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MERRICK MC3, Operation And Maintenance Manual

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MERRICK MC3 Operation And Maintenance Manual Download Page 43

MC³ 24.96.EX O&M Manual

Page 35

08/14/01 4:34 PM/LDD

PHYSICAL
INPUTS
(WORLD)

PHYSICAL
OUTPUTS
(WORLD)

LOGICAL

INPUTS

(MC³)

LOGICAL

OUTPUTS

(MC³)

1   TO    MANY

LI1

LI2

LI3

LI4

LI5

LI6

LI7

LI8

LI9

LI10

PI1

PI2

PI3

PI4

PI5

PI6

PI7

PI8

PI9

PI10

LO1

LO2

LO3

LO4

LO5

LO6

LO7

LO8

LO9

LO10

PO1

PO2

PO3

PO4

PO5

PO6

PO7

PO8

PO9

PO10

MANY   TO  1

1. 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

PI4

PI5

PI6

PI7

PI4

LO1

LO3

LO6

LO3

LO7

LO6

MAP

MAP

X

X

X

1

0

X

FC

0

0

0

0

RM

0

0

1

0

0

0

RV

0

0

0

0

0

RM

0

X

X

1

X

FC

0

1

0

0

RV

4. Remote Property is mapped to the Logical layer.

Mapping inputs

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

Mapping outputs

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

Inverting inputs and outputs

You can invert the function  of the physical inputs and outputs. For example, you can have one
logical output controlling two physical outputs with one output normally closed and one normally
open.

Forcing inputs and outputs

The MC³ also allows you to force the physical inputs and outputs On or Off.  Forcing simulates the
action of switches (inputs) or relays (outputs) for an easier way to troubleshoot your system.  For
example, 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 to
verify the General Alarm indication in your control room, you can force the General Alarm output

Summary of Contents for MC3

Page 1: ...NGLISH MC3 2496ex_g 2496_G1 doc 08 14 01 3 57 PM LDD MC Controller Operation and Maintenance Manual for the 24 96 EX G Belt Feeder Merrick Industries Inc 10 Arthur Drive Lynn Haven FL 32444 850 265 3611 Revisions ...

Page 2: ...y to Merrick Industries Incorporated This manual is provided to the user of equipment purchased 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...

Page 3: ...Assembly 5 LCD Board 5 LCD Display 5 Touch Keypad 5 SOFTWARE 5 Application Software 5 BIOS 5 Register Database 5 GETTING STARTED 6 INSTALLATION 6 Panel Mount 6 Installation 6 Wall Mount 6 Installation 6 STARTING THE CONTROLLER 6 PASSWORD PROTECTION 7 MAIN SCREENS 7 Changing Main Screens 7 Feeder Screen 7 Graph Screen 8 Numerical Display 9 ENTERING NEW VALUES 9 Numeric Entry Screen 9 Sub Menus 10 C...

Page 4: ...S 14 SETPOINT 15 Setpoint Screens 15 Batch setpoint 15 Local 15 Remote Serial 15 Setpoint 15 Batch Parameters 15 Feedrate 16 Feedrate setpoint 16 Manual Speed 16 Local 17 Remote Analog Input 17 Remote Analog Ratio 17 Remote Serial 17 Snap Button 17 Setpoint Button 17 Fallback Setpoint 18 Common Setpoint buttons 18 Accept Button 18 Arrow Buttons 18 Return Button 18 ACTIONS 18 Cal 18 Reset Total 18 ...

Page 5: ...ad 29 Max Step Alwd 29 Max Z Track 29 Tachometer Parameters 29 Type 29 Mode 30 Speed Sensing Operational Mode 30 Numeric Parameters 31 Setpoint 31 Totalizer Cut Off 31 Calibration Parameters 31 Calibration Weight 31 E Cal Liveload 31 Weigh Span 31 Chain Load 31 Calibration Speed 31 Display Dampening 32 SETUP SCREEN 2 33 Analog Inputs 33 IN1 Zero Level IN2 Zero Level 33 IN1 100 Level IN2 100 Level ...

