Related Manuals for MERRICK MC3
Summary of Contents for MERRICK MC3
- Page 1 MC³ Controller Hardware Manual Revision 2 MERRICK INDUSTRIES, INC. 10 Arthur Drive Lynn Haven, FL 32444 U.S.A Tel: +1 850.265.3611 Fax +1 850.265.9768 E-mail: info@merrick-inc.com www.merrick-inc.com...
- Page 2 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.
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Page 3: Table Of Contents
HPAD Board ..........................18 Straps............................18 HPAD 1/2 Determination......................18 PCIO Board ........................... 20 PCIO 1/2 Determination......................20 Connections ..........................21 Analog I/O Current/Voltage Strapping ..................21 Analog Input..........................21 AIN Adjustments........................22 Analog Outputs .......................... 22 MC3 Hardware Manual... - Page 4 No Speed Detected........................39 Analog Output Problem......................39 Analog Inputs ..........................39 MC3 Flashloader Programming (appLication upgrade) ..............41 Procedure for Rev 10 or earlier CPU boards................42 Procedure for Rev 11 or Later CPU boards................43 Sample Session ......................... 44 STORAGE .............................
- Page 5 Door Mount Power Supply Mounting Dimensions (S60213, 19-102-32402)......54 Door Mount Power Supply (VL30) Mounting Dimensions (A36539) ......... 54 Backplane Mounting Dimensions (M21882, M22108, M22535)..........55 Watchdog Timer Board Mounting Dimensions (N41215) ............55 IOC Input Connection Board (M22536) ..................56 MC3 Hardware Manual...
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Page 6: Introduction
INTRODUCTION Merrick MC³ controllers are used in industrial weighing applications, typically handling a material feeder, conveyor belt scale or flow meter. This manual describes the MC³ hardware. It is a microprocessor based system, with support for: • Isolated Analog I/O, 4..20 ma or 0..10V, •... -
Page 7: Controller Enclosures
CONTROLLER ENCLOSURES PANEL MOUNT The Merrick MC³ Panel Mount Controller is designed for mounting in a control cabinet. It is suitable for use in environments that generally clean, within temperature range of 32 to 104 F (0 C). It must be protected from water or significant dirt or dust. -
Page 8: Door Mount
DOOR MOUNT The Merrick MC³ Door Mount Controller is designed for mounting on the door of a control cabinet. It is suitable for use in environments that are generally clean, and within the temperature range of 32 F (0 to 50 C). -
Page 9: Installation
INSTALLATION Carefully unpack the controller and inspect it for obvious damage because of shipping or handling. If the unit appears to be damaged in any way, contact the Merrick Service Department for assistance. Insure that the power is disconnected from the power supply. Make the wiring connections to the controller, following the instructions on the electrical connection diagram. -
Page 10: Card Stack Assembly
PCIO boards at the connectors labeled “Racks”. The diagram below shows the card stack as seen from the back, with additional optional boards in the card stack. If an older revision CPU is present, then the diagram on the following page should be used. MC3 Hardware Manual... -
Page 11: Card Stack With Revision 11 Or Newer Cpu Board
RACK 2 DIGITAL I/O RACK 1 DIGITAL I/O PCIO #1 HPAD #2 LOAD CELL #2 (OPTIONAL) SIMM SOCKET (PROGRAMMING) HPAD #1 LOAD CELL #1 DB9-S (FEMALE) DB9-P (MALE) DC POWER CABLE COMM 2 COMM 1 Back Panel Rear View MC3 Hardware Manual... -
Page 12: Card Stack With Revision 10 Or Older Cpu Board
RACK 2 DIGITAL I/O RACK 1 DIGITAL I/O PCIO #1 HPAD #2 LOAD CELL #2 (OPTIONAL) SIMM SOCKET (PROGRAMMING) HPAD #1 LOAD CELL #1 DB9-S (FEMALE) RESET DC POWER PROGRAMMING COMM 2 BUTTON CABLE JUMPER Back Panel Rear View MC3 Hardware Manual... -
Page 13: Controller Disassembly
Add the 5 additional standoffs to secure the board. • Replace the LTI board and the 5 small standoffs. Again make sure the pins and the holes line up properly. • Replace the ribbon cable and cover. MC3 Hardware Manual... -
Page 14: Cpu Board
The RS-232 serial port is not isolated. COM 1 RS-485 4 WIRE J6 Signal TX + TX - RX + RX - The 4 wire RS-485 serial port is not isolated, but may float ± 50 V with respect to MC³ ground. MC3 Hardware Manual... -
Page 15: Com 2 Rs-232 J4
