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Summary of Contents for MERRICK MC3 90.10.EX
- Page 1 MC³ 90.10.EX MasterSet Controller Operation and Maintenance Manual Version ß Merrick Industries, Inc 10 Arthur Drive Lynn Haven, FL 32444 +1 850.265.3611 +1 850.265.9768 http://www.merrick-inc.com...
- Page 3 Merrick Industries, Inc. Patents owned by Merrick Industries, Inc. have been issued or are pending on at least some of the information in this manual, and unauthorized use of this subject matter of such patents is a violation of such patents and is prohibited.
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Page 5: Table Of Contents
TABLE OF CONTENTS INTRODUCTION ........................2 ......................2 ANUAL ONVENTIONS Important points ....................... 2 Buttons..........................2 Screens ........................... 2 ..........................2 AFETY In General ........................2 Electrical Precautions ....................... 2 Solving Problems ......................2 Technical Support ......................3 SYSTEM CONCEPTS ......................4 ...................... - Page 6 ....................... 21 NTERING ALUES Units Select ........................21 Design Capacities ......................22 Decimal Points....................... 22 Comm Parameters ......................22 Comm 1 Numeric ......................23 Comm 2 Numeric ......................24 Limit Switches........................ 24 Panel Meter........................25 Display Parameters ......................25 EMT Parameters ......................25 Date/Time ........................
- Page 7 Digital Inputs........................41 Digital Outputs ....................... 41 Analog Inputs ........................ 41 Analog Outputs......................42 LCD Board ........................42 CPU B ........................42 OARD Communication Ports ..................... 42 Printer Operation ......................44 ......................44 ACKPLANE OARD DC Style Backplane Board ..................... 45 AC Style Backplane Board....................
- Page 8 MC³ 90.10.EX O&M Manual - 1 -...
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Page 9: Introduction
Safety The Merrick MC³ Controller is used for the control of process weighing equipment. As such, it is normally responsible for the control of a process and is not intended as a motor control device. To insure personnel safety please read the following instructions and precautions carefully. -
Page 10: Technical Support
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) and ask for service. The call will be routed to the next available phone support technician. -
Page 11: System Concepts
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 12: Enclosures
Enclosures Panel Mount The Merrick MC³ Panel Mount 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 40º C). It must be protected fro m water or significant dirt or dust. -
Page 13: Electronic Cards
The Merrick MC³ Door Mount 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... - Page 14 The RS-485 Serial Communications port is a feature that provides the circuitry necessary for the MC³ Controller to communicate with other serial devices such as a SuperBridge or Personal Computer. For more information regarding MC³, Serial Communications see the Merrick Communications Specification Manual. This specification lists some hardware options and interconnection examples and describes the Merrick Communications Protocol in detail.
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Page 15: Software Overview
Serial Communications to variables used in the MC³. A numeric listing o f registers for each application is available from Merrick. Procedures for using Serial Communications to access the register list are also provided in the Merrick Serial Protocol Specification. -
Page 16: Running & Controls
Running & Controls Initial Setup 1. Slaves must be set to use Modbus/RTU. This usually is accomplished by setting the Comm Protocol Value to 2 then cycling power to use the protocol. Default Line Parameters - Baud Rate 9600, 8 Data Bits, 1 Stop Bit, Even Parity. 2. -
Page 17: Master Setpoint
The Master Total of all recipes. Below the Fault and Warning buttons there are several text indicators that provide additional information regarding the state of the controller. The first line displays whether the process is running or stopped. The second line displays the current setpoint method. Local Analog R Ratio... -
Page 18: Analog
NOTE: When the controller is to be used in SuperBridge or any other system, which transmits setpoint information using Serial Communications, the Remote Serial mode must be selected. The rules and format of the data exchange is described in a separate publication, Merrick Serial Protocol Specification. -
Page 19: Faults
Faults The Fault button is used to indicate an error has occurred. A Fault condition will stop all feeders. The system will not restart until the Fault condition has been cleared. A Fault will also prevent the system from starting. Up to 16 Logical Inputs and Outputs may be selected to give you a Fault indication. -
Page 20: Graph Screen
Warning button will continue to be displayed on the main screens and the Warning will continue to be indicated on this screen. Graph Screen This button displays a trend screen that graphically compares the current feedrate to the setpoint. Also displayed on this screen is the Sub-Total (ST), Master Total (MT), Feedrate (FR), and Setpoint (SP). -
Page 21: Reset Sub-Total
Once Run Permission is turned on the controller will display “Running" until the controller is stopped. While running the Stop button is displayed. If the controller is stopped by touching the Stop Feeder buttons or the Stop Feeder logical input, the text message “Stopped”... -
Page 22: Feeder Amount
Feeder Amount This menu allows direct entry of the percentage for the specific feeder of the selected recipe. Once in this menu, the buttons cycles through the available feeders. NOTE: A setting of 0.00% indicates that the feeder is not used in this recipe. Recipe String This menu allows e ntry or changing of the Recipe name. -
Page 23: Feeder Settings
This set of strings should be the same as on the selected feeder. If unsure contact Merrick Industries to properly set this value. The units button select the type of feeder that is connected (BELT, LIW or FMTR). The button is used for Belt Feeder Controllers (ex. -
Page 24: Feeder Numeric
Flowmeter Controllers (40.10.EX). Then the Units Select (page 17) numeric parameter sets the unit strings. Warning: The setting of this value incorrectly can cause erroneous calculations to be made and may affect the operation of the system. The next set of data that is displayed are the Max settings for each feeder. These values are used to scale the setpoint sent to the feeder and the bar graphs on the Feeder Display screen. -
Page 25: Feeder Strings
Feeder Strings This menu allows entry and changing of the Feeder name string. The Recipe menu uses a similar display as this one. At the top of the display is a ‘v’ that points to the character that is under edit. The index of the character in the string is directly below and noted with “Char #”. -
Page 26: Printer Menu
Printer Menu Print Line Editing and Printout Selection This menu allows editing or printing one of the four available print strings and the Feeder Screen Display String. The print strings (1[_], 2[_], 3[_], and 4[_]) are lines of characters that convey information to a printer for permanent record. - Page 27 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 functions. MC³ 90.10.EX O&M Manual...