Page 6: ...ts 45 Parity 45 Numeric Parameters 45 Controller Number 45 Comp Start Code 45 Comp End Code 45 Communication Time out 45 Set Date and Time 46 PCAD Settings 46 CAL 46 ZERO 46 GAIN 46 Set Status 46 Number of PCAD s 46 Allowed Difference 46 Display Parameters 47 CALIBRATING YOUR CONTROLLER 48 INITIAL CALIBRATION CHECKLIST 48 CALIBRATION MENU 48 Speed Calibration 49 Zeroing Procedure 50 Material Calib...

Page 7: ...tup 63 Quick Setup 63 SOLVING PROBLEMS 64 Unit does not power up 64 Controller Fails to Boot Up 64 LCD Display too dark or too light 65 No load or bad Load Reading 65 Tacho not counting pulses or no speed indication 65 No analog Input 65 External Totalizer problems 65 General Alarms 65 No Serial Communications 66 Hang Message Appears 66 HARDWARE CALIBRATION AND TESTING 66 Analog Outputs 66 Analog ...

Page 8: ...ORY 71 Storage Longer than 6 Months 71 Storage up to 6 Months 71 STORAGE FOLLOWING USE 71 OPERATION AFTER STORAGE 71 SPARE PART LIST 72 MC CONTROLLER SPARE PARTS LIST 72 ACCESSORIES FOR THE MC CONTROLLER 72 I O System 72 Spare I O Plugs 72 Miscellaneous 72 Feeder Connection 73 APPENDIX A 74 MC PANEL MOUNT DIMENSIONS 74 WALL MOUNT DIMENSIONS 75 ...

Page 9: ...from the panel mount style controller or switch off the main power in a wall mount before attempting any service procedure 2 Verify that all grounds that are called for on the wiring diagrams are in place and are securely 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 ...

Page 10: ...re or parameter this button is available to give some guidance Technical Support Merrick 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 Standard Time During normal hours call 1 888 MERRICK 637 7425 extension 7811 After normal hours and on holidays and week ends technical assistanc...

Page 11: ...intenance and simplified training The Standard Merrick MC 24 96 EX Controller consists of an Enclosure an LCD Display Card Stack and a Power Supply Enclosure Panel Mount The panel mount enclosure consists of a rectangular box with a hinged door on the rear covering the I O connections a removable top cover a system grounding bar and a sliding tray The slide tray allows the Card Stack Assembly to b...

Page 12: ...s allows the Analog Load Cell signal to be resolved into approximately 1 000 000 digital 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 or Electronic Calibration The PCAD Board contains specialized circuitry for dynamically adjusting these parameters through software There ...

Page 13: ...he 24 96 EX controller The BIOS is common for many different applications Application Software Application 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 to configure the software for your specific process There are four modes of operation of this software package Belt...

Page 14: ...controller following the instructions on your electrical connection diagram 4 Verify all wiring connections before re installing the Power Cord and applying power to the unit Wall Mount The Merrick MC Wall Mount Controller is designed to be weatherproof and can generally be mounted anywhere where the temperature range is within 10o to 40o C Merrick recommends that it be located out of direct sunli...

Page 15: ...od to be used by your application See Setpoint on page 15 9 Record all essential parameters for your reference Use a copy of the specification sheet 10 Change the Calibration Diagnostic and Setup passwords to protect your settings PASSWORD PROTECTION The Password Entry screen is used to provide protection of the settings in the Calibration Setup and Diagnostic screens MC controller The password is...

Page 16: ...en Graph Screen A Graph screen is available to show trend information This screen also displays the current running status of the controller Graph Screen IDLE Iblft QY otch 0 0 Ib AM mum I SP SO lb u LD 7 Iblft SPD 7 2 ftl u FR SO Ibl u 1 1 S b T 90 Ib Toto 90 Ib ...

Page 17: ...The active 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 be changed Enter 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 ENT button to save this value The ...

Page 18: ...he current batch setpoint will be displayed If PID mode only is enabled the feedrate setpoint method and value will be displayed If both Batch and PID are disabled neither setpoint will be displayed More information on Setpoint see page 15 Feedrate This is the Current Feedrate in current units for feedrate FR Belt Load This is the current belt load value in the engineering units for load LD Sub To...

