Professional Documents
Culture Documents
OM Manual 3010E
OM Manual 3010E
EX
Weigh Feeder Controller
PROPRIETARY NOTE
The information in this manual, including technical data and copies of drawings, embodies
information proprietary 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, 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
CONTENTS
Introduction ................................................................................................................................................... 3
Safety........................................................................................................................................................ 3
In General............................................................................................................................................. 3
Electrical Precautions ........................................................................................................................... 3
Related Publications ................................................................................................................................. 3
Manual Conventions ................................................................................................................................. 3
Screens ................................................................................................................................................ 4
Solving Problems...................................................................................................................................... 4
Technical Support................................................................................................................................. 4
System Overview .......................................................................................................................................... 5
Dynamic Control ....................................................................................................................................... 5
Key parameters .................................................................................................................................... 6
Digital ControL .......................................................................................................................................... 8
Feeder States ....................................................................................................................................... 8
Digital Control Parameters ................................................................................................................... 9
Feeder State Transitions .................................................................................................................... 10
Hardware..................................................................................................................................................... 11
Getting Started ............................................................................................................................................ 12
Installation............................................................................................................................................... 12
Starting the controller ............................................................................................................................. 12
Quick Setup ........................................................................................................................................ 12
Main Screens.......................................................................................................................................... 13
Feeder Screen.................................................................................................................................... 13
Graph Screen ..................................................................................................................................... 15
Numeric Screen.................................................................................................................................. 15
Warnings ............................................................................................................................................ 16
Faults .................................................................................................................................................. 17
Setting the Setpoint ................................................................................................................................ 17
Actions .................................................................................................................................................... 20
Feeder Start and Stop buttons ........................................................................................................... 20
Clean Off Screen ................................................................................................................................ 21
Reset Sub-Total.................................................................................................................................. 21
Reset G-Total ..................................................................................................................................... 21
Diag Menu .......................................................................................................................................... 21
Home Screen...................................................................................................................................... 21
Calibrate Menu ................................................................................................................................... 21
Printer Menu ....................................................................................................................................... 21
Settings Menu..................................................................................................................................... 23
Setting Up Your Controller .......................................................................................................................... 24
Settings Menu Items ............................................................................................................................... 25
Select Units ........................................................................................................................................ 25
Set Dec Pts......................................................................................................................................... 25
Design Capacities............................................................................................................................... 25
Control Settings .................................................................................................................................. 26
Hopper Settings.................................................................................................................................. 28
Stability Settings ................................................................................................................................. 30
Calibrate Settings ............................................................................................................................... 30
Quick Setup ........................................................................................................................................ 31
Sample Rate....................................................................................................................................... 32
Dampening & Display ......................................................................................................................... 32
Set Date and Time.............................................................................................................................. 33
Inputs and Outputs Menu ....................................................................................................................... 33
Analog Inputs Setup ........................................................................................................................... 33
Analog Outputs Setup ........................................................................................................................ 35
SAFETY
The Merrick MC³ Controller is used for the control of process weighing equipment. To
insure personnel safety please read the following instructions and precautions carefully.
In General
1. Observe all standard precautions that pertain to moving machinery.
2. Observe all standard precautions that pertain to electrical drives and electrical
controls.
3. Pay particular attentions to special notes and precautions that appear throughout
this manual.
4. Please read and familiarize yourself with this entire manual before attempting
service or repair of the Merrick MC³ Controller. If you have any questions or
problems please call the Merrick Service Department for assistance.
Electrical Precautions
1. Before undertaking work on the electrical system, the drives, or the Controller,
open the main-disconnect switches and lock boxes. Work should never be
performed on the Controller with power on the unit. It is recommended to
disconnect the power from the controller 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 or near areas of live high voltage, always
keep one hand clear of the machine, the cabinet, or any other conductors to
avoid the possibility of electrical shock traveling across your chest. NEVER
undertake any electrical work in areas with wet or flooded standing areas.
4. NEVER impair or disable the function of a fuse or a circuit breaker.
IF YOU ARE IN DOUBT ABOUT ANY PROCEDURE, CONTACT THE MERRICK
SERVICE DEPARTMENT.
RELATED PUBLICATIONS
You will find related publications regarding MC³ controller hardware, internal register
database information and industrial networking capabilities at the support web site at
http://www.merrick-inc.com/mct. In the rest of the manual, this is referred to as [MCT].
MANUAL CONVENTIONS
NOTE: Any additional information that may be useful follows the note marker.
CAUTION: Be careful, certain settings may cause problems.
WARNING: Follow the directions prescribed in the warning. Serious problems can occur if the
recommendations are not followed.
A graphic of this size and type will show the functions available and/or information
available in diagnostic screens and special display screens.
SOLVING PROBLEMS
Several methods are available for use to assist in solving problems. The application
contains help buttons for giving text explanations of the current selected function or
parameter. Also included in this manual is a troubleshooting section to assist in solving
technical problems (Diagnosing Problems, page 61).
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 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 telephone extension where you can be reached. Someone will return
your call as soon as possible.
When you call Merrick for Technical Support, please have your machine serial number or
a controller serial number. This information will better help us to serve you.
DYNAMIC CONTROL
The MC³ 30.10.EX controller uses two different control algorithms that normally compete
with each other for the control of the feeding device. The PID (Proportional, Integral, and
Derivative) control algorithm is suitable for high feedrates and stable weight values. The
CSG (Conditional Step Gravimetric) control algorithm is suitable for slow feedrates and
when occasional disturbances in the weight signal are present.
Most applications fall in between the two categories. By keeping both algorithms active,
and letting an arbitrating algorithm determine to which degree the PID and CSG are
allowed to control the speed of the feeding device, it is possible to take advantage of the
desired properties of both. For very slow or very fast feeders however, it is better to use
only CSG or only PID control.
