 Controller Firmware Upgrade 54 Fatal Error Crash 55 Forcing a Parameter Reset 56 Diagnostic Menus 56 HPAD Diagnostics 56 Communication Diagnostic 57 Clean Off Screen 59 Calibrate Diag 59 Analog Diagnostics 59 Digital Diagnostics 60 Mapping view 60 List View 61 Faults and Warnings Diagnostics 61 DF1 Diagnostics 61 Register Monitor 61 Mi...

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Page 6: ...rely connected Proper grounding not only helps insure your personal safety but also 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 keep one hand clear of the machine the cabinet or any other conductors to avoid the possibility of electrical shock traveling across your chest 4 NEVER impair or disable the f...

Page 7: ...ubleshooting section to assist in solving technical problems Diagnosing Problems page 54 Technical Support Merrick provides customer technical and spare part support 24 hours a day seven days a week Assistance is available by calling 1 850 271 7878 After normal business hours you will receive instructions on how to reach the support technician on call You can also email support merrick inc com Whe...

Page 8: ...g Setpoint Filter Rate Calculation State Logic Hopper Parameters Batch Parameters Feeder Speed Demand Signal Stability Calculation The MC 35 00 EX controller uses a self correcting algorithm to optimize batch accuracy and batch performance There is always a trade off between the two meaning that that faster batching reduces batch accuracy and vice versa Key parameters Each of the function blocks a...

Page 9: ...ormally zero SP Max Value This is the maximum setpoint value normally the same as the Max Batch Weight for the feeder Setpoint filter A fluctuating setpoint is undesirable To avoid fluctuations due to noise on analog signals or in networked follower implementations this averaging filter can be used to produce a smoother value It takes the Batch Setpoint as input and produces the Average Setpoint R...

Page 10: ... used Curr Preact As the Batch Total approaches the Setpoint the controller will turn off the feeder before the batch total is reached The switch point is when the batch total equals the setpoint plus the Preact Hence the Preact is typically a negative value The parameter is normally adjusted by the controller after every batch Preact Limit Absolute limit of the Preact positive or negative Pre Max...

Page 11: ...out by time The hopper is cleaning out the weight is below the Empty Weight Idle Empty 28 Cleanout Completed The hopper is cleaned out and there is still a cleanout command Idle BLOCKED 2 Idle Blocked or Manual Setpoint Method is Manual there is a Fault or the Feeder Block logical input is On Stable Chk 5 6 Stable Weight before feeding The stable weight before start of feeding is being acquired Fa...

Page 12: ...nou t Clear Batch Paused Note 1 Stable Chk Before Re fill Cleanout weight Idle Note 2 Idle Note 1 Stable Chk Before Re fill Cleanout weight Idle Note 2 Stable Chk Before Fast Feed Idle Note 2 Fast Feed Note 3 Fine Feed or Re fill Note 3 Stable Chk After Paused Stable Chk After Re fill Stable Chk Cleanout Idle Note 2 Fine Feed Note 4 Stable Chk After Stable Chk After Paused Stable Chk After Re fill...

Page 13: ...when the block condition occured Issuing commands There are three sources for commands 1 Local from the MC screen 2 Remote by means of Logical Inputs mapped to Physical Inputs The logical inputs are named Rem Start Batch Rem Stop Batch etc 3 Network by means of Logical Inputs mapped to External Inputs The logical inputs are named Net Start Batch Net Stop Batch etc By default Local Remote and Netwo...

Page 14: ...mplified training The Standard Merrick MC 35 00 EX Controller consists of an Enclosure an LCD Display Card Stack and a Power Supply Refer to MC Hardware manual for details It is available for download from MCT The hardware manual describes the different enclosures installation wiring and hardware related configuration and troubleshooting 35 00 EX O M Manual 10 ...

Page 15: ...l operations are being performed This sequence takes twenty seconds The start up screen counts down the time remaining during the start up sequence Check for any error messages during the power up sequence Start up Screen 3 The controller is normally pre programmed from the Merrick Factory for your specific application A document called the Programming Specification Sheet Spec Sheet is inserted in...

Page 16: ... be close to what the system can obtain at 100 output 4 Perform the Quick Setup page 28 function This will set reasonable values for parameters in the controller 5 Verify all parameters for correct values 6 Run test batches and adjust the stability parameters so that the weight is stable when idling and not stable while fast feeding MAIN SCREENS There are two main screens Main Screen Default view ...

Page 17: ...ator Blank when the hopper weight is unstable 11 22 04 Date Format Month Day Year 01 45 PM Time Format Hour 0 12 Minute AM PM Batch Statistics Button to reach the Batch Statistics screen Batch Statistics Screen A statistics screen is available to monitor immediate data about the current batch as well as some statistics Batch Statistics Screen Item Description Fast Feed Variable text for Batch Stat...

Page 18: ...ror in is calculated 100 S S T E n n n n Where E is the error T is the Batch Total and S is the Batch Setpoint The Mean Error X Merr is recursively updated 1 n E X n X n n 1 n Merr should converge to Zero if the Batch Parameters are set correctly Finally the Standard Deviation D SDev is recursively updated 2 n 1 n 2 n 1 n X E 1 n 1 n 1 n D D Warnings A Warning indicates a potential problem and cal...

Page 19: ...ify a fault See Digital I O Mapping on page 34 The Fault button is visible in the main screen if there is an active fault condition or there has been a fault condition that has not yet been acknowledged Main Screen with Faults Indicator Pushing the Fault button takes you to the Fault screen The following screen shot shows the default faults Your I O configuration may be different producing a diffe...

Page 20: ...ong as there is no communication timeout If a timeout occurs the Remote setpoint is used Remote Fallback fr Network Remote inputs are used because there is a communication timeout Before the timeout occurred the Network Fallback to Remote setpoint was used The fallback scheme is engaged by turning on the Force Comm SP logical input See Logical Inputs on page 35 The Curr 10 00 lb text indicates you...

Page 21: ... adjusting the Feeder Drive or when troubleshooting NOTE You can only select the Manual Speed method when the controller is in the Idle state ACTION MENU Pushing the Action Menu button anywhere takes you to the Action Menu This is where you start and stop the feeder and perform maintenance tasks Action Menu This is what the Action Menu looks like when the feeder is in the Idle state waiting for a ...

Page 22: ...ny time When cleared a message Subtotal Cleared appears on the screen Reset G Total Clears the Total If you use a non zero calibration password you will be asked to enter it Enter the password to clear the total or push the ESC button in the password screen to escape to the action screen without clearing the Master Total When cleared a message G Total Cleared appears on the display Diag Menu Takes...

Page 23: ... the strings The string to edit is selected in the function These allow you to move character by character in the selected print string Pushing 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 alphanumeric characters on the buttons If a button has two lines displayed the upper set is selected by pushi...

Page 24: ...otal PF4 Date Prints the MC date PF5 Time Prints the MC time PF6 Clear Sub total Clears the Sub total PF7 Counter Prints the value of the print counter PF8 Increment counter Increment the counter PF9 Net Weight Prints the current Net Weight PF10 Feedrate Prints the current feedrate PF11 Setpoint Prints the current setpoint PF12 Register value Prints the value of a register PF13 Weight unit Prints ...

Page 25: ...Settings Menu This is where you set up all the controller parameters See Setting Up Your Controller below 35 00 EX O M Manual 21 ...

Page 26: ...ated parameters the controller displays three at a time otherwise it will only show one parameter The active parameter is enclosed in a rectangle Any button entry will act upon this value Typical Numeric Entry Screen First find the value by using the Up or Down arrow buttons to scroll to the parameter to be changed Enter the new value for the selected parameter using the numeric buttons The displa...

Page 27: ...imal point selection values See below Even if no changes to the decimal points are necessary you should at least look at each decimal point setting Set Dec Pts Internally the MC Controller uses floating point numbers Any changes to the decimal point settings affect only the display of the values It is a good idea to set the number of decimal places so that you get 3 or 4 digit representation of th...

Page 28: ...of Zero eliminates fine feed altogether The Fine Feed Wt is automatically adjusted if a non zero value is used for Fine Feed Tm see below The value is critical Too much Fine Feed Wt will result in unnecessarily slow batching To little will result in poor batch accuracy It is highly recommended to let the MC adjust this parameter automatically A common scenario is zig zagging which happens if the F...

Page 29: ...e batch error to the Preact Max Batch Tm If the time used for a batch exceeds Max Batch Tm the logical output Batch Timeout goes on No other action is taken meaning that the batch will complete in a normal fashion The Batch Timeout output typically qualifies a Warning See Logical Outputs on page 39 Batch Dev Hi Lo These are the batch tolerances in percent of the batch setpoint If the batch error a...

Page 30: ...eed and observe Rate in the Batch Statistics screen It should initially stay almost constant Typically at some weight it will start changing The Heel Weight should be set above this weight The default behavior is to start re fill whenever the weight goes below the Heel Weight This will happen inside an ongoing batch It is possible to change this behavior by modifying some registers The default val...

