Merrick

MC³ ControllerHardware Manual Revision 2 MERRICK INDUSTRIES, INC. 10 Arthur Drive Lynn Haven, FL 32444 U.S.A Tel: +1 850.265.3611 Fax+1 850.265.9768 E-mail: [email protected] www.merrick-inc.com Revisions 0 1 2 06/08/04 06/30/04 01/05/05 RGB Initial Release RGB RGB All trademarks referenced are the property of their respective owners. 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 Table of Contents Introduction ...................................................................................................................................... 4 Controller Enclosures ...................................................................................................................... 5 Panel Mount ................................................................................................................................. 5 Wall Mount ................................................................................................................................... 5 Door Mount .................................................................................................................................. 6 Installation........................................................................................................................................ 7 Physical Installation ..................................................................................................................... 7 Panel Mount ............................................................................................................................. 7 Wall Mount................................................................................................................................ 7 Door Mount............................................................................................................................... 7 Card Stack Assembly ...................................................................................................................... 8 Connections ................................................................................................................................. 8 Card Stack with Revision 11 or newer CPU Board .............................................................. 9 Card Stack with Revision 10 or older CPU Board .............................................................. 10 Controller Disassembly .............................................................................................................. 11 Controller Reassembly............................................................................................................... 11 CPU Board..................................................................................................................................... 12 New CPU Board (Rev 11 or Newer) .......................................................................................... 12 Communication Ports ............................................................................................................. 12 COM 1 RS-232 J7 .............................................................................................................. 12 COM 1 RS-485 4 WIRE J6................................................................................................. 12 COM 2 RS-232 J4 .............................................................................................................. 13 COM 2 RS-485 4 WIRE J5................................................................................................. 13 Board Features .......................................................................................................................... 13 Option Switch Settings ........................................................................................................... 14 LED Display............................................................................................................................ 14 JTAG/Service Port (J8) .......................................................................................................... 14 Old CPU Board (REV 10 or older) ............................................................................................. 15 Communication ports ............................................................................................................. 15 Comm 2 (RS-232)............................................................................................................... 15 Board Features....................................................................................................................... 16 Jumper Settings.................................................................................................................. 16 Printer Operation (Old CPU Only) ...................................................................................... 16 HPAD Board .................................................................................................................................. 18 Straps......................................................................................................................................... 18 HPAD 1/2 Determination............................................................................................................ 18 PCIO Board ................................................................................................................................... 20 PCIO 1/2 Determination............................................................................................................. 20 Connections ............................................................................................................................... 21 Analog I/O Current/Voltage Strapping ....................................................................................... 21 Analog Input............................................................................................................................... 21 AIN Adjustments..................................................................................................................... 22 Analog Outputs .......................................................................................................................... 22 MC3 Hardware Manual i AOUT Adjustments................................................................................................................. 22 Adding an additional PCIO board to a MC3 controller ............................................................... 22 LTI Board ....................................................................................................................................... 23 Connections ............................................................................................................................... 23 Serial Communications (for Older CPU Boards).................................................................... 23 Encoder .................................................................................................................................. 24 EMT ........................................................................................................................................ 24 Backplane Boards ......................................................................................................................... 25 DC Style Backplane Board - BKPN ........................................................................................... 26 AC Style Backