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MERRICK MC3 90.10.EX, Operation And Maintanance Manual

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MERRICK MC3 90.10.EX Operation And Maintanance Manual Download Page 47

 

MC³ 90.10.EX O&M Manual  

 

- 40 -  

Controller Hardware 

The MC³ is  capable of processing many different types of inputs and outputs.  Most of the 
connections necessary for the inputs and outputs are located on the Backplane Board. 

 

 

Back Panel Rear View 

LTI BOARD 

EMT 

The EMT outputs are provided to you for connection to a remote totalizer.  Both AC and DC pulse 
outputs are available.  See “" on page 64 for more information. 

Encoder 

If only one (1) encoder input is to be used it must be in the “A” position.  The mode should be No - 
Direction.   

Serial Communications 

Serial Channel #1 is a four wire RS -485 port.  The baud rate, parity, stop bit settings and protocol 
of the ports are setup in the software. For further information on configuring the Serial 
Communications Board and its interface to different  types of serial equipment, see 
Communications on page 64.  For users of the updated CPU board, this communication port has 
been moved to the CPU, this port is no longer supported. 

Summary of Contents for MC3 90.10.EX

Page 1: ...MC 90 10 EX MasterSet Controller Operation and Maintenance Manual Version ß Merrick Industries Inc 10 Arthur Drive Lynn Haven FL 32444 Ph 1 850 265 3611 Fax 1 850 265 9768 Web http www merrick inc com ...

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Page 3: ...sed 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 som...

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Page 5: ...are 8 BIOS 8 Register Database 8 Digital I O Mapping 8 RUNNING CONTROLS 9 INITIAL SETUP 9 MAIN DISPLAY 9 MASTER SETPOINT 10 Local 10 Analog 11 Ratio 11 Serial 11 FAULTS 12 WARNINGS 12 GRAPH SCREEN 13 ACTION MENU 13 Recipe Select 13 Start Stop Feeders 13 Reset Sub Total 14 Reset Master Total 14 Diagnostic Display 14 Settings 14 RECIPE MENU 14 Feeder Amount 15 Recipe String 15 FEEDER DISPLAY 15 FEED...

Page 6: ...PLAY 34 Feeder Diagnostics 34 Analog I O Diagnostics 34 Communication Diagnostics 34 DF1 and Modbus Diagnostics 35 Digital I O Diagnostics 35 Register Monitor 36 Misc Data 36 Faults 36 Warnings 36 DIAGNOSTIC SETTINGS 37 Password Settings 37 Quick Setup 37 Register Editor 37 SOLVING PROBLEMS 38 SYMPTOMS 38 Unit does not power up 38 Controller Fails to Boot Up 38 LCD Display too dark or too light 38...

Page 7: ...e Board 45 AC Style Backplane Board 45 STORAGE 47 STORAGE ON RECEIPT FROM FACTORY 47 Storage Longer than 6 Months 47 Storage up to 6 Months 47 STORAGE FOLLOWING USE 47 OPERATION AFTER STORAGE 47 SPARE PART LIST 48 SPARE PARTS LIST 48 ACCESSORIES 48 I O System 48 Spare I O Plugs and Miscellaneous 48 APPENDIX A 49 PANEL MOUNT DIMENSIONS 49 WALL MOUNT MOUNTING DIMENSIONS 50 DOOR MOUNT DIMENSIONS 51 I...

Page 8: ...MC 90 10 EX O M Manual 1 ...

Page 9: ...he Merrick MC Controller If you have any questions or problems please call the Merrick Customer Support Department for assistance All trademarks referenced are the property of their respective owners Electrical Precautions Before undertaking work on the electrical system the drives or the Controller from the main disconnect switches and lock boxes insure power is disconnected Work should never be ...

Page 10: ...ll will be routed to the next available phone support technician After normal hours and on holidays and weekends technical assistance is available by calling 1 888 MERRICK extension 7878 Follow the instructions and be sure to enter the area code and the phone extension where you can be reached Someone will return your call as soon as possible When you call Merrick for Technical Support please have...

Page 11: ...m variables and states 9 Ability to print information on a printer Hardware Overview The MC Controller has been designed to control many di fferent types of feeding weighing and metering equipment This allows for easier maintenance and simplified training The Standard Merrick MC 90 10 EX Controller consists of an Enclosure an LCD Display Card Stack and a Power Supply Installation Carefully unpack ...

Page 12: ... maintenance while the controller is mounted into a panel The Display assembly is mounted on the front bezel The top cover may be removed for easier access to the boards Access to the terminal blocks for interconnection with other equipment is obtained by unscrewing the rear cover Installation Cut panel to dimensions provided in Panel Mount Dimensions on page 49 Care must be used when cutting due ...

Page 13: ...Controller is designed for mounting in a control panel It is suitable for use in environments that are generally clean and within the temperature range of 32º to 122º F 0º to 50º C It must be protected from all but incidental water or significant dirt or dust Installation Mount the controller in the panel Cut panel to dimensions provided in Door Mount Dimensions on page 51 Insure there is adequate...

Page 14: ...rial Communications see the Merrick Communications Specification Manual This specification lists some hardware options and interconnection examples and describes the Merrick Communications Protocol in detail PCIO Board The PCIO Board provides the circuitry for two 2 isolated analog outputs one 1 isolated analog input sixteen 16 digital outputs and eight 8 digital inputs An additional PCIO Board is...

Page 15: ...on and off different modes of operation which allows you to configure the software for your specific process BIOS The BIOS is the portion of the software that directly manipulates the hardware It is the interface between the application and the hardware Register Database The Register Database is a set of variables used in the software application It is provided to allow structured access through S...

Page 16: ...recipes used must be entered into the design parameters 5 The total number of feeders slaves must be entered into the design parameters 6 There are several parameters from the feeders slaves that need to be entered into the MC 90 10 EX Parameter Port that the slave feeder is attached to Controller number for the slave feeder Type of feeder Belt feeder Loss In Weight Feeder Flowmeter Unit settings ...

Page 17: ...as above logical output is enabled AND Run Permission logical input is enabled Good Feed All feeders associated with the current running recipe are feeding good The associated output for Feed Good is enabled in each running feeder AND The In Control logical output is enabled same as above AND The feedrate is within the feedrate and deviation limits set in the Limit Switch Menu AND The recipe is ru...

Page 18: ...gured to provide material to a process using one analog input for control System number one provides 25 system number 2 provides 35 and system number 3 will provide 40 of the material needed for the total p rocess When the setpoint changes for the process all three systems will properly scale for the new setpoint Serial This setpoint mode allows the MC Controller to receive a setpoint from a remot...

Page 19: ...s used to acknowledge all Faults If the error that caused an indication has not been corrected the Fault button will continue to be displayed on the main screens and the Fault will continue to be indicated on this screen Warnings The Warning button is used to indicate a problem has occurred Up to 16 Logical Inputs and Outputs may be selected to give you a warning indication A Warning condition wil...

Page 20: ...a recipe is currently running the button will not be displayed To change the selected recipe the system must be stopped either by removing Run Permission or touching the Stop Feeders button Start Stop Feeders These buttons are used to start and stop the Feeders that are attached to this controller when the logical input Run Permission is enabled A status message associated is displayed directly to...

Page 21: ...without clearing the Master Total Feedback is provided just above this button Diagnostic Display This selection takes you to the Diagnostic Display Menu See Diagnostic Display page 34 for more information This menu is not password protected Settings This button displays the feeder settings menu where the feeder design parameters may be entered See Settings Menu on page 21 for more information Reci...

Page 22: ...uttons cycles through each of the available feeders The information displayed is Feedrate This is the feedrate from the controller Setpoint This is the setpoint that is being sent to the controller based on the selected recipe and the MasterSetpoint Weight Load This is the current weight if a LIW unit or the Load if a BELT type unit Speed This is the current speed of the selected feeder If the uni...

Page 23: ...x Wt Load value page 17 The speed value is scaled to the Max Speed value page 17 Feeder Settings The and buttons cycle through each of the available feeders The heart rate indicator is used to confirm that communications is taking place and will toggle between and If one of the indicators stays on for an inordinate amount of time communications may have been lost The first line displays the curren...

Page 24: ...er is the index into the unit string array for the selected feeder The 90 10 EX uses this number to select the correct conversion factor for use when determine the setpoint CAUTION It is very important that this parameter be set to the correct value since the calculation of the setpoint is directly affected Max Feedrate This value is the Design Feedrate of the attached controller This parameter is...

Page 25: ...the selected print string The Char displays the current character in the line Alpha Increment Decrement Increments or decrements Alpha Characters A B C D E F G H I J K L M N O P Q R S T UY V W X Y Z Toggle Caps Toggles the current character between small and caps If not a alpha character no changes will take place Numeric Character Cycles through the numeric characters 0 1 2 3 4 5 6 7 8 9 Miscella...

Page 26: ... line 1 and have embedded line 2 and 3 into line 1 When you send an external print command for line 1 lines 2 and 3 will be printed would be printed also If the last line tested printed was line 3 then only line 3 would be printed Edit Strings This selection allows editing of the strings The string to edit is selected in the function Line 1 4 D This button cycles through the print line to Edit Thi...

Page 27: ...In addition this menu allows 1 Entry of a value for the print counter and the counter increment value 2 Entry of a value for print lines to be printed at specific intervals setting the timed print value to zero 0 turns off the timed print function Extended Character Cycles through the following the Extended Character set Contact Merrick for more information regarding the Extended Character set of ...

Page 28: ...the new value for the selected parameter using the numeric buttons The display will show the value area as they are entered If the value is correct press the button to save this value The controller tests the number to insure that it is a valid entry If the number is within the minimum and maximum values a message will appear under the parameter list If the value is incorrect press the button and ...

Page 29: ...ipe by eliminating the 75 that are not used when selecting recipes Decimal Points Internally the MC Controller uses floating point numbers Any changes to the decimal point setting affects only the display of the values which will be rounded appropriately NOTE Note that the maximum number of decimal places is four and is used for display purposes only Comm Parameters Serial Communications provides ...

Page 30: ...art Code This 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 arrow keys to select you choice Limits are minimum of 1 and a maximum of 127 Comp End Code This value is always sent at the end of a communications message This default value is 13 for an ASCII representati...

Page 31: ...nly When the device writes to words which are write protected the corresponding Tag n W value changes accordingly but the corresponding MC register Tag n R Value is unaffected Byte Word Order The Byte Word Order Bit when set reverses the order of the two words that contains value information Int Frac FP The Integer Fraction bits are used when the device using the data does not support floating poi...

Page 32: ...detected A value of 0 will turn off this feature NOTE This feature requires the proper hardware upgrade to the controller LTI and LCD boards must be of the appropriate type for this feature to work Graph Time This parameter is the update time of the Graph Main Screen With the default of 1 second per sample the controller can display approximately 2 minutes of data By changing the sample rate to 5 ...

Page 33: ...e The value can be set in the numeric parameter selection see below Analog Input Source Settings The source used is analog input number 1 on PCIO board number 1 The source used is analog input number 2 which is located on the PCIO board number 2 The value that is used for the function selected is always 0 The value used is controlled through a register using the serial port Analog Input Numeric Lo...

Page 34: ...s Adjust the input for a zero level The live counts will vary accordingly When zero is reached touch the 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 has been reached touch the Snap full button The live value will snap to the new Hi column If the values you selected are correct fo...

Page 35: ...current setpoint scaled to the design feedrate This mode makes the output available for use by an external source via the communications port Type The mode selected is scaled between 0 and 20 mA 0 and 10V The mode selected is scaled between 4 and 20 mA 2 and 10V Numeric Parameters Zero Values The zero values are used to scale the zero point for each of the analog outputs This allows you to scale t...

Page 36: ...e 1 negative logic The MC also allows forcing of the physical layer I O ON or OFF Forcing simulates the action of switches inputs or relays outputs for an easier way to troubleshoot the system For example by forcing on the weight simulators the entire process can be simulated for troubleshooting your system Alternatively if there is no longer an alarm indication on the system console force the out...

Page 37: ...abled When off the pulses going to External Electromechanical Totalizer EMT are disabled Total Enabled Enables the main Totalizer When Off the main total does not increment Sub Total Enabl Enables Sub Totalizer When Off the sub total does not increment Extended Access Allows access to calibration constants in the register editor and via communications Register Access Input permitting the user to a...

Page 38: ...o stop feeding This is the Logical or of all outputs and inputs qualified for FAULT Warning A condition has occurred that needs attention but is not serious enough to stop the feeder This is the Logical or of all outputs and inputs qualified for WARNING High Feedrate Output indicating that the feedrate has exceeded a set limit for a set time The settings for this parameter is in the Limit Switches...

Page 39: ...it Switch Menu AND The recipe is running the Running logical output is enabled AND There are no Warnings or Faults In Menu System Output indicating that the user interface is not in one of its main screens In Calibration NOT USED Register Access Used by the controller to permit the user to enter the low level register editor Screen Locked NOT USED Serial Setpoint The controller is using serial com...

Page 40: ...e outputs may be used as an auxiliary timed output Contact Merrick for more details Always ON Output is always ON closed Always OFF Output is always turned OFF open List of Physical Outputs Physical Output Description Rack 1 Output 1 8 PCIO 1 1st bank Rack 2 Output 1 8 PCIO 1 2nd bank Rack 3 Output 1 8 PCIO 2 1st bank Requires use of a second PCIO board Rack 4 Output 1 8 PCIO 2 2nd bank Requires u...

Page 41: ...e button clears the error and status counters on the Status Screen 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 the particular output The EST mA column displays the estimated milliamp value for the output In the Input section the current...

Page 42: ...DF1 or Modbus telegrams If no telegrams have been received most values are zero The layout follows the MC data map exactly The e format of the floating points can help troubleshooting FP transfers You are reading from the first six rows to the left and writing to the first 3 rows on the right If you succeed with the integrity bit you should see the Sts DNI and Ctl DNI toggle between XX00 and XX80 ...

Page 43: ...egptr0 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 the register you wish to view in the monitor You may enter up to eight different registers for viewing with the register monitor Changing the values for pointers 1 5 will directly affect the Modbus DF1 mapping Misc Data This screen displays various ope...

Page 44: ...asonable values for the following parameters I t will appear when the Register Access logical input is enabled Register Editor Access to the Register Editor menu is only allowed if the logic input Register Access is enabled If the logical input is off the button for the Register Editor button will not appear on the diagnostic screen Use of the register editor is simple The symbol is used to denote...

Page 45: ...ormal operation can resume WARNING Make sure that you check all settings carefully before starting the feeder Otherwise the feeder could operate in an unsafe mode LCD Display too dark or too light The contrast of the LCD display is affected by large temperature changes It may need to adjust it The contrast adjustment R3 is located inside the controller on the backside of the display assembly in th...

Page 46: ...log output 1 adjust the A01 S pot R67 until the meter reads 20 0 mA If calibrating analog output 2 adjust the A02 S pot R65 until the meter read 20 0 mA Set the output to 50 and verify that 10 mA is read on the meter Analog Output 1 Zero Analog Output 2 Zero Analog Output 1 Scaling Analog Output 2 Scaling Analog Input Zero Analog Input Scaling A O 1 Z A O 1 S A O 2 Z A O 2 S AIN Z AIN S Potentiome...

Page 47: ...n page 64 for more information Encoder If only one 1 encoder input is to be used it must be in the A position The mode should be No Direction Serial Communications Serial Channel 1 is a four wire RS 485 port The baud rate parity stop bit settings and protocol of the ports are setup in the software For further information on configuring the Serial Communications Board and its interface to different...

Page 48: ...Inputs The digital inputs are provided so that the customer may provide logical on off signals to the MC Controller The default digital input is Digital Outputs The digital outputs are provided so that the customer may use these outputs as status indicators The default digital output map is Analog I O Current Voltage Strapping On the PCIO board are straps to convert the analog signals from current...

Page 49: ...aximum of two outputs per board Provided with two PCIO s a maximum of four analog outputs can be used LCD Board 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 CPU Board Communication Ports Comm 1 RS 232 J7 Pin Signal 2 Rx 3 Tx 4 DTR 5VDC 5 Com DC GND 7 RTS 8 CTS Comm 1 RS 485 J6 Pin Signal 1 TX 2 TX 3 RX 4 RX Comm 2 RS 232 J4...

Page 50: ...ckout OFF Program when SIMM installed ON Normal Operation SW2 Power Fail Detection Level OFF High Level Detection Old Style Modified Power Supplies ON Low Level Detection Unmodified Power Supplies SW3 Test Pin 1 Led 5 E Forced OFF SW4 Test Pin 2 Led 6 F Forced OFF LED Display LED Desc 1 A Com 2 Receive 2 B Com 2 Transmit ...

Page 51: ...ASH PROGRAMMING VOLTAGES Strap 1 to 2 for 12VDC Flash Programming Voltage Strap 2 to 3 for 5VDC Flash Programming Voltage Default 2 3 Printer Operation MC CPU board must be specifically configured for Printer operation Call Merrick for details to verify your CPU board configuration Backplane Board Each Back plane board is termed a Rack in the MC controller A standard controller consists of one PCI...

Page 52: ... with the fuses rated at 1 16 Amp F8 is a spare fuse Inputs Terminals Fuse 1 15 19 1 2 16 20 2 3 17 21 3 4 18 22 4 Outputs Terminals 1 1 2 2 3 4 3 5 6 4 7 8 5 9 10 6 11 12 7 13 14 AC Style Backplane Board Each AC Style Back plane board consists of four 4 inputs and eight 8 outputs The inputs are to be 110VAC switched type The outputs are N O relay contacts with a rating of 5 amps at 250 VAC Output...

Page 53: ...MC 90 10 EX O M Manual 46 Inputs Terminals 1 17 18 2 19 20 3 21 22 4 23 24 Outputs Terminals 1 1 2 2 3 4 3 5 6 4 7 8 5 9 10 6 11 12 7 13 14 8 15 16 ...

Page 54: ...r two months 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 Use Clean all equipment and enclosures thoroughly inside and out Remove rust as necessary Touch up painted surfaces as necessary to protect bare metal surfaces Protect electrical and electronic componen...

Page 55: ...Spare Parts List Name Part Number Power Supply Assembly M21912 1A Fuse Q 73 CPU Board M21746 1A PCIO Board 1 M21735 1A PCIO Board 2 M21735 2A LTI Board M21689 1A Display Assembly M21729 2A LCD Board M21684 1A LCD Graphic Display 19 411 00002 Backlight Assembly 13 903 79001 Fastcom 422 4 104 25 001 00009 Accessories I O System Name Part Number Backplane Board M21882 1 Backplane Board AC M22108 1A C...

Page 56: ...MC 90 10 EX O M Manual 49 APPENDIX A Panel Mount Dimensions 1 25 31 75mm 10 50 266 70 mm 2 00 50 80 mm 13 25 336 55 mm 0 75 19 05 mm 1 75 44 45 mm 1 75 44 45 mm 7 25 184 15 mm 7 5 190 5 mm Top View ...

Page 57: ...MC 90 10 EX O M Manual 50 Side View Wall Mount Mounting Dimensions ...

Page 58: ...MC 90 10 EX O M Manual 51 Door Mount Dimensions ...

Page 59: ...tics 34 Feeder Display 15 Feeder Settings 16 Feedrate Dampening 25 Feedrate Limit Switch 24 Initial Setup 9 Installation 4 Limit Switches 24 List of Physical Outputs 33 Local Setpoint 10 Logical Inputs 30 Logical Outputs 31 LTI BOARD 40 Main Display 9 Misc Data 36 Modbus Diagnostics 35 Panel Meter Limit Switch 25 Panel Mount 5 Password 37 PCIO Board 41 Physical Inputs 30 Printer 19 Pulse Length 25...

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