Page 31: ...the Empty Time is reached the controller turns off the Fdr Drive Enabl logical output and zeroes the Speed Demand Signal Fill Gt Time This parameter should be set to the time it takes for the fill gate above the hopper to close and material to finish falling and stabilizing in the hopper The purpose is to avoid a situation where batching starts too early after a fill If the logical input Fill Gt C...

Page 32: ...rameter You can not use the default value 1 5 mV V Limits are 0 2 to 3 mV V Performing an E Cal Factor Procedure page 52 will adjust this value Zero Weight This parameter represents all of the dead weight on the load cells This may include the hopper feeding device motor etc This does not include the weight of the material Default is 0 Normally adjusted by performing a Zeroing Procedure page 47 Sc...

Page 33: ...ad Cell Signal All other calculations regarding Batch Control and State Logic are done right after a HPAD sample so the timing set here will be the heartbeat of the entire controller Sample Rate Screen There are two settings You can adjust them by pushing the Numeric Params button Time while running is used when the controller is batching or filling Time while idle is used when the controller is c...

Page 34: ...nput for the Batch Setpoint you may have to average low pass filter setpoint samples to get a reliable setpoint value Increase this number if the setpoint value in the main screen is noisy Date Time Settings You can adjust the date and time settings here in 24 hour format Parameter Min Max Year 0 99 Month 1 12 Day 1 31 Hour 0 23 Minute 0 59 Seconds 0 59 INPUTS AND OUTPUTS MENU The I O system is co...

Page 35: ...ware reference manual available at MCT for details on analog inputs Panel Meter Setup When you utilize an unused analog input for a general purpose panel meter an Analog Input Source must be defined for this input either Analog Input 1 or Analog Input 2 In addition the input must be scaled and calibrated If possible use the Analog Input Procedure page 52 to set these parameters The Analog Diagnost...

Page 36: ... up to four analog outputs In the Analog Outputs menu you select what you will be using the analog outputs for You also select between 0 20 mA 0 10 V and 4 20mA 2 10 V type outputs Refer to the MC hardware reference manual available at MCT for details on analog inputs Analog Output Setup By pushing the button under a specific Output you can select what it will be used for The button caption will c...

Page 37: ... fixed at 4 mA 4 mA 20 mA 0 100 50 125 Example Design Feedrate 10 lb min by setting the Low val to 25 would set the output range equal to 2 5 10 lb min over the 4 20 mA range 25 2 5 lb min 10 lb min If you want zero level mA to be adjusted such that 0 lb min feedrate equals 7 2 mA then you would set the zero level to 25 4 mA 20 mA 0 100 50 25 7 2 mA For example Design feedrate 10 lb min by setting...

Page 38: ...ample relays or bits in a PLC The logical layer is function related The logical outputs have names like Rem Start Batch and Reset Total The MC actually acts upon the logical layer The logical input layer is mapped to the physical input layer It is possible to have one physical input control one or more logical inputs For example one physical input can be used to reset both Warnings and Faults The ...

Page 39: ...This button toggles the FC indication through Forced On 1 Forced Off 0or no Force There will be a blinking indication on the Main Screen if forces are present The button is only available when you have the Physical Input column selected since the Force property is associated with the physical input Alarm None Warning Fault This button cycles the FW column between Fault F Warning W and None If a lo...

Page 40: ... in On WARNING When On this input will typically cause the feeder to immediately re fill when the controller is powered up after maintenance Auto Fill Set to Always On if you are using a fill gate to automatically re fill the hopper when needed When Off the only way to finish a re fill is to issue a Stop Fill command This is useful if you are filling the hopper manually WARNING If you have an auto...

Page 41: ...in the Faults screen Fill Gt Closed This is normally connected to a limit switch on the fill gate to indicate that the fill gate is closed See Fill Gt Time on page 27 Map to Always On if unused Net Start Batch Network Start Batch command When turned on if logical output Ready is On a batch is started See Feeder State Transitions on page 8 The Start Batch button in the Action Menu page 17 this inpu...

Page 42: ...en the weight is stable See Stability Settings on page 27 Keyboard Locked On when the touch screen is locked out by means of serial communications Acc Switch 1 through 4 Access Switches Not used in this application Keyboard A1 H4 Touch Screen Location Codes You can map a logical input to positions on the touch screen This is useful for testing purposes Rack 1 Input 1 through 4 I O Rack 1 PCIO 1 Ra...

Page 43: ...ou have the Physical Output selected since the Force property is associated with the physical output Alarming Since un mapped logical outputs are not visible in this screen this button takes you to another screen where you can set the Faults and Warnings properties for all logical outputs both mapped and un mapped WARNING If you have made changes to the mapping press Accept before pressing Alarmin...

Page 44: ...m the last good DF1 telegram received on COM2 has expired See the DF1 Timeout parameter under Comm 2 Numeric on page 44 If you set R 078 to 1 an integrity toggle bit is used instead This is a more stringent communications integrity check See MCT for more information Ser Comm Lost Output indicating that serial communication on COM1 ScaleNet or Modbus has timed out See Comm 1 Numeric on page 44 If y...

Page 45: ...ge 27 Goes on when the time is exceeded Goes off again when the Empty Weight is reached or when any command that aborts the cleanout is issued Scale Empty On whenever the hopper weight is below the Empty Weight See page 26 Batch Inprocess On whenever batching activity takes place Off in Idle and Cleanout state Batch Paused An ongoing batch was paused by a Stop Batch command The batch has to be res...

Page 46: ...Time page 27 Fill Gt not Cls The Fill gate did not closed within the Fill Gt Time page 27 The output goes on then the time has expired and goes off when the Fill Gt Closed input goes on again Drive Fault The Drive Fault logical input was On when Fdr Drive Enable logical output was On There is a forgiveness time in R 408 which allows for the Drive Fault input to stay on for a while after Fdr Drive ...

Page 47: ...cations provides the means to exchange information between the MC Controller and other devices There are two serial ports Comm 1 and Comm 2 On Comm 1 you can run a Merrick proprietary protocol called Scalenet or a subset of Modbus ASCII or RTU which is a Modicon protocol in the public domain On Comm 2 you can connect a printer with a serial interface or you can run a subset of DF 1 which is an All...

Page 48: ...erface Table CIT variables Decimal representation Word Order Floating point representation word order bit pattern for CIT Int Frac FP Integer Fraction floating point representation bit pattern for CIT Tag Reg 1 5 MC register number tagged Comm 2 Numeric For details refer to DF 1 documentation at MCT Param Meaning Prtr 0 DF1 1 Set to 0 for Comm2 to be used for a serial printer Set to 1 for Comm2 to...

Page 49: ...eight 0 150 Eng Lo Weight 10 of Design Weight 0 100 Eng Hi Wt Dly 10 0 3600 Seconds Lo Wt Dly 10 0 3600 Seconds The High Weight parameter is significant because you can t perform a Weight Calibration procedure if the Current Weight plus the Calibration Weight exceeds this limit See Weight Procedure on page 49 Panel Meter Limits This button allows you to set the upper and lower limits for the High ...

Page 50: ...assumes that you have just done a Zeroing Procedure and that the hopper is empty 3 Correct the totalizing and weight indication by running a Material Calibration page 48 This also updates the Scale Factor parameter Use this procedure if you can t do a Weight Procedure but you can weigh the material passing through the feeder on a reference scale or have some other means of establishing a reference...

Page 51: ... when you perform this procedure When you push Start The controller will take the Stable Weight as the new Zero Weight If you do not wish to run the Zeroing Procedure push the Cancel button to return to the Calibration Menu However if you are ready to begin the Zeroing Procedure push Start The display will show the elapsed time of the test and an indication on the stability of the scale When the p...

Page 52: ...he Action Menu 2 Run a known amount of material through the feeder The feeder will totalize it 3 Enter the actual weight from the reference scale by pushing the Actual Total button The Scaled Totalized value is the current Sub Total by default You can change it by pushing the Scale Totalized button 4 Push the Accept button 5 The difference between the actual and the totalized amount is calculated ...

Page 53: ...mple the current weight and then the weight with the calibration weights added To begin the Weight Procedure push the Start button If the total weight weight in the hopper plus calibration weights exceeds the Hi Weight limit the display will show an Overload Condition screen Normally the start weight is sampled This requires that the weight value is stable In the next screen the sampled weight bef...

Page 54: ...ve the controller ignore the entire calibration procedure NOTE The logical input Allow Calibr has to be ON for the Accept button to appear Electronic Calibration The Electronic E Cal Procedure is provided as an alternate method to set the Scale Factor It is used when it is not possible to run either a Material or Weight procedure The HPAD board can inject a known artificial load cell signal to sim...

Page 55: ...Zero Procedure must be performed immediately before the E Cal Procedure To start the test push the Ecal button from the Calibration menu If the ECAL Live Load value is incorrect or if you do not wish to complete the E Cal Procedure for any reason push the Cancel button to return to the Calibration menu If you are ready to execute the E Cal Procedure push the Start button The procedure goes through...

Page 56: ...s To run an E Cal Factor procedure select this option from the Calibration menu From this point on the test runs just like the E Cal Procedure The ECAL mV V parameter will be adjusted No change is made to the Scale Factor The calibration of the feeder is not affected Analog Input Procedure This procedure allows you to calibrate the two high resolution analog inputs 1 and 2 You must be able to set ...

Page 57: ...ve counts should follow the input and be around 1 000 000 counts Push the Snap Full button The live value will snap to the New column Hi row If the values are acceptable push the Accept button followed by the Cancel button else the Cancel button only 35 00 EX O M Manual 53 ...

Page 58: ...n the MC that holds controller parameters is corrupt The crash screen will look like this Checksum Error Crash Screen You will then be given the opportunity to either reset all parameters Reset Ram to their factory default values or continue operation Cont with the current possibly corrupt parameters None of these alternatives are attractive Resetting to factory default will require you to enter y...

Page 59: ... Report A fatal error should always be reported to Merrick Technical Support The last line normally will contain additional information I this example an attempt was made to perform a division with a zero value in the denominator The most common reason is that an invalid parameter has been entered into the controller by means of serial communications or by using the Register Editor If you have bee...

Page 60: ...es you to the Diagnostics Menu Diagnostic Menu It is usable for troubleshooting It is not necessary to access these menus under normal operating conditions HPAD Diagnostics HPAD stands for High Performance Analog to Digital converter It is the board in the MC that takes the Load Cell signal as input and produces a digital value Counts as output This screen helps you diagnose weight indication rela...

Page 61: ...ate this date Cal Zero Gain HPAD Scaling settings See HPAD Settings on page 63 Min Max The lowest and highest value of Counts with the date and time that have occurred since the last time the Clear Min Max button was pushed Min should stay above 100 000 and Max should stay below 900 000 in normal operation Communication Diagnostic When you are using ScaleNet on Comm 1 for communications this scree...

Page 62: ...ed Bit Description Bit 7 Not used Bit 6 Transmitter Empty 1 No byte in transmitter hold or transmitter shift register 0 One byte in transmitter hold or transmitter shift register Bit 5 Transmitter Buffer Empty 1 no byte in Transmitter Hold Register 0 one byte in Transmitter Hold Register Bit 4 Break 1 Break Detected 0 No Break Detected Bit 3 Framing Error 1 Framing Error Detected 0 No Framing Erro...

Page 63: ...ght Material or ECal procedure See Calibrating Your Controller on page 46 NOTE If you change the Zero Weigh or Scale Factor manually in the Calibrate Settings menu page 28 there will be no record of the changes in this screen Analog Diagnostics The top section displays the selected function Cntrl Spd Batch Tot etc and type 0 20 mA or 4 20 mA for each of the Analog outputs The Actual column in the ...

Page 64: ...ng view Physical Outputs and Logical Inputs Mapping View The button between the up and down arrows toggles between Outputs and Inputs Use the up and down arrow buttons to page the digital I O points This screen displays the current mapping properties and status for the logical inputs and physical outputs NOTE You can only see used mapped logical outputs and physical inputs in this view To see all ...

Page 65: ...Input I O both Input and Output I Physical I O point is inverted 0 Physical I O point Forced Off 1 Physical I O point Forced On Faults and Warnings Diagnostics Pushing the Faults or Warnings button allows you to see the Faults or Warnings screen even if there are no Faults and Warnings active This is useful when you have finished all your Digital I O configurations See Warnings on page 14 and Faul...

Page 66: ...ime spent on core functions Max Core Peak CPU time spent on core functions Reset by Clear Min Max button UI Time CPU time spent on user interface functions Max UI Peak CPU time spent on user interface functions Reset by Clear Min Max button Freq Hz Found In rare occasions the HPAD sampling can be synchronized with the power line This requires special hardware You can see the found and used power l...

Page 67: ...ifications to parameters in the Diagnostic Settings are potentially dangerous It is quite possible to crash the application from here Diagnostic Settings HPAD Settings You can change the default HPAD scaling here to improve live load resolution or to make a somewhat overloaded 3 mV V load cell operational Use in conjunction with the HPAD Diagnostics screen page 56 CAL This value is used by the HPA...

Page 68: ...n Setup and Diagnostic screens The passwords are four digit numeric values The default Setpoint Password is 0 no password Calibration password is 1234 Setup password is 5678 and the Service Menu password is 1030 Register Editor You can access the internal MC database directly with the register editor All protection and values within reason checks are disabled There are some undocumented or experim...

Page 69: ...e Register Name Value line The left arrow is used a backspace key 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 value is the current selection First enter the number of the register you want to see or change in the number row Then TAB to the Name Value row if you need to change the value There is a...

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