Page 19: ...s 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 been reached the Discharge Gate logical output will turn off see Batch Parameters on page 15 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...

Page 20: ...ormal keypad operation AUTO Auto When this indicator is on the controller is in the Automatic Setpoint Control Mode This is active when a Setpoint mode other than Manual Speed is active If the controller is in Manual Setpoint the indicator will be off See Page 15 for a complete explanation of the Setpoint modes RPER Run Permission This indicator will be on when the Logical Input Run Permission is ...

Page 21: ...lculated zero change was larger than the maximum specified by the operator See Page 28 for an explanation of Zero Tracking Parameters PCAD Discrepancy If there is a discrepancy between two load cell channels PCADs greater that the allowed difference 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 ...

Page 22: ...eset all alarms If an error that caused an alarm has not been corrected the alarm button will continued to be displayed on one of the main screens and the alarm will continue to be indicated on this screen CONTROLLER MODES The four modes of operation for MC 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 t...

Page 23: ... units for total Remote Serial This setpoint mode allows the MC Controller to receive a batch setpoint from a remote device 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 ...

Page 24: ... per batch Batch Setpoint Preact Close Discharge Gate Setpoint Preact Open Discharge Gate Batch Running End Run Belt Load Time Feedrate This button is displayed when the PID option is enabled This allows you to go to the Feedrate setpoint 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...

Page 25: ... total process When the setpoint changes for the process all three feeders will properly scale the outputs for the new setpoint Remote Serial This setpoint mode allows the MC Controller to receive a setpoint from a remote device 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...

Page 26: ...t the setpoint by adding or subtracting a percentage 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 add or subtract 0 5 TN h to the current value of the setpoint Return Button This button will allow you to exit out of the Setpoint menu If you do this without first touching the Accep...

Page 27: ...tic menu system Alarms This selection allows you to view the status of all alarms at any time For more information on alarms see General Alarms on page 12 Print Touch this selection to enter the Print Line Editing and Printout Selection screens see page 19 for more information Print Line Editing and Printout Selection This menu allows you to edit or to print one of the four available print strings...

Page 28: ...e un shifted mode this button places a linefeed character in the string When shifted 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 Description PF1 ASCII CODE DO NOT USE PF2 Total Prints the total PF3 Sub total ...

Page 29: ...rocedure 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 for your specific application by entering the custom setup menu and changing the value See Entering New Values on page 9 for the proper method to enter values into Numeric Entry Screens Touch to enter the Units Selec...

Page 30: ...LL START MOVING TO COMPLETE THIS TEST Next the chain calibration procedure will be performed You must put the test chain on the controller 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 SETUP This procedure assumes 1 All Electrical conn...

Page 31: ...s page 28 to accumulate then touch If value is reasonable touch The speed will automatically increase to determine the design speed of the feeder 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 t...

Page 32: ...rate ft s lb ft lb ft lb min ft s lb ft lb ft lb h ft s lb ft TN ft lb min ft s lb ft TN ft lb h ft s lb ft TN ft TN h ft min lb ft lb ft lb min ft min lb ft lb ft lb h ft min lb ft TN ft lb min ft min lb ft TN ft lb h ft min lb ft TN ft TN h m s kg m kg m kg min m s kg m kg m kg h m s kg m t m kg min m s kg m t m kg h m s kg m t m t h m min kg m kg m kg min m min kg m kg m kg h m min kg m t m kg ...

Page 33: ...MC Controller when in control mode uses a PID Proportional Gain Integral Derivative control algorithm To tune this algorithm to a particular feeder changes can be made to these parameters When the MC is in control it is the MC s job to maintain a feedrate setpoint This is done by controlling the belt speed to a point where the difference between the setpoint and the actual feedrate is minimal In t...

Page 34: ...e 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 from bouncing around on the belt or falling off the belt The parameters are expressed as percent per second Start Speed This is a feature that when enabled makes the belt sped quickly jump to a pre calculated speed at feeder star...

