MERRICK MC3 Manuals

MERRICK MC3 Manuals

Manuals and User Guides for MERRICK MC3. We have 2 MERRICK MC3 manuals available for free PDF download: Operation And Maintenance Manual, Hardware Manual

MERRICK MC3 Operation And Maintenance Manual

MERRICK MC3 Operation And Maintenance Manual (83 pages)

for the 24.96.EX.G Belt Feeder

Brand: MERRICK | Category: Controller | Size: 0 MB

Table of Contents

Table of Contents
3
Introduction
9
- Safety
  9
  - In General
    9
  - Electrical Precautions
    9
- Manual Conventions
  9
  - Buttons
    9
  - Screens
    10
- Solving Problems
  10
  - Help Button
    10
  - Technical Support
    10
System Concepts
11
- Hardware
  11
  - Enclosure
    11
    
    Backplane Board
    12
  - Card Stack Assembly
    12
    
    CPU Board
    12
    
    PCAD Board
    12
    
    PCIO Board
    12
    
    LTI Board
    12
  - Power Supply Assembly
    12
  - Display Assembly
    13
    
    LCD Board
    13
    
    LCD Display
    13
    
    Touch Keypad
    13
- Software
  13
  - Application Software
    13
  - Bios
    13
  - Register Database
    13
Getting Started
14
- Installation
  14
  - Panel Mount
    14
  - Wall Mount
    14
- Starting the Controller
  14
- Password Protection
  15
- Main Screens
  15
  - Changing Main Screens
    15
  - Feeder Screen
    15
  - Graph Screen
    16
  - Numerical Display
    17
- Entering New Values
  17
  - Numeric Entry Screen
    17
  - Sub Menus
    18
  - Common Displays in Main Screens
    18
    
    Speed
    18
    
    Setpoint
    18
    
    Feedrate
    18
    
    Belt Load
    18
    
    Sub-Total
    18
    
    Total
    18
    
    Date and Time
    18
    
    Pulses
    18
    
    Blank Button
    19
  - Setpoint
    19
  - Logo
    19
  - Start, Stop, Clear Batch
    19
  - Indicators ( on Feeder Screen)
    19
  - General Alarms
    20
    
    Belt Load over Limit
    21
    
    Belt Load under Limit
    21
    
    PCAD Near Zero
    21
    
    PCAD Near Full
    21
    
    Z Track out of Range
    21
    
    PCAD Discrepancy
    21
    
    Tachos Do Not Comply
    21
    
    Communications Lost
    21
    
    Setpoint out of Range
    21
    
    No Speed Detected
    22
    
    Anain out of Range
    22
    
    LCD Not Responding
    22
    
    No Data from PCAD
    22
- Controller Modes
  22
- Setpoint
  23
  - Setpoint Screens
    23
  - Batch Setpoint
    23
    
    Local
    23
    
    Remote Serial
    23
    
    Batch Parameters
    23
    
    Feedrate
    24
  - Feedrate Setpoint
    24
    
    Manual Speed
    24
    
    Local
    25
    
    Remote Analog Input
    25
    
    Remote Analog Ratio
    25
    
    Remote Serial
    25
    
    Snap Button
    25
    
    Setpoint Button
    25
  - Fallback Setpoint
    26
  - Common Setpoint Buttons
    26
    
    Accept Button
    26
    
    Arrow Buttons
    26
    
    Return Button
    26
- Actions
  26
  - Cal
    26
  - Reset Total
    26
  - Sub-Total
    27
  - Clean Screen
    27
  - Diagnostics
    27
  - Alarms
    27
  - Print
    27
  - Print Line Editing and Printout Selection
    27
    
    PF Buttons
    28
Setting up Your Controller
29
- Setup
  29
- Chain Ez Setup
  29
- Weight Ez Setup
  30
- Custom Setup
  31
- Setup Screen 1
  32
  - Units Select
    32
    
    List of Unit String Combinations
    32
  - Decimal Points
    33
  - Design Capacities
    33
  - PID Parameters & Output Dynamic Protection
    33
    
    Gain
    34
    
    Integral
    34
    
    Derivative
    34
    
    SCR Accel %/S and SCR Decel %/S
    34
    
    Start Speed
    34
  - Limit Switches
    34
    
    Feedrate HI/LO
    35
    
    Feedrate Rel Dev
    35
    
    Feedrate Setpoint Deviation
    35
    
    Numeric Parameters
    35
  - Belt Parameters
    36
    
    Pulses / Rev
    36
    
    Length
    36
    
    Proc Revs
    36
    
    Speed Revs
    36
    
    Nominal Speed
    36
    
    Alarm Delay
    36
  - Zero Tracking Parameters
    36
    
    Wait Time
    37
    
    Max Load
    37
    
    Max Step Alwd
    37
    
    Max Z Track
    37
  - Tachometer Parameters
    37
    
    Type
    37
    
    Mode
    38
    
    Speed Sensing Operational Mode
    38
    
    Numeric Parameters
    39
  - Setpoint
    39
  - Totalizer Cut-Off
    39
  - Calibration Parameters
    39
    