DALLAS Scalenet Modbus ASCII Modbus RTU Anybus Ehthernet IP U 53 Profibus 60HZ RS-232 +5V RED PF GREEN +5V RED +12V YELLOW -12V BLUE COM2 COM1 COM BLACK COM2 COM1 RS 232 RS232 COM BLACK RS485 RS485 MC3 Hardware Manual... -
Page 16: Option Switch Settings
DC power fail cable between the Power Supply and the CPU board is not connected, or that SW2 is in incorrect position. JTAG/Service Port (J8) Description +5VDC Test Pin 1/LED 5/E Test Pin 2/LED 6/F Test Pin 3/LED 7/G Test Pin 4/LED 8/H MC3 Hardware Manual... -
Page 17: Old Cpu Board (Rev 10 Or Older)
The Com 1 serial interface has a 4 wire RS485 port located on the LTI Board (page 23). This port is isolated from the rest of the MC³ circuits. There is no RS-232 port for Com 1. MC3 Hardware Manual... -
Page 18: Board Features
NMI INPUT Older power supplies connect power fail to pins 3 & 4 Printer Operation (Old CPU Only) MC³ CPU board must be specifically configured for Printer operation. Call Merrick for details to verify your CPU board configuration. MC3 Hardware Manual... - Page 19 MC3 Hardware Manual...
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Page 20: Hpad Board
All load cell connections, including the Guard terminal, are isolated from the rest of the MC³ circuitry. Connect the load cell cable shield to the guard terminal, not to the ground strip. The load cell cable shield should be grounded at one point, as close to the load cell as possible. MC3 Hardware Manual... - Page 21 NOTE: In all cases the Sense (3 & 5) pins must be connected. If a 4 wire load cell is connected directly to the HPAD board, jumpers must be placed between pins 2 & 3 and 6 & 7 as illustrated above. MC3 Hardware Manual...
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Page 22: Pcio Board
If a “second” PCIO Board is added to the card stack, the chip labeled in blue “F1” should be labeled “2 ”. If the second PCIO board is not marked in this manner, it is most likely a first board and will not work with another first board. MC3 Hardware Manual... -
Page 23: Connections
There is one isolated analog input per PCIO board. If the T15 is jumper installed (current input) the typical input impedance is 50Ω, and the range is 0..20 mA. If jumper is removed (voltage input) they typical impedance is 200kΩ, and the range is adjustable 0..1V to 0..10V. MC3 Hardware Manual... -
Page 24: Ain Adjustments
PLCC marked U4. If it is not, contact Merrick for the correct part. This part is not field programmable. The first and second board have different U4 addressing chips (see PCIO 1/2 Determination on page 20). -
Page 25: Lti Board
Communications found in the Software Manual. For users of the updated CPU board, this communication port has been moved to the CPU, this port is no longer used. For more information regarding communications, refer to the website http://www.merrick-inc.com/mct. MC3 Hardware Manual... -
Page 26: Encoder
No - Direction. The second encoder connects to would connect to 2A and 2B for 2 channels or 2A for single.. The EMT outputs are provided to you for connection to a remote totalizer. Both AC and DC pulses are available. The outputs are dry contact relay outputs. MC3 Hardware Manual... -
Page 27: Backplane Boards
Each Back plane board is termed a Rack in the MC³ controller. A standard controller consists of one PCIO and one Backplane board. Up to four Backplane boards may be connected to the MC³ Controller when two (2) PCIO boards are present in the card stack assembly. MC3 Hardware Manual... -
Page 28: Dc Style Backplane Board - Bkpn
Terminals 19..22 are all connected to the MC³ digital ground. All outputs (terminals 1..14) are floating. Ribbon Cable to PCIO Board Digital Outputs Digital Inputs Outputs Terminals Inputs Terminals 15/19 16/20 17/21 18/22 9,10 11,12 13,14 MC3 Hardware Manual... -
Page 29: Ac Style Backplane Board - Bpac
Care must be taken not to exceed these values. All inputs and outputs are floating with respect to MC³ ground. Ribbon Cable to PCIO Board Digital Inputs Digital Outputs Outputs Terminals Inputs Terminals 17,18 19,20 21,22 23,24 9,10 11,12 13,14 15,16 MC3 Hardware Manual... -
Page 30: Power Supply Assemblies
Power Fail Detect circuits that send a warning to the processor when the input voltage begins to fail, so that parameters can be saved before the power is lost. The MC3 Power Supply has no user serviceable parts, such as fuses. In the Panel and Wall Mount controllers, the fuse is located in the switch assembly. - Page 31 MC3 Hardware Manual...