Page 35: ...tion the logical outputs will turn on if the feedrate deviates from the setpoint 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 min and the setpoint is 10 00 lb min the High Rate Alarm output would turn on when the feedrate exceeds 12 00 lb min and the Low Rate Alarm output would...

Page 36: ...ocedure see page 49 Length The 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 Revs The Number of Calibration Procedure Revolutions variable represents the number of belt revolutions to perform for calibration procedures with the exception of the Speed Calibration Limits are minimum of 1 and maximum of...

Page 37: ...ed and the wait time is started for a new test Limits are minimum of 0 and maximum equal to the Design Load Max Step Alwd This parameter is the maximum allowable Zero Tracking step change If the new calculated Zero Load differs from the old more than this parameter then no change is made Limits are minimum of 0 and maximum of 20 of the Design Load Max Z Track The Maximum Zero Tracking parameter is...

Page 38: ...n is detected The MC determines left hand rotation as channel B leading channel A see diagram below A Leads B R HAND A B B B Leads A L HAND A Speed Sensing Operational Mode The lower left button is used to toggle between different operational modes of the belt sped sensing The following operational modes are available NONE No tacho is used at all The speed is set in the Nominal Speed parameter in ...

Page 39: ...rom the total This is desirable if there is 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 Parameters The following parameters are used during the calibration procedures to set the proper scaling for the feeder Calibration Weight This value is the sum of the weights you will be using when you are performing the...

Page 40: ...ore dampening of the displayed feedrate or speed Note that the Speed Factor is critical for the dynamics of the controller and the Feedrate Factor is not Set the Speed Factor for a low 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 ...

Page 41: ...ould be around 200 000 counts If the input is set to 0 20 mV then the zero level should be close to 0 counts Limits are minimum of 0 and a maximum of 1 040 000 IN1 100 Level IN2 100 Level This value is the representation of the 100 value of the incoming signal Normally this value will be 1 000 000 counts representing 20 mA or 10 V 100 of the incoming signal Limits are minimum of 1 and a maximum of...

Page 42: ...face to borrow the analog output Type 0 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 Mapping The MC allows you to configure the digital inputs and outputs to your system s requirements By allowing mapping of the I O the MC gives you flexibility in design of your system I O mapping requires a lay...

Page 43: ...your application are normally mapped to one of these two inputs Mapping outputs The logical output layer is mapped to the physical output layer This allows you to use several physical outputs mapped to one logical output For example some action may need to take place due to a low feedrate condition and you also would like an indication that the feedrate went low in the control room The MC can map ...

Page 44: ...uts inside a controlling PLC The Ladder Program can have direct control over the feeder Digital Inputs Setup You reach the Digital Inputs screen from Setup Screen 2 See page 33 The screen allows you to change the mapping for the Digital Inputs The Physical inputs are mapped to the Logical inputs The logical inputs appear to the left and the physical inputs appear to the right When you enter the sc...

Page 45: ...nuous automatic mode The feeder will run when the input is on If the Feedrate Setpoint Mode is set to Manual Speed this input is ignored and the feeder will run regardless of the state of the input See Feedrate setpoint on page 16 Gravimetric This input allows the controller adjust the belt speed using the PID control algorithm If this is turned off the SCR OUTPUT Analog Output value will freeze I...

Page 46: ...e Controller modes on page 14 Start a Batch Starts a batch This input has the same effect as touching the Start Batch button in the Feeder Screen page 7 Stop the Batch Pauses the current batch This input has the same effect as touching the Stop Batch button in the Feeder Screen page 7 Clear the Batch Clears and resets the batch This input has the same effect as touching the Clear Batch button in t...

Page 47: ...s to support a third I O rack Rack 4 Input 1 through 4 Inputs on I O rack 4 if present Normally mounted outside the controller The MC must have 2 PCIO boards to support a fourth I O rack Extern input 1 16 Inputs controlled by communications See External physical 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 Mapping After...

Page 48: ...ys On or Always Off The black dot to the right of the Physical Output name indicates the state of the Physical Output ON or OFF The black dot to the right 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 Not Fo...