    Calibration Weight
    39
    
    E-Cal Liveload
    39
    
    Weigh Span
    39
    
    Chain Load
    39
    
    Calibration Speed
    39
  - Display Dampening
    40
- Setup Screen 2
  41
  - Analog Inputs
    41
    
    IN1 Zero Level / IN2 Zero Level
    41
    
    IN1 100% Level / IN2 100% Level
    41
    
    IN1 Scaling / IN2 Scaling
    41
  - Analog Outputs
    41
    
    Mode
    42
    
    Type
    42
  - Digital I/O Mapping
    42
    
    Mapping Inputs
    43
    
    Mapping Outputs
    43
    
    Inverting Inputs and Outputs
    43
    
    Forcing Inputs and Outputs
    43
    
    Available Logical I/O Points
    44
    
    External Physical I/O Points
    44
    
    Digital Inputs Setup
    44
    
    Tab
    44
    
    INV (Button) / RV (Indication)
    45
    
    FRC (Button) / FC (Indication)
    45
    
    List of Logical Inputs
    45
    
    List of Physical Inputs
    46
    
    Default Input Mapping
    47
    
    Digital Outputs
    48
    
    INV (Button) / RV (Indication)
    48
    
    FRC (Button) / FC (Indication)
    48
    
    Tab
    48
    
    List of Logical Outputs
    49
    
    List of Physical Outputs
    50
    
    List of Default Output Settings
    51
  - Sample Rate
    51
    
    Internal Sample Rate Parameters
    51
    
    External Sample Rate Parameters
    52
  - External Totalizer Parameters
    52
    
    Divide Value
    52
    
    Pulse Length
    52
  - Communications
    52
    
    Baud Rate
    52
    
    Data Bits
    53
    
    Stop Bits
    53
    
    Parity
    53
  - Numeric Parameters
    53
    
    Controller Number
    53
    
    Comp Start Code
    53
    
    Comp End Code
    53
    
    Communication Time-Out
    53
  - Set Date and Time
    54
  - PCAD Settings
    54
    
    Cal
    54
    
    Zero
    54
    
    Gain
    54
    
    Set Status
    54
    
    Number of Pcad's
    54
    
    Allowed Difference
    54
  - Display Parameters
    55
Calibrating Your Controller
56
- Initial Calibration Checklist
  56
- Calibration Menu
  56
  - Speed Calibration
    57
  - Zeroing Procedure
    58
  - Material Calibration
    59
    
    Scale Totalized
    59
    
    Actual Total
    59
  - Chain Procedure
    60
  - Chain Factor Procedure
    61
  - Weight Procedure
    61
  - Weight Factor Procedure
    62
  - Electronic Calibration
    62
  - E-Cal Factor Procedure
    63
  - Grab Sample Calibration
    64
  - Analog Input Setup and Calibration
    64
Diagnosing Problems
66
- Diagnostic Menus
  66
  - PCAD Diagnostics
    66
    
    Out
    66
    
    PCAD1 and PCAD2
    66
    
    Abs
    66
    
    Cnts
    67
    
    Z Ld
    67
    
    Settings
    67
    
    Scale Factor
    67
  - Communication Diagnostics
    67
    
    Rx Buffer
    67
    
    Tx Buffer
    67
    
    Error Counters
    67
    
    Iir
    68
    
    Lsr
    68
    
    Communication Parameters
    69
  - Tacho Diagnostics
    69
    
    Emt Puls
    69
    
    Tst
    69
    
    Blt Trvl
    69
    
    Curr Ratio
    69
    
    Diff
    69
  - Analog I/O Diagnostics
    70
  - Digital I/O Diagnostics
    70
  - Register Monitor
    70
  - Register Editor
    71
  - Advanced Setup
    71
  - Quick Setup
    71
- Solving Problems
  72
  - Unit Does Not Power up
    72
  - Controller Fails to Boot up
    72
  - LCD Display too Dark or too Light
    73
  - No Load, or Bad Load Reading
    73
  - Tacho Not Counting Pulses, or no Speed Indication
    73
  - No Analog Input
    73
  - External Totalizer Problems
    73
  - General Alarms
    73
  - No Serial Communications
    74
  - Hang Message Appears
    74
- Hardware Calibration and Testing
  74
  - Analog Outputs
    74
  - Analog Inputs
    74
  - Pcad
    75
  - Simulator
    75
Working with Inputs and Outputs
76
- Lti Board
  76
  - Emt
    76
  - Tacho
    76
  - Serial Communications
    76
- Pcio Board
  77
  - Digital I/O
    77
    
    Digital Inputs
    77
    
    Digital Outputs
    77
  - Analog I/O
    77
    
    Analog Inputs
    77
    
    Analog Outputs
    78
- Pcad Board
  78
- Keyboard Location Codes
  78
- Printer Port
  78
Storage
79
- Storage on Receipt from Factory
  79
  - Storage Longer than 6 Months
    79
  - Storage up to 6 Months
    79
- Storage Following Use
  79
- Operation after Storage
  79
Spare Part List
80
- MC³ Controller Spare Parts List
  80
- Accessories for the MC³ Controller
  80
  - I/O System
    80
  - Spare I/O Plugs
    80
  - Miscellaneous
    80
  - Feeder Connection
    81
  - Appendix A
    82
- MC³ Panel Mount - Dimensions
  82
- Wall Mount - Dimensions
  83

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MERRICK MC3 Hardware Manual

MERRICK MC3 Hardware Manual (58 pages)

Brand: MERRICK | Category: Controller | Size: 3 MB

Table of Contents

Table of Contents
3
Introduction

6
Controller Enclosures

7
- Panel Mount
  7
- Wall Mount
  7
- Door Mount
  8
Installation

9
- Physical Installation
  9
  - Panel Mount
    9
  - Wall Mount
    9
  - Door Mount
    9
Card Stack Assembly

10
CPU Board

14
- New CPU Board (Rev 11 or Newer)
  14
  - Communication Ports
    14
    
    Com 1 Rs-232 J7
    14
    
    Com 1 Rs-485 4 Wire J6
    14
    
    Com 2 Rs-232 J4
    15
    
    Com 2 Rs-485 4 Wire J5
    15
- Board Features
  15
  - Option Switch Settings
    16
  - LED Display
    16
  - Jtag/Service Port (J8)
    16
- Old CPU Board (REV 10 or Older)
  17
  - Communication Ports
    17
    
    Comm 2 (RS-232)
    17
  - Board Features
    18
    
    Jumper Settings
    18
    
    Printer Operation (Old CPU Only)
    18
HPAD Board

20
- Straps
  20
- HPAD 1/2 Determination
  20
PCIO Board

22
- PCIO 1/2 Determination
  22
- Connections
  23
- Analog I/O Current/Voltage Strapping
  23
- Analog Input
  23
  - AIN Adjustments
    24
- Analog Outputs
  24
  - AOUT Adjustments
    24
- Adding an Additional PCIO Board to a MC Controller
  24
LTI Board

25
- Connections
  25
  - Serial Communications (for Older CPU Boards)
    25
  - Encoder
    26
  - Emt
    26
Backplane Boards

27
- DC Style Backplane Board - BKPN
  28
- AC Style Backplane Board - BPAC
  29
Power Supply Assemblies

30
- MC 3 DC Power Cables
  30
  - MC 3 DC Power Cable Details
    32
  - Power Receptacle and Switch
    32
Display Assembly

34
- LCD Board
  34
  - Brightness and Contrast Adjustments
    34
- LCD Display
  35
  - Replacing Backlight Assembly
    35
  - Touch Keypad
    35
- Touch Screen Location Codes
  36
  - MC 3 Troubleshooting
    37
1100 MC Troubleshooting

37
- MC³ Crash Screens
  37
  - Start-Up Crash
    37
    
    Parameter Corruption
    37
    
    Controller Firmware Upgrade
    37
  - Fatal Error Crash
    38
    
    Forcing a Parameter Reset
    39
    
    Controller Reboots and Displays Ram Reset Screen
    39
- Unit Does Not Power up
  39
- LCD too Dark/Light or out
  40
- No Belt Load or Weight
  40
- No Speed Detected
  41
- Analog Output Problem
  41
- Analog Inputs
  41
MC3 Flashloader Programming (Application Upgrade)

43
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
- MC³ Controller Spare Parts List
  48
- Accessories
  49
  - I/O System
    49
  - Options (Communication)
    50
  - Spare I/O Plugs and Miscellaneous
    50
  - Feeder Connection Board (FCB)
    50
Appendix A

51
Appendix A

51

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