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Page 32: Mc 3 Dc Power Cable Details
Panel Mount and Wall Mount enclosures. On the top above the switch, is the fuse holder. Push up on the small catch to release this holder from assembly. The fuse is a 1A 250V 5X20mm fuse. MC3 Hardware Manual... - Page 33 MC3 Hardware Manual...
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Page 34: Display Assembly
Most of the adjustments will be made with the contrast pot. If the brightness needs to be adjusted, avoid contact with the inverter boards next to the pot. It is a high voltage, low current circuit and could produce a shock or burn if contact with a non-insulated adjustment tool is made. MC3 Hardware Manual... -
Page 35: Lcd Display
MC³ Panel Mount and Wall Mount enclosure. It consists of a four by eight touch cell array. The Touch Keypad works with the LCD Display to provide a way for you to interface with controller. some MC3 Hardware Manual... -
Page 36: Touch Screen Location Codes
LCD Board, but has the same functionality. TOUCH SCREEN LOCATION CODES The touch screen has 32 pressure sensitive pads. They can be used as physical inputs for testing and demonstration purposes. This table shows the names of the physical inputs. MC3 Hardware Manual... -
Page 37: Mc 3 Troubleshooting
If the controller firmware has been changed or upgraded, the parameters in the non-volatile memory will typically not be compatible with the new firmware. The crash screen will look like this, if you upgraded from 35.00.B to 35.00.C: MC3 Hardware Manual... -
Page 38: Fatal Error Crash
Parameters Version: 56, 66 Firmware ID and Version ID before upgrade. In this case, you should reset the parameters (Reset Ram) to factory default (unless instructed otherwise by Merrick Customer Support), and then enter the new parameters either from the spec sheet or from a prepared parameters file, using WinMerik. -
Page 39: Forcing A Parameter Reset
If the fuse is good, check the DC voltages as marked on the drawing below. • If the DC voltages are not present, then the power supply or cable is defective. Without +12VDC the display will not light up MC3 Hardware Manual... -
Page 40: Lcd Too Dark/Light Or Out
The cable may have gotten damaged from heat or excessive stress. If the display is okay and the CPU seems to be processing data, one of the boards could be defective, such as the LTI boards. Consult Merrick for more information. LCD TOO DARK/LIGHT OR OUT –... -
Page 41: No Speed Detected
If the setpoint indicated on the screen does not equal the desired setpoint being sent by an analog signal, the input may not have been calibrated properly. Also check the scaling units in the analog input settings. You can quickly verify this in the analog diagnostic screen. MC3 Hardware Manual... - Page 42 MC3 Hardware Manual...