Setpoint Weight
Average Setpoint
Average Weight
_ Loss Calculation
Weight Loss
PID Control
Dynamic
Protection
CSG Control
Speed
Method Demand
Arbitrator Signal
DIGITAL CONTROL
The feeder operates in a cyclic fashion. The hopper must be filled periodically. The
typical operation will follow a sequence like Start, Fill, Feed, Fill, …, Cleanout, Stop. The
sequences are affected by external commands, the weight in the hopper and Faults.
Feeder States
The controller uses states for digital control. All states have a name, displayed in the
main feeder and graph screen.
Blocked Feeder is blocked from either Feeder Block logical input On or from
an unacknowledged Fault. This state has the highest priority. If the
conditions for block go away, state changes to Stopped.
Stopped Feeder is stopped due to s stop condition (see below). This state has
the second highest priority. A start condition (see below) changes the
start to Checking.
Checking Intermediate state following Stopped or Cleaned. Determines if the
hopper needs to be filled or not. Changes immediately to Filling or
Stabilize.
Stabilize Precursor to feeding. Allows for filters to saturate, the fill gate to close
etc. When the feedrate is stable, state changes to Feeding or
Cleanout. Stabilize comes in three flavors. Stabilize S (Start),
Stabilize C (Cleanout) Stabilize F (After Fill).
Note 1 Blocked will change to Stopped when the Blocked Condition goes away.
Note 2 Stopped is the state after a MC³ power On.
Note 3 Transitory state.
Note 4 Start Cleanout Condition in the Cleaned or Stopped can be used to test the feeding device without filling the hopper.
Note 5 The MC³ will not leave the Filling state if the logical input AutoFill Gt is Off. The only way to transition to Stabilize F is with a Stop Fill
condition.
INSTALLATION
1. 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.
2. Mount the controller in your panel, following the instructions on the drawings in
the MC³ Hardware Manual. Make sure there is adequate clearance around the
unit for maintenance and ventilation.
3. Insure that the Power is disconnected from the Power supply. Make the wiring
connections to the controller, following the instructions on your electrical
connection diagram.
4. Verify all wiring connections before re-applying power to the unit.
3. The controller is normally pre-programmed from the Merrick Factory for your
specific application. A document called the Programming Specification Sheet
(Spec Sheet) is inserted in the last section of the Operator’s manual. The Spec
Sheet contains a record of all parameters.
4. If the controller has not been programmed, or requires programming changes,
see the Quick Setup (page 12) procedure. Remember to record all changes to
the parameters on the Spec Sheet. Merrick keeps a record of all Spec Sheets in
a database. If you forward the updated Spec Sheet to the Merrick Customer
Support Department, they will update the database.
5. Choose Set Point method to be used by your application. See Setting the
Setpoint on page17.
6. Change the Calibration, Diagnostic and Setup passwords to protect your
settings.
Quick Setup
This is a start up procedure to follow when you have to set up a controller that has never
been used before. Following this procedure will overwrite all parameters in the controller.
1. Enter the following parameters:
MAIN SCREENS
There are three main screens:
Feeder Screen Default view of all essential operational parameters.
Graph Screen Feeder trend data.
Numeric Screen Four selectable parameters, large typeface.
Feeder Screen
The first and default main screen is the Feeder Screen. It is designed to provide all
essential information at a glance. It also allows you to enter the sub menus for setting the
controller parameters, calibration and other functions. The “SOAP POWDER 4982-qa”
text in this screen shot is an editable text string. See Printer Menu, on page 21 for more
information.
Feeder Screen
This is what you see in the feeder screen:
Graph Screen
Item Description
04:54 PM Time. Format: Hour (0-12):Minute AP/PM.
“Feeding” State Texts. See page 14.
SP: Actual Setpoint.
FR: Actual Feedrate.
ST: Sub Total. See Page 21
OP: Speed Demand Signal for the feeding device.
WT: Net (material) weight in the hopper.
GT: Grand Total. See Page 21
Local Setpoint Button to reach the Setpoint Menu. See Setting the Setpoint, page17
Action Menu Button to reach the Actions Menu. See Actions, page 20.
Numeric Screen Button to reach the Numeric Screen.
Numeric Screen
A Numerical screen is also available to display the values in a larger typeface for easier
viewing from a distance. Pushing the buttons at the left of the screen will cycle through
various parameters. You also have the option of locking the selections with the Lock
Num Displ logical input. See Digital I/O Mapping on page 37.
Numeric Screen
Warnings screen
Faults
A Fault indicates a malfunction that prevents the feeder from running. Any logical input or
output can be configured to qualify a fault. See Digital I/O Mapping on page 37. The Fault
button is visible in any of the main screens if there is an active fault condition or there has
been a fault condition that has not been acknowledged.
Faults screen
The Faults Screen works just like the Warnings Screen. You can’t start the feeder if the
there is an unacknowledged Fault.
Manual Setpoint
The Manual setpoint method allows you to directly control the Speed Demand Signal, in
percent. The controller will not attempt to control the speed. This is sometimes referred to
as “Volumetric Mode”. It is useful at Startup, when adjusting the Feeder Drive or when
troubleshooting. There are three buttons associated with the output speed. The Snap
button allows you to capture the current Speed Demand Signal, and use it as the Manual
Speed Setpoint. This will allow you to make a Bumpless Transfer. You may also directly
enter the output by pushing the Setpoint button and entering the value in %.
WARNING When in Manual Setpoint, you can start the feeder regardless of the status of the Run
Permission Input.
WARNING When starting, the feeder will immediately fill if the weight in the hopper is below the
heelpoint, even if the setpoint is 0%.
Local Setpoint Method
Local Setpoint
With this method, you enter a Feedrate Setpoint directly at the controller, in engineering
units. The controller will be active. The Snap button allows you to capture the current
feedrate. This will allow you to make a Bumpless Transfer. The Setpoint button allows
you to directly enter the Setpoint using the numeric entry screen.
Analog Setpoint Method
Analog Setpoint
Serial Setpoint
The setpoint is taken from Serial Communications.
NOTE: When the controller is to be used in a networked configuration, the Remote Serial
method must be selected. The rules and format of the data exchange is described in
separate publications.
Forced Serial Setpoint
In networked applications, the Force Serial SP logical input can be used to
unconditionally use the serial setpoint method as long as the outputs Ser Comm Lost and
DF1 Comm Lost outputs both are Off. In these cases, the Change Setpoint screen will
look like this
ACTIONS
Pushing the Action Menu button in any of the main screens takes you to the Action
Selection menu. This is where you start and stop the feeder and perform maintenance
tasks.
Action Menu
This is what the Action Menu looks like when the feeder is stopped and the logical input
Run Permission is off.
Reset Sub-Total
Clears the Sub-Total. It may be cleared at any time. When cleared, a message Subtotal
Cleared appears on the screen.
Reset G-Total
Clears the Total. If you use a non-zero calibration password, you will be asked to enter it.
Enter the password to clear the total or push the ESC button in the password screen to
escape to the action screen without clearing the Master Total. When cleared, a message
“Total Cleared” appears on the display.
Diag Menu
Takes you to a menu with several diagnostic screens for troubleshooting your system.
See Diagnosing Problems on page 61.
Home Screen
Takes you back to the Main Screen from which you entered the Action Menu.
Calibrate Menu
Takes you to the Calibrate Menu. See Calibrating Your Controller on page 51.
Printer Menu
This menu allows you to edit or to print one of the four available print strings and the
Feeder Screen Display String. The print strings (1>, 2>, 3>, 4>) are lines of characters
that convey information to a printer for permanent record. The Feeder Screen Display
(D>) string allows you to place custom text on the main screen for easier controller
identification.
Pushing one of these buttons will send the selected print string to the printer. The last
selected line will be the line that is printed. For example, if you have pushed the button
for line 1 for a test print, line 1 is the line printed when the external print command is
triggered.
You can embed one or more strings into the printed line. For example, you have just
edited 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 you test printed was line 3 then only line 3 would be printed.
This selection allows editing of the strings. The string to edit is selected in the function.
Pushing these buttons will allow you to rotate through the character selection screens.
This is the shift button. This allows you to select uppercase or non-alphanumeric
characters on the buttons. If a button has two lines displayed the upper set is selected
by pushing this button (SHIFT will appear under the print string) then pushing the
appropriate button.
This allows you to enter specific ASCII values that are not supported with a button.
Also you may enter a value for the print counter and the counter increment value. You
may also enter 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.
When un-shifted this is used to place a space character in your string. When the shift is
enabled, it places a NULL value at that character position, which marks the end of the
character string. Any characters beyond the NULL are not printed or displayed.
In the 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 and the main screen text
display.
FF - Form feed
HT - Horizontal tab
Settings Menu
This is where you set up all the controller parameters. See Setting Up Your Controller,
below.
Settings Menu
You reach the second (Inputs & Outputs Menu), with I/O related parameters, by pushing
Inputs & Outputs.
Select Units
Use the Up or Down arrow buttons to scroll through the list of units until the desired
combination appears in the center box, then push the Settings Menu button.
NOTE: It may be necessary, after selecting the units, to update the decimal point selection
values. See Page 25. Even if no changes to the decimal points are necessary, you
should at least look at each decimal point setting.
Design Capacities
These parameters are the design values relating to the maximum useful weight of
material in the hopper and the maximum feedrate that the feeder can obtain.
The Design Weight is important, because it is used for automatically setting the fill and
heel points and for scaling the Weight analog output.
Hopper Settings
The Hopper Parameters are related to the physical properties of the feeder.
Fill Point
Heel Point
Empty Weight
Fill Point
The Fill point is the weight at which the hopper is considered to be filled to normal
capacity. It must be greater than the Heel Point. When the Autofill Device logical input is
turned ON (see List of Logical Inputs, page 39), the controller will turn off the Filling
logical output in such a way that the weight in the hopper reaches this weight at the end
of the fill cycle. See also Min Preact on page 29.
Heel Point
This value represents the weight at which the hopper should be refilled. Normally there
will still be material left in the hopper. The heel point can sometimes have to be
surprisingly high. There are several reasons for this:
• The push from the material falling into the hopper when filling can cause mass flow
through the feeding device.
• If there is an agitator in the hopper, there has to be enough material to make the
agitator effective.
• There has to be enough head pressure into the feeding device to have a
reproducible relation between the Speed Demand Signal and the actual feedrate.
One easy way to determine a good usable heel point is to set it low, and then run a feed
cycle observing the Feedfactor in the Numerical Display. It should initially stay almost
constant. Typically, at some weight it will start changing. The Heel Point should be set
above this weight.
Empty Weight
The Empty Weight value is used to determine when the hopper is empty. It is expressed
in weight units and can range from 0 to the Design Weight. It should be set to a value
representing the amount of material that may be left in the hopper and that the feeding
device can not feed out. The parameter is used in the Cleanout state, to determine when
the hopper is empty.
Fill Time
This is the maximum time allowed for the hopper to be refilled when the controller is in
the Filling State. When the weight in the hopper first drops below the Heel Point, the
controller starts a timer. If the hopper has not been filled to the Fill Point, or taken out of
Fill
W
e
Point
i
g
h
Start of Fill t
(Heel Point)
Fill Time
Clean Time
In the Cleanout state, the feeder will run until the empty weight is reached. If the empty
weight is not reached within Clean Time, the logical output “Slow Cleanout” is turned on.
This value is expressed in seconds and can range from 0 to 6000 seconds (100
minutes).
W Start of Cleanout
e
i
g
h
t Empty Weight
Empty Time
This is an extra time that the feeder will run the feeding device after the empty weight has
been reached during cleanout. When the weight in the hopper drops below the Empty
Weight, the controller starts a timer. When the Empty Time is reached, the controller
turns off the Drive Enable logical output, and zeroes the Speed Demand Signal.
Gate Time
This parameter is set to the time it takes for the fill gate above the hopper to close and
material to finish falling and stabilizing in the hopper. The purpose is to avoid a situation
where the control algorithms are engaged too early after a fill. If the logical input “Fill
Gate Closd” is used with a fill gate limit switch, it has to indicate “Closed” within this time.
If the input fails to turn on within this time, the logical output “Fill Device Err” goes ON. It
can be used to qualify a Warning.
Low Cutoff Wt
This value is added to Heel Point and is used to limit the total Preact value. It keeps the
fill turn-off weight from drop below the heel point.
Min Preact
The Preact is a weight value used to turn off the logical output “Filling” before the fill point
is reached. The purpose is to try to hit the fill point exactly. It is updated every fill cycle.
This parameter is the Preact minimum limit. This parameter and the Maximum Preact
parameter are the limits allowed when the controller adjusts the Preact. If you set
Maximum Preact and Minimum Preact both to Zero, the Preact mechanism is disabled.
Stability Settings
The parameters are used to set stability criteria for weight. They are used in calibration
procedures.
For the weight to be considered stable, the weight indication must stay within the Stable
Span for a certain number of weigh samples (Stable Sampls). In calibration procedures,
the controller will wait for stability a limited time (Stable Time).
Stable Time
This is maximum time the calibration Procedures will wait for weight stability. For noisy
environments, narrow Stable Spans or many Stable Samples, increase this time from its
default, which is 10 s.
Stable Span
This is how much the weight indication may change over the set stable samples, for the
weight to be considered stable. Default is 0.2 % of the design weight. If possible, reduce
this value to get better calibration accuracy.
Stable Samples
This is the number of consecutive weigh samples for which the weight must stay within
the Stable Span, for the weight to be considered stable. Default is 3. For calibration
accuracy, increase this value.
Calibrate Settings
The following parameters are used for calibration. They are used or affected by
calibration procedures. See Calibrating Your Controller on page 51.
Cal Weight
The weight you will be using when running a Weight Procedure (page 53). Default is
Design Weight. Limits are 10 to 110% of Design weight.
E-Cal Liveload
This parameter is used for the Electronic Calibration procedure (page 55). IF you are
going to be using Electronic calibration, you must calculate this parameter. You can not
use the default value (1.5 mV/V). Limits are 0.2 to 3 mV/V. Performing an E-Cal Factor
Procedure (page 56) will adjust this value.
Zero Weight
This parameter represents all of the dead weight on the load cells. This may include the
hopper, discharge device, motor, etc. This does not include the weight of the material.
Default is 0. Normally adjusted by performing a Zeroing Procedure (page 52).
Scale Factor
The Scale factor is used to calculate the weight from the counts coming out of the load
cell A/D (HPAD) converter. It is normally adjusted using the Material Calibration (page
53), Weight Procedure (page 53) or Electronic Calibration (page 55) procedures.
You can calculate the weight from the HPAD counts by using the following formula:
HPADCounts
Weight = − ZeroWeight
ScaleFactor
Sample Rate
Use the Sample Rate menu to change how often the HPAD is sampling the Load Cell
Signal. All other calculations regarding Feedrate Control are done right after a HPAD
sample, so the timing set here will be the heartbeat of the entire controller.
There are two settings. You can adjust them by pushing the NUMERIC PARAMS button.
The Feed Sample Time is used when the controller is feeding. The Fill Sample Time is
used when the controller is filling the hopper. Normally, the Fill Sample time is shorter
than the Feed Sample time
The Learn feature will adjust the Feed Sample Time setting based on the discharge time.
Setpt Slots
Increase this value when a noisy analog signal is used for the Setpoint. You can see the
dampened value in the Feeder Screen. The Setpoint Filter is important if you use CSG
control. Since the algorithm is based on feedrate stability, the setpoint also has to be
Value =
(A / DCounts − LoCnts ) ⋅ MaxValue + MinValue
HiCnts
There is one set of parameters for the Setpoint and one for the Panel Meter.
Panel Meter Units
You can select the unit that will be displayed on the Numerical Screen for the Panel
Meter function.
0 – Amps
1 – Volts
2 – Drv Amps
3 – Torque, %
4 – Temp, F
5 – Temp, C
20 mA
4 mA
0% 25 % 50 % 100 % 125 %
2.5 lb/min 10 lb/min
Example, Design Feedrate = 10 lb/min, by setting the Low val to
25% would set the output range equal to 2.5 - 10 lb/min over the 4
- 20 mA range
If you want zero level mA to be adjusted such that 0 lb/min feedrate equals 7.2 mA then
you would set the zero level to –25%.
20 mA
7.2 mA
4 mA
-25 % 0% 50 % 100 %
0 lb/min 10 lb/min
For example, Design feedrate = 10 lb/min by setting the Low val to
-25% would set the 0 - 10 lb/min range would equal to 7.2 - 20 mA
Full Values – This allows you to adjust the full scale output. For example, if 20 mA output
to the feeding device drive causes the feedrate to exceed your system requirements, you
can adjust the SCR Out Full Value up to obtain the desired feedrate at 100% output.
4 mA
0% 50 % 100 % 125 %
10 lb/min
For example, design feedrate = 10 lb/min, by setting the Full
value to 125% would set the 0 - 10 lb/min range equal to 4 -
16.8 mA
Another example is if you want to scale the output from 0 – 7.5 lb/min over the full range
(4 – 20 mA). You would then set the full value to 75%.
20 mA
4 mA
0% 50 % 100 %
7.5 lb/min 10 lb/min
For example, design feedrate = 10 lb/min, by setting the f
value to 75% the 4 - 20 mA range would equal 0 - 7.5 lb/
min.
Whenever you are using non-standard output scaling, you can see the actual output,
together with the underlying engineering value in Analog Diagnostics. See page 64.
Select Column This button switches the active scroll area between the Logical and
Physical sections. First select the logical input you want to work with,
using the Up and Down arrow buttons. Then push the Select Column
button to map it to a physical input, again using the Up and Down
arrow buttons.
Invert Off/On This button inverts the logic of the Physical input. For example, if the
Fill Gt Closed logical input is mapped to a physical input that is Off
when the gate is closed, you would have to invert that input. An
inverted input will have a “1” in the “IV” column. The button is only
available when you have the Physical Input selected, since the
“Invert” property is associated with the physical input.
Force None/Off/On This button toggles the FC indication through Forced On “1”, Forced
Off “0”or no Force “-“. There will be an indication on the Main Feeder
Screen if forces are present. The button is only available when you
have the Physical Input selected, since the “Force” property is
associated with the physical input.
Alarm None/Warning/Fault This button cycles the FW column between Fault (F),
Warning (W) and None (-). If a logical input with “Fault” property is
turned on, the feeder will stop. See Warnings (page 16) and Faults
(page 17). The button is only available when you have the Logical
Input selected, since the “Fault” and “Warning” properties are
associated with the logical input.
Accept When you are done with your Logical Inputs configuration, push this
button to make your configuration changes permanent. The button is
only available when you have the Logical Input selected.
Esc Takes you back to the Inputs and Outputs Setup Screen. If you push
this button without first pushing the Accept button, The Digital Inputs
configuration will be restored to the condition it had when you entered
this menu.
Digital Outputs
This selection allows you to change the mapping and properties for the digital outputs. A
Physical Output is always mapped to a Logical.
NOTE On Always and Off Always are valid logical inputs. You typically map unused physical
outputs to Off Always. Unused is the same as Always Off.
Select Column This button switches the active scroll area between the Physical and
Logical sections. First select the physical output you want to work
with, using the Up and Down arrow buttons. Then push the Select
Column button to map it to a physical output, again using the Up and
Down arrow buttons.
Invert Off/On This button inverts the logic of the physical output. For example, if the
Rack 1 Output 1 is mapped to the logical output Fault, you would
typically invert that output, so that the output contact is closed when
there is no fault. An inverted output will have a “1” in the “IV” column.
The button is only available when you have the Physical Output
selected, since the “Invert” property is associated with the physical
output.
Force None/Off/On This button toggles the FC indication through Forced On “1”, Forced
Off “0”or no Force “-“. There will be an indication on the Main Feeder
Set the Warning and Fault properties for all Logical Outputs by
scrolling to the output with the up and down arrows and then push the
Select F/W button. When you are done, push the Return button.
Accept When you are done with your Logical Outputs configuration, push this
button to make your configuration changes permanent. The button is
only available when you have the Logical Output column selected.
Esc Takes you back to the Inputs and Outputs Setup Screen. If you push
this button without first pushing the Accept button, The Digital
Outputs configuration will be restored to the condition it had when you
entered this menu.
List of Logical Outputs
Logical Output Description
Fdr Drv Enable Intended for enabling the feeding device drive Turns on when
the controller is running and the setpoint is greater than 0. If
the Drv Enable at 0 logical input is On, the output will be On
when the controller is started regardless of the setpoint.
Fill Gate Open The weigh hopper needs filling. Normally connected t a fill
gate solenoid.
Weight Stable The weight value is stable, according to the Stability Settings
(page 30).
Cleaning Out The feeder is in the Cleanout or Cleaned State.
Cal Weights On Place calibration weights on the feeder during a Weight
Calibration procedure. Intended for automatic calibration
equipment.
Agit Drv Enable Intended for enabling the agitator. There are two modes of
operation:
1: The agitator runs whenever the weight in the hopper
exceeds the Low Weight Limit and the Ready output is on.
2: The agitator runs whenever the Running output is on.
EMT Settings
EMT Divisor
This is the value used to scale the EMT (External Mechanical Totalizer) output. If the
Weight per Pulse is set to 1 then there is a pulse for every pound or kilogram that is
totalized. If Weight per Pulse Value is set to 100.0, there must be 100.0 pounds or
kilograms totalized before a pulse is sent to the external totalizer. Limits are minimum
0.001 and a maximum of 100,000.0.
EMT Pulse Width
This value is the length in seconds for the pulse that is sent to the EMT. A mechanical
totalizer will require a longer pulse than an electronic. The pulse output from the
controller is buffered, in order to allow slow EMT’s to “catch up”. The recommended
value for a mechanical totalizer is 0.10, and 0.01 for an electronic totalizer. Limits are
0.01 to 5.0. The duty cycle is 50% at full pulse rate.
Comm Settings
Serial Communications provides the means to exchange information between the MC³
Controller and other devices. There are two serial ports, Comm 1 and Comm 2.
On Comm 1, you can run a Merrick proprietary protocol, called Scalenet, or a subset of
Modbus ASCII or RTU, which is a Modicon protocol in the public domain.
On Comm 2, you can connect a printer with a serial interface, or you can run a subset of
DF-1, which is an Allen-Bradley protocol in the public domain.
Through interfaces, it is possible to connect to many Industrial Networks, such as
ProfiBus, DeviceNet, ControlNet or EtherNet/IP. More information on network
connections and available Merrick communications solutions can be found at [MCT].
There are PC based software products available from Merrick that utilizes ScaleNet.
WinMerik allows you to
• Upload and download all MC³ parameters to and from PC files.
• Monitor, in real time, up to 10 MC³ registers, and log them to a CSV file periodically.
• Access, in real time, up to 10 MC³ registers using Dynamic Data Exchange (DDE).
For more information, refer to [MCT].
WARNING: Failure to program communications correctly can result in the operational failure of the
controller. It is possible, for example, to write a non-valid floating point number to a
controller parameter. This will cause a controller fatal exception. You will have to reset all
parameter to their default values, and then enter all of them.
Communications Settings
For Baud Rate, Data Bits, Stop bits and Parity parameters, simply pushing the button for
the corresponding parameter will toggle through the available settings.
There are several programmable limit switches. This is where you set the limits and
delays associated with them.
Main screen indicators and logical outputs are directly affected. See Digital I/O Mapping
on page 37 and Status Indicators on page 14.
Feedrate Limits
This button allows you to set the upper and lower limits for the feedrate and feedrate
deviation logical outputs. Hi and Lo FeedRate are absolute limits, in engineering units,
that control the Hi Feedrate and Lo Feedrate logical outputs. The Hi/Lo Setpt Dev logical
outputs are used to signal a sustained difference between the Setpoint and Feedrate.
They are controlled by combining the Hi/Lo Rel Dev and Hi/Lo Rate Dev conditions. The
Weight Limits
This button allows you to set the upper and lower limits for the Hi/Lo Weight logical
outputs. The limits are absolute values in engineering units. When the weight exceeds
the limit the output will turn On, after the delay time.
Parameter Default Min Max Unit
Hi Weight 110% of Design Weight 0% 150% Eng
Lo Weight -10% of Design Weight 0% 100% Eng
Hi Wt Dly 10 0 3600 Seconds
Lo Wt Dly 10 0 3600 Seconds
The Hi Weight parameter is significant:
• During normal operation of the feeder, no active control action is taken if the actual
weight is higher.
• You can’t perform a Weight Calibration procedure, if the Current Weight plus the
Calibration Weight exceeds this limit.
Output Limits
This button allows you to set the upper and lower limits for the Speed Demand output to
the feeding device, and the logical outputs Hi Output and Lo Output. The output to the
drive will stay between the High Output and Low Output parameters, as long as the
feeder is running.
Parameter Default Min Max Unit
Hi Output 100 0 100 %
Lo Output 0 0 100 %
Hi Outp Dly 10 0 3600 Seconds
Lo Outp Dly 10 0 3600 Seconds
Setpoint Limits
This button allows you to set the upper and lower limits for the High and Low Setpoint
logical outputs. If the logical input Clamp Setpoint is ON, the setpoint used by the
controller always stays between the limits.
NOTE: It is not possible to set a local setpoint outside the limits in the Setpoint Screen.
Calibration Menu
To enter the Calibration Menu, push the Calibrate Menu button while in the Action
Menu. The display will show the password entry screen
Calibration Password
A four digit numeric password must be entered at this time. The default Calibrate
Password is 1234. While entering the password an asterisk (*) will appear for each digit
entered. If the correct password has not been entered, you will be prompted again for
the Calibration Password. If the correct password has been entered, the Calibration
menu will be displayed.
Calibration Menu
When you push Start, The controller will average weight readings, when the weight value
is stable, as determined by Stable Weight and Stable Samples parameters. If you do not
wish to run the Zeroing Procedure, push the Cancel button to return to the Calibration
Menu. However, if you are ready to begin the Zeroing Procedure, push Start. The
display will show the elapsed time of the test and an indication on the stability of the
scale.
When the procedure is complete the display will show the current and new Zero Weight
values, as well as the change in the Zero Weight value as a percent of Design Weight.
If you wish to accept the new Zero Weight value, push Accept. Otherwise, push Cancel.
Pushing either button will return you to the calibration menu.
The Zeroing Procedure can fail if the hopper weight is unstable. You will get an error
reporting screen if this happens. The parameters for hopper weight stability are settable
in Stable Weight and Stable Samples, in the Stability Settings screen.
The Scaled Totalized value is the current Sub Total, by default. You can change it by
pushing the Scale Totalized button.
4. Push the Accept button.
5. The difference between the actual and the totalized amount is calculated in percent
of actual total.
Push Accept to accept changes. The controller will adjust the Scale Factor parameter. If
you don’t want to proceed, push the Cancel button. The “Never Performed!” indication in
this screen shot means that this procedure has never been executed since the last time
the controller was subject to a RAM Reset procedure.
Weight Procedure
The Weight Procedure is used to calibrate the scale to show a correct net weight.
To run this procedure, you will need calibration weights that represent at least 20% of the
Design Weight. The weight in the hopper plus the sum of the calibration weights may not
exceed the Hi Weight limit. The procedure will first sample the current weight, and then
the weight with the calibration weights added.
Normally, the start weight is sampled. This requires that the weight value is stable.
In the next screen, the sampled weight before applying the calibration weighs is
displayed (“Test Zero”), along with the expected calibration weight. By pushing the
Change Value button, you can alter the Calibration Weight value.
Push the OK button and load the calibration weights onto the hopper.
Push Start when the calibration weights are on, and the hopper weight is stable.
This screen indicates that most likely, no calibration weights were applied. Your only
option is to push Cancel.
Normally, after the weight has been sampled, the changes that are about to be applied
are displayed. You have the option of pushing Accept, to apply the changes, or Cancel
to have the controller ignore the entire calibration procedure.
NOTE: The logical input Allow Calibr has to be ON for the Accept button to appear.
Electronic Calibration
The Electronic (E-Cal) Procedure is provided as an alternate method to set the Scale
Factor. It is used when it is not possible to run either a Material or Weight procedure. The
HPAD board can inject a known artificial load cell signal to simulate weight. You must
calculate a parameter, called the ECAL mV/V, found in Calibrate Settings. Use the
following formula to calculate the E-Cal Live Load mV/V:
Design Weight * mV/V rating of Load Cell
ECAL mV/V =
Capacity of Load Cells
If there are more than one load cell supporting the hopper, add the load cells capacities.
For example, for three 1000 lb load cells:
1000 * 3
Capacity of Load Cells = = 1361 Kg
2.204
If the load cells are 3 mV/V, and the Design Weight is 400 kg, then:
400 * 3
ECAL mV/V = = 0.8817 mV/V
1361
Enter ECAL mV/V, in Calibrate Settings, before running the procedure. The hopper
must be empty, and a Zero Procedure must be performed immediately before the E-Cal
Procedure.
If the ECAL mV/V is incorrect or if you do not wish to complete the E-Cal Procedure for
any reason, push the Cancel button to return to the Calibration menu. If you are ready to
execute the E-Cal Procedure, push the Start button.
The procedure goes through two phases. In the first phase, the HPAD sets up a known
artificial load cell signal, in mV/V.
At this point, the proposed change to the Scale Factor will be shown. If you wish to
accept the new value push Accept button, otherwise, push Cancel to abort the test.
E-Cal Factor Procedure
This procedure will update the ECAL mV/V parameter, using current Scale Factor. In
other words, it is the reverse of the E-Cal Procedure. It should only be run after a
material or weight procedure has been completed, followed by emptying the hopper and
performing a Zero Procedure. The purpose is to correct the calculated ECAL mV/V
parameter so that it is based on better calibration procedures. If you later run an E-Cal
Procedure, you will get more accurate results.