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Page 28: Settings Menu
Settings Menu Entering New Values Numeric Screen Example Most values are entered into the Controller via a numeric entry screen (see the above example). This screen shows the name of the parameter, the current value, units and the minimum and maximum allowed values for the parameter. -
Page 29: Design Capacities
The rules and format of the data exchange is described in a separate publication, Merrick Serial Protocol Specification. Please refer to Merrick’s web site at www/merrick-inc.com/mct/ for information concerning the Modbus ASCII Communications Specifications. CAUTION: Failure to program communications correctly can result in the operational failure of serial communications. -
Page 30: Comm 1 Numeric
MC³ Controller. Since not all computers and protocols have the same Begin and End Codes, an operator may wish to change them in order to attempt to communicate with non-Merrick equipment. A specific controller number is used to identify each controller on the network. -
Page 31: Comm 2 Numeric
10000. (4 implied decimal places). Tag Reg 1- 5 These are the registers to be monitored by DF1 communications. NOTE: Please consult Merrick’s Customer Service Department for any questions or comments regarding the available communication protocols. Limit Switches There are several programmable limit indicators available in this controller. -
Page 32: Panel Meter
Panel Meter This button sets the upper and lower limits for the Panel Meter monitor. This is an analog input that is available for monitoring another device such as the current used by a VFD. Output (NOT USED) Display Parameters This menu allows you to customize the display settings. -
Page 33: Date/Time
Date/Time For setting the date and time parameters, follow the direction given the Entering New Values section found on page 21. Analog Input The analog inputs can be mapped to Analog Setpoint or Panel Meter functions. Two analog inputs are available when there are two PCIO boards installed into the controller. Once the inputs are mapped, you should adjust the high, low and scaling values. -
Page 34: Analog Input Cal
Minimum Scale Values This is the value representing the zero value used for scaling the inputs. Panel Meter Units Amps Volts Torque % Temp ºF Temp ºC Incl º Analog Input Cal This procedure allows you to setup your analog inputs. Touch the number of the analog input to calibrate to edit the analog input alarm values. -
Page 35: Analog Outputs
When done, touch return. If return is touched without touching accept the new values will not be placed into memory. Analog Outputs The purpose of this section is to configure the Analog Outputs. Each analog output may be 0 - 20mA (0-10V) or 4 -20mA (2-10V). -
Page 36: Digital Io
0-20mA 4-20mA (adj. %) 4 (0%) 12 (50%) 20 (100%) Digital IO I/O mapping requires a layered approach to the design process. In the MC³, there ar e two layers, one is a physical layer and the other is a logical layer. The physical layer is connected to the outside world, for example relays and switches. - Page 37 inputs. For example the Physical Input "Rack 2 Input 1" may be mapped to the Logical Inputs "Calibr. Access" and "Advanced Set". This will allow calibration acceptance and custom setup access only if the input Rack 2 Input 1 is set appropriately. Digital input screens List of Logical Inputs Name...
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Page 38: Digital Outputs
Physical Inputs Description Keyboard A1 - H4 Keyboard Location Codes Rack 1 INPUT 1 through 4 PCIO #1 1st bank. Rack 2 INPUT 1 through 4 PCIO #1 2nd bank. Rack 3 INPUT 1 through 4 PCIO #2 1st bank. Requires use of a second PCIO board. Rack 4 INPUT 1 through 4 PCIO #2 2nd bank. - Page 39 Name Description High Panel Meter Output Indicating that the Analog Input mapped to the Panel Meter function has exceeded the limit switch value High Panel Meter. The settings for this parameter is in the Limit Switches on page 24. Low Panel Meter Output Indicating that the Analog Input mapped to the Panel Meter function has dropped below the limit switch value Low Panel Meter.