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Page 43: Mc3 Flashloader Programming (Application Upgrade)
This instruction details the procedure to use when loading (new or revised) application firmware into the Flash EPROM of an MC³ Controller. It is recommended you use a Merrick Programming Kit (S60234-1), which consists of a serial cable, memory SIMM, application and firmware. A straight serial DB9-P to DB9-S cable between the serial port on the PC and COM 2 serial port on the MC³... -
Page 44: Procedure For Rev 10 Or Earlier Cpu Boards
Wait for FLASHLDR to update the flash tables and shut down. Turn off power to the controller. Remove power cord. Remove JP1 jumper. Remove SIMM memory. Reinstall power cord. Turn on power. Watch screen for normal MC³ countdown. Touch the upper left and right corners of the screen to perform a ram reset. MC3 Hardware Manual... -
Page 45: Procedure For Rev 11 Or Later Cpu Boards
Remove power cord. Return SW1 to On Position. Remove SIMM memory. Reinstall power cord. Turn on power. Watch screen for normal MC³ countdown. Touch the upper left and right corners of the screen to perform a ram reset. MC3 Hardware Manual... -
Page 46: Sample Session
Flash programming complete FLASH CMD: sb 2496exr Program name set to 2496EXR Boot program set to 2496EXR (start vector = 8000:0000) FLASH CMD: q Start shutdown ... Update flash tables ... Flash tables OK Shutdown complete C:\MC3\APPS\2496EN\V003C>exit MC3 Hardware Manual... -
Page 47: Storage
When electrical equipment has been stored at either high humidity or low temperature, do not apply power until the equipment has been allowed to stand at ambient conditions a minimum of three (3) hours. Remove all packing and/or protective materials. Remove all desiccants. MC3 Hardware Manual... -
Page 48: Spare Part List
If you need further assistance, or would like to place a parts order, contact the Merrick Spare Parts Department. MC³ CONTROLLER SPARE PARTS LIST MC³... -
Page 49: Mc³ Door Mount A33432 (Hitachi)
M22108-1A Cable - 9 inch M20184-6 Cable 12 inch M20184-5 Cable 18 inch M20184-3 Cable 22 inch M20184-4 Cable 48 inch (door mount) 09-600-20001 Watchdog Timer Board N41215-1A IOC Input Board M22536-1A BPACIN AC Input Board M22535-1A MC3 Hardware Manual... -
Page 50: Options (Communication)
Options (Communication) Name Part Number WinMerik MC Kit – Disk Only S61118-1 WinMerik MC Kit – Disk & MC3 only Cable S61118-2 WinMerik MC Kit – Disk & MC3/MC2 Cable S61118-3 Programming Kit – 3 ½ Floppy w/Cable S60234-1 Programming Kit – CD w/Cable... -
Page 51: Panel Mount (A30685) - Dimensions
APPENDIX A PANEL MOUNT (A30685) – DIMENSIONS BEZEL FRONT PANEL CUTOUT MC3 Hardware Manual... - Page 52 TOP VIEW SIDE VIEW MC3 Hardware Manual...
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Page 53: Wall Mount (A30833, A31534) - Mounting Dimensions
WALL MOUNT (A30833, A31534) – MOUNTING DIMENSIONS FRONT VIEW MC3 Hardware Manual... -
Page 54: Wall Mount - Mounting Dimensions Cont
WALL MOUNT – MOUNTING DIMENSIONS CONT SIDE VIEW MC3 Hardware Manual... -
Page 55: Door Mount (A33432, A39307) - Dimensions
DOOR MOUNT (A33432, A39307) - DIMENSIONS FRONT VIEW SIDE VIEW BACK VIEW MC3 Hardware Manual... -
Page 56: Door Mount Power Supply Mounting Dimensions (S60213, 19-102-32402)
DOOR MOUNT POWER SUPPLY MOUNTING DIMENSIONS (S60213, 19-102-32402) DOOR MOUNT POWER SUPPLY (VL30) MOUNTING DIMENSIONS (A36539) MC3 Hardware Manual... -
Page 57: Backplane Mounting Dimensions (M21882, M22108, M22535)
BACKPLANE MOUNTING DIMENSIONS (M21882, M22108, M22535) WATCHDOG TIMER BOARD MOUNTING DIMENSIONS (N41215) MC3 Hardware Manual... -
Page 58: Ioc Input Connection Board (M22536)
IOC INPUT CONNECTION BOARD (M22536) MC3 Hardware Manual...
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