Set the signal at the source to represent zero value, typically 4 mA. The live counts will
vary accordingly. Since the nominal full scale of the high resolution analog input A/D
converter in 1,000,000 counts, the value you see should typically be around 200,000
counts. Push the Snap Zero button.
The live value will snap to the New column, Lo row.
Set the signal at the source for full-scale value, typically 20 mA. The live counts should
follow the input, and be around 1,000,000 counts. Push the Snap Full button.
Start Learning
This function allows the controller to “learn” the characteristics of the feeder (hopper and
discharge device).
To successfully set up your controller using this method, it must be possible to run two fill
sequences, with a complete, undisturbed feed cycle in between. During the learning
operation, the setpoint must be at a fixed value. This can be accomplished by using the
Local setpoint method. The performance of the system will not be optimal while the
learning operation is in progress because the controller is adjusting parameters to collect
enough data to be able to optimize.
Although self-learning is an effective method to set controller parameters, it does not
always produce a perfectly tuned controller. In extreme cases, such as very low and very
high feedrates, manual tuning methods, used by an experienced technician, works
better.
The following parameters are set:
Parameter Description
Feedfactor Represents the output to the feeder drive required to obtain the
design feedrate. Set to 100% at the start of the learn cycle,
measured and continuously updated during the cycle.
Upper Feedfactor This is the feedfactor when the weight in the hopper is relatively
high, near the fill point. Set to 100% at the start of the learn
cycle, and then updated.
Lower Feedfactor This is the feedfactor just before entering fill. It is used together
with the High Feedfactor if the “Auto FF Adjust” logical Input is
ON. The CSG function uses them together with the weight to
set the Speed Demand Signal at feeder start, and to keep the
feedrate at the setpoint during fill. Set to 100% at the start of
the learn cycle, and then updated.
Feeding Sample Time This is the sample time to use when the controller is normally
feeding material. Set, based on the discharge time, according
to the table below. See also Sample Rate on page 32 for more
information.
Setpoint Filter Set, based on the discharge time, to twice the value of the
Average / Loss Slots according to the table below. The highest
value is 100. See Dampening & Display on page 32 for more
information.
Average Slots Set, based on the discharge time, to Average / Loss Slots
according to the table below. See Average Slots on page 27 for
more information.
Loss Slots Set, based on the discharge time, to Average / Loss Slots
according to the table below. See Loss Slots on page 27 for
more information.
When the learn cycle is started, which happens the first time the control state changes
form Feeding to Filling, the controller calculates the minimum discharge time (Fill Point –
Heel Point / Design Feedrate) and pre-sets parameters according to the following Table.
Discharge Time Average / Max Feeding FF High FF time
(seconds) Loss Slots Slots Sample time Dampening
3–9 3 10 0.10 1 0.6
10 – 29 3 15 0.20 1 1.2
30 – 99 4 20 0.33 2 3
100 – 299 8 30 0.33 3 5
300 – 999 16 50 0.33 3 11
1000 – 2999 32 100 0.33 4 25
3000 – 9999 54 300 0.33 6 36
10000 – 29999 90 500 0.50 7 100
30000 – 999999 90 500 1.00 9 200
100000 - 90 500 2.00 12 400
During the next discharge cycle, statistics is gathered, without using the PID controller
algorithm. At the end of this cycle, parameters are set automatically, based on the
performance during the Learn Cycle.
While the controller is learning the characteristics of the feeder, you may push the
Cancel button to abort the learn process. This will re-instate the parameters used before
the learning process was started.
DIAGNOSTIC MENUS
Pushing the Diag Menu button in the Action menu takes you to the Diagnostics Menu.
It is usable for troubleshooting. It is not necessary to access these menus under normal
operating conditions.
HPAD Diagnostics
HPAD stands for “High Performance Analog to Digital converter”. It is the board in the
MC³ that takes the Load Cell signal as input and produces a digital value (Counts) as
output. This screen helps you diagnose weight indication related problems.
HPAD Diagnostics
Counts HPAD output counts. With default HPAD scaling settings, 0 –
1,000,000 corresponds to 0 – 3 mV/V relative output of the load cell.
A value below 255 will turn on the HPAD Underload logical output. A
value above 1048320 will turn on the HPAD Underload logical output.
Values 0 and 1,048575 indicate that the A/D converter is saturated at
one on its end limits. Since the load cell excitation voltage normally is
around 10 volts, dividing Counts with 33,333 should give you the
approximate load cell input analog voltage in mV.
mV/V Load cell relative output. This value takes into account any non-
default HPAD scale settings.
Wt Result of weight calculation. Counts divided by ScaleF minus Z Wt
(see below). This is the weight value shown in all main screens.
Z Wt Zero weight – the weight of everything on the load cells when the
hopper is empty. The date and time below in the last time a Zero
Procedure was performed.
NOTE: Changing the Zero Weight manually will not update this date.
ScaleF Scale Factor. Set by calibration procedures or manually. The date
and time below in the last time a Weight, Material or ECal Procedure
was performed.
NOTE: Changing the Scale Factor manually will not update this date.
Communication Diagnostics
When you are using ScaleNet on Comm 1 for communications, this screen is useful for
troubleshooting.
ScaleNet Diagnostic
Rx Buff The first 28 characters in the receiver buffer; start character and
controller number stripped out.
TX Buffer The first 28 characters in the transmitter buffer; start character and
controller number stripped out.
NOTE: Not all characters can be displayed so some may appear as spaces. When a long
telegram is followed by a short, you will see the tail of the long, following the short.
ERR Errors and statistics counters
Counter Description
A Receive Errors Counter
B Status Errors Counter. A status error is a UART error
condition, such as parity or overrun error.
C Input Buffer Overrun Errors Counter. Too many
characters have been received without an End character
D Bad Message Counter. The MC³ does not understand
the incoming telegram.
E Communication Interrupts Counter. Increments for every
character transmitted or received.