- Page 40 AuxIO Output 1-8 Output associated with the Available I/O that has the capability to be delayed on or off. These outputs may be used as an auxiliary timed output. Contact Merrick for more details. Always ON Output is always ON (closed).
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Page 41: Diagnosing Problems
Diagnosing Problems Diagnostic Display The Diagnostic Menus for the MC³ Controller is provided to allow access to additional displays and values. It is provided as a troubleshooting tool. Feeder Diagnostics Status Screen Data Screen These screens give an overview of the port and slave communication status and the data exchanged by each slave feeder attached and this controller. -
Page 42: Df1 And Modbus Diagnostics
Consult Merrick for more information regarding this display. DF1 and Modbus Diagnostics DF1/DNI Status DF1/DNI Data Modbus Status Modbus Data The data table exposed to communications can be inspected in the MC³.. Note that the values are only updated on valid DF1 or Modbus telegrams. If no telegrams have been received, most values are zero. -
Page 43: Register Monitor
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. Register Monitor This screen is used to monitor the values of specific registers. The display includes the register number, the value and the register name. -
Page 44: Diagnostic Settings
It is called the challenge response system. On the Diagnostic screen a string is displayed called challenge. Phone this number into Merrick service and a response will be given to allow entry to the diagnostic settings menu to observe or change the password. -
Page 45: Solving Problems
SOLVING PROBLEMS If the following procedures do not assist in solving the problem, see Technical Support on page 2 on obtaining factory support for the controller. Symptoms Unit does not power up. WARNING: Only qualified service technicians should work on the controller. When working with live voltages insure all safety precautions are taken. -
Page 46: Hang Message Appears
If the hang screen appears, write down the exact error that is displayed on the screen and call customer support at Merrick Industries. Several types of errors may cause the controller to reset or reboot. If this occurs, verify all parameters. -
Page 47: Controller Hardware
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 The EMT outputs are provided to you for connection to a remote totalizer. Both AC and DC pulse outputs are available. -
Page 48: Pcio Board
PCIO Board A O U T 1 A O U T 2 A I N 1 Digital I/O2 Digital I/O1 D i g i t a l I / O P i n L a y o u t PCIO BOARD Digital Inputs The digital inputs are provided so that the customer may provide logical on/off signals to the MC³... -
Page 49: Analog Outputs
NOTE: If the analog signal is a current input, a jumper must be installed. If the input is a voltage, a jumper must be removed for proper conversion. Analog Outputs Isolated Analog Outputs are provided with the PCIO Board. There is a maximum of two outputs per board. - Page 50 Comm 2 RS-485 J5 Signal TX + TX - RX + RX - Option Switch Settings Flash Programming Lockout OFF - Program when SIMM installed ON – Normal Operation Power Fail Detection Level OFF – High Level Detection (Old Style) Modified Power Supplies ON - Low Level Detection Unmodified Power Supplies...
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Page 51: Printer Operation
Strap 2 to 3 for +5VDC Flash Programming Voltage Default 2-3 Printer Operation MC³ 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 MC³ controller. A standard controller consists of one PCIO and one Back plane board. -
Page 52: Dc Style Backplane Board
DC Style Backplane Board Each DC Style Back plane board consists of four (4) inputs and seven (7) outputs. The inputs are to be dry contact type. The outputs are N/O relay contacts with a rating of eight amps at 125 VAC or five amps at 30VDC. - Page 53 Inputs Terminals 17,18 19,20 21,22 23,24 Outputs Terminals 9,10 11,12 13,14 15,16 MC³ 90.10.EX O&M Manual - 46 -...
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Page 54: Storage
STORAGE Storage On Receipt from Factory Storage Longer than 6 Months Outside storage is NOT recommended. If possible, store electrical equipment in a heated warehouse, above freezing temperatures. Operate all electrical and electronic equipment at least once (1) a year for a minimum of two hours, preferably during a low humidity season. -
Page 55: Spare Part List
If you need further assistance, or would like to place a parts order, please contact the Merrick Spare Parts Department. -
Page 56: Panel Mount - Dimensions
APPENDIX A Panel Mount - Dimensions 1.75" (44.45 mm) 7.5" (190.5 7.25" (184.15 1.75" (44.45 mm) 0.75" (19.05 mm) 1.25" 10.50" 2.00" (31.75mm) (266.70 mm) (50.80 mm) 13.25" (336.55 mm) Top View MC³ 90.10.EX O&M Manual - 49 -... -
Page 57: Wall Mount - Mounting Dimensions
Side View Wall Mount – Mounting Dimensions MC³ 90.10.EX O&M Manual - 50 -... -
Page 58: Door Mount - Dimensions
Door Mount - Dimensions MC³ 90.10.EX O&M Manual - 51 -... -
Page 59: Index
Index AC Style Backplane ........ 45 Local Setpoint ........10 Action Menu ........... 13 Logical Inputs ......... 30 Analog I/O Diagnostics......34 Logical Outputs ........31 Analog Input ........... 26 LTI BOARD ..........40 Analog Outputs........28 Main Display..........9 Analog Setpoint ........11 Misc.
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