Page 49: ...s on page 26 Action is delayed according to the Low Delay parameter High Feedrate Feedrate is above High Feedrate See Limit Switches on page 26 Not delayed Low Feedrate Feedrate is below Low Feedrate See Limit Switches on page 26 Not delayed High Belt Load Belt Load is above Overload Limit See Limit Switches on page 26 Not delayed Low Belt Load Belt Load is below Underload Limit See Limit Switches...

Page 50: ...eed limit See Limit Switches on page 26 Action is delayed according to the High Speed Delay parameter Low Speed Limit The belt speed is below the Low Speed limit See Limit Switches on page 26 Action is delayed according to the Low Speed Delay parameter Discharge Gate This output is used to control the discharge ahead of the feeder gate for batching Batch Running On when a batch in running Batch Pa...

Page 51: ...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 Rate There are two modes of sample rates...

Page 52: ...minimum 1 and a maximum of 100 000 Pulse Length This value is the length in seconds for the pulse which is sent to the EMT A mechanical totalizer will require a longer pulse than a electronic The pulse output from the controller is buffered in order to allow slow EMT s to catch up and be accurate The recommended value for a mechanical totalizer is 0 10 and 0 01 for an electronic totalizer Limits a...

Page 53: ...dentify each controller on the network Controller Number This number is used to identify the numeric address of the controller when utilizing serial communications on a multi drop line No controllers connected to the same communication line should have the same controller number Limits are minimum of 1 and a maximum of 64 Comp Start Code This value is always sent at the beginning of a communicatio...

Page 54: ...esent The actual offset signal is added is 0 2 mV V times the Cal Set number ZERO This value is used by the PCAD Converter to control an amount of negative offset added to the load cell signal It is used to electronically remove dead load from the load cell signal This allows the PCAD to operate at a higher gain and achieve better resolution when measuring the load cell signal The actual offset si...

Page 55: ...hen entering the display setup Touching the INVERT DISPLAY button makes the display operate in reversed mode This can be used when difficult light conditions exist The only numerical parameter that can be set is the backlight turn off time in seconds Default is 3600 that is one hour Display Parameters I VERT II DISPLfIY I DISPLfIY II NOMERI I II ESC ...

Page 56: ...e Specification Sheet have been entered into the controller correctly Improper entry of some values in the controller can cause inaccurate calibration of the feeder Below is a checklist with the order in which calibration tests should be accomplished The first time a controller is installed all of the Calibration Routines listed below should be completed for proper operation After the initial cali...

Page 57: ...ength must be measured and entered before you run this procedure 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 those parameters If two tachos are connected the r...

Page 58: ...rdingly 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 computed the belt should be empty during the test The controller will record load readings for a certain amount of belt revolutions The number of belt revolutions for the test is determined by the parameter Proc Revs page 28 After the corre...

Page 59: ...ation procedure requires that there is a way to measure the weight of the material fed i e by collecting it and weighing it on a certified platform scale Stop the feeder and Zero the sub total before starting the procedure See Sub Total on page 10 Feed the weighed material over the feeder and stop it again Then enter the procedure by touching the MATERIAL button Scale Totalized The MC Controller w...

Page 60: ... correct number of belt revolutions is reached the controller will display a difference between the measured load and the chain load stored in the controller A new lads scale factor will be calculated You will then have the 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 di...

Page 61: ...n Procedure See Page 52 After the procedure is complete the chain load will be updated The load scale factor is not affected with this procedure Weight Procedure This 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 procedure to work A calibration weight is placed on the feeder usually by hanging ...

Page 62: ...From this point on the procedure is just like the Weight Procedure See Page 53 After the procedure is complete the weigh span will be updated The load scale factor is not affected with this procedure Electronic Calibration The Electronic E Cal Procedure is provided as a third method to calculate the internal Load Scale Factor The E Cal Procedure is used when it is not convenient to run either a Ma...

Page 63: ...fter 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 to abort the test E Cal Factor Procedure This procedure will adjust the E Cal Liveload page 31 It could be adjusted to compensate for small inaccuracies between ...

Page 64: ...totalizer for the grab sample A limit switch on the diverter valve must be connected to the logical input Diverter Valve See List of Logical Inputs on page 37 After opening and closing the diverter valve and then weighing the diverted sample enter the GRAB SAMPLE screen Enter the weight of the diverted material by touching the Sample Weight button then touch ACCEPT You will be presented with the d...

Page 65: ...uch 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 be asked if you want to edit the values This gives you the opportunity to perform fine adjustments to the zero and full level values If you want to manually adjust the values press the Yes button The numeric entry screen for analog inpu...

Page 66: ...r will not appear on the diagnostic screen CAUTION The values in this menu are very sensitive Changing any of these values could adversely affect the operation of the Feeder Controller PCAD Diagnostics Ld This 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 PCAD2 A D Counts are a digital representation of the analog load ce...

Page 67: ... the actual Belt Load in engineering units It is set by various calibration 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 scale to a known calibration after the system has been reset or damaged in some way After a g...

Page 68: ...nding 2 Transmitter buffer empty 3 No interrupt pending 4 Receiver buffer full 5 No interrupt pending 6 Receiver buffer full and receive character error 7 No interrupt pending 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 r...

Page 69: ...EMT PULS The number of buffered pulses for the EMT The controller can buffer pulses for the EMT if a slow counter is used This is the number of EMT pulses not yet delivered to the EMT See External Totalizer Parameters on page 44 PT Pulse counter Increments with incoming pulses TST Pulse counter for the ongoing discrepancy test run These parameters are used to detect belt slippage or malfunctioning...

Page 70: ...the allowed range and the value based on the scaler for the particular input are displayed See Analog Input on page 33 for more information Digital I O Diagnostics The 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 ...

Page 71: ...splays the register name and the value that the register contains Before entering new values into the controller you must clear the previous value by pressing the button The tab button is used to switch between the Register Number line and the Register Name 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 ...

Page 72: ...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 power receptacle 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 Fa...

Page 73: ... type of encoder is selected in the setup menu and the Speed calibration has been run 4 In the Large Font Display screen select PULSES for one of the displayed values Verify that you are receiving pulses from the encoder 5 Check to see that the correct mode direction is selected in Tachometer Parameters page 29 If R Hand or L Hand direction is selected try setting the direction to No Direction and...

Page 74: ... calibrating analog output 1 adjust the A01 Z pot R68 until the meter reads 0 0 milliamps If you are calibrating analog output 2 adjust the A02 Z pot R66 until the meter read 0 0 milliamps 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 0 milliamps If you are calibrating analog output 2 adjust the A0...

Page 75: ...mmy load cell be attached 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 Simulator 1 A load and speed simulator is available for demonstration purposes and to assist in troubleshooting pr...

Page 76: ... 485 DC EMT A B EMT The EMT outputs are provided to you for connection to a remote totalizer Both AC and DC pulse outputs are available See External Totalizer Parameters on page 44 for more information Tacho If 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 C...

Page 77: ...igital 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 Located on the PCIO board are straps to convert the analog signals from current to voltage Strap top row for current out Strap bottom row for voltage out Strap for Current Input Ana Out 2 Ana Out 1 Analog IO Connector Digital Rack 2 This examp...

Page 78: ...p on this board to switch between normal operation and Zener Barrier operation 1 2 3 4 5 6 7 8 O U T P U T O U T P U T S E N S E S E N S E E X C I T E E X C I T E S H I E L D N O C O N N E C T 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 PORT MC CPU board must be specifically configured for Printer operation Call Me...

Page 79: ...e ground If the equipment has been in transit for 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 A Clean all equipment and enclosures thoroughly inside and out B Remove rust as necessary Touch up painted surfaces as necessary to protect bare metal...

Page 80: ...OLLER 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 MC CONTROLLER I O System Description Part Number Backplane Board BMKM21882 1 Cable 9 inch BMKM20184 6 Cab...

Page 81: ...on 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 ...

Page 82: ...MC 24 96 EX O M Manual Page 74 08 14 01 4 34 PM LDD APPENDIX A MC PANEL MOUNT DIMENSIONS Front View Top View ...

Page 83: ...MC 24 96 EX O M Manual Page 75 08 14 01 4 34 PM LDD Side View WALL MOUNT DIMENSIONS ...

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