F UART Status Register
Analog Diagnostics
The top section displays the selected function (SCR Out, Feedrate, Weight etc.) and type
(0-20 mA or 4-20 mA) for each of the Analog outputs. The “Actual” column in the output
section displays the engineering value, used to generate the output. The “EST-mA”
column displays the estimated current output in mA for the output. See Analog Outputs
on page 35 for more information. As long as standard output scaling is used, the
translation between engineering value and output current is straightforward. If you have
to use non-standard output scaling, this is where you can see the effect of your changes
to the analog output scaling. If you are using voltage output, divide EST-mA with two.
Analog Diagnostics
Analog inputs use a 20 bit A/D converter, just like the HPAD. In the Input section, you
can see
• The counts, directly from the A/D converter. For a 4-20 mA or 2-10V input, the value
should stay between approximately 200,000 and 1,000,000.
• The percentage of full scale of the analog input.
• The calculated engineering value based on the scaling.
The last row in this screens shot is what you will see if there is no second PCIO board
installed.
See Analog Inputs on page 33.
Digital Diagnostics
The screen offers two views of all digital input and outputs. The mapping view displays
mapping, qualifiers and status of all physical outputs and all logical inputs. The List View
displays either all logical I/O points or all physical I/O points. For more information see
Digital I/O Mapping on page 37.
Mapping view
In the List View, you can see status and properties of all logical or physical I/O points,
regardless if they are used or not, but you can’t se the mapping. Logical outputs are
listed before the logical inputs. Physical inputs are listed before physical outputs. Logical
list view has 4 columns:
ST (Status) Current state of logical I/O point. - OFF - ON
Logical Name of logical I/O point
OUT – Output, IN – Input, I/O – both Input and Output.
F – Logical I/O point generates a Fault when on. W – Logical I/O point
generates a Warning when on.
Physical list view has 5 columns
ST (Status) Current state of physical I/O point. - OFF - ON
Physical Name of physical I/O point
OUT – Output, IN – Input, I/O – both Input and Output.
I - Physical I/O point is inverted.
0 – Physical I/O point Forced Off. 1 – Physical I/O point Forced On.
Register Monitor
This screen is used to monitor the values of 8 specific registers. The display includes the
register number, the value and the register name.
Register Monitor
This screen shot displays the default register monitor set-up. It is possible to select the
registers you see. Enter the numbers of the registers you want to see into register 379 -
386. See Register Editor on page 69. The screen is used mostly for telephone support.
Misc Datc
Start Date and Time The date and time the controller was powered up.
Current Time The current date and time
Serial Number Not used. You can enter a number into register 15 to be displayed
here.
Core Time CPU time spent on core functions.
Max Core Time Peak CPU time spent on core functions. Reset by Clear Min Max
button
UI Time CPU time spent on user interface functions.
DIAGNOSTIC SETTINGS
This selection takes you to the Diagnostic Settings menu. The menu is password
protected, with default password 1030. Any modifications to parameters in the Diagnostic
Settings must be done with some afterthought. It is quite possible to crash the application
from here.
HPAD Settings
You can change the default HPAD scaling here, to improve live load resolution or to
make a somewhat overloaded 3 mV/V load cell operational.
CAL
This value is used by the HPAD Converter simulate load on the load cell during an
Electronic Calibration, and is normally zero. A non-zero setting will inject a positive load
cell signal before the A/D converter. The injected signal is 0.2 mV/V times the setting. In
the rare occasion of negative dead load, a positive value can be present.
ZERO
This value is used by the HPAD Converter to electronically remove dead load from the
load cell signal. This allows the HPAD to operate at a higher Gain and achieve better
resolution when measuring the load cell signal. A non-zero setting will inject a negative
load cell signal before the A/D converter. The injected signal is -0.2 mV/V times the
setting.
GAIN
This value is used by the HPAD Converter to control the Gain on the analog side of the
HPAD converter. The amount of Gain depends on how much dead load and live load
there will be on the scale. The Gain Parameter decreases as the HPAD Gain increases.
This value is normally set to 15.
WARNING: The previous three values are set at the factory and should never be changed.
Set Status
This value is the hardware calibration setting and is preset at the factory. This value
should not be changed.
WARNING: This number should not be changed from its setting of 2. DO NOT CHANGE THIS
NUMBER!
Normal HPAD settings.
CAL 0
ZERO 0
GAIN 15
Set Status 2
Number of HPAD’s
There are three possible settings for this parameter:
0 Used for simulation or training purposes only. The HPAD is not sampled at all.
1 Normal setting, used when you have one HPAD present.
2 Dual HPAD setting. In rare occasions, there are two HPAD’s installed.
Passwords
This option is used to select the passwords that allow specific users access to the
Setpoint, Calibration, Setup and Diagnostic screens. The passwords are four digit
numeric values. The default Setpoint Password is 0 (no password), Calibration password
is 1234, Setup password is 5678 and the Service Menu password is 1030.
Register Editor
You can access the internal MC³ database directly with the register editor. All protection
and “values within reason” checks are disabled.
There are some “undocumented” or experimental functions included, that do not have an
associated user menu. The only place to set parameters for them is here. You may also
be instructed by technical support to use the register editor for error trapping purposes.
There are 629 registers, numbered 1 to 629. Some of them are not used. Some are
write-protected, and some are conditionally write protected. All used registers have a
name, which can give you a hint of what they are used for.
Access is only allowed if the logic input Register Access is On. If the logical input is Off,
the button 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. In fact, you can easily crash the
application. This would require you to perform a complete controller reset to factory
default conditions. You would then have to enter every parameter.
In the register editor the ‘>’ symbol is used to denote the active line. The top line displays
the register number. The second line displays the register name and value.
Register Editor
Before entering new values into the controller, you must clear the previous value by
pushing the CLR button. When you have entered the number, you mast push the ENT
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 the register list.
This works when either the register number or register name/value is the current
selection.
First enter the number of the register you want to see or change in the number row. Then
TAB to the Name/Value row if you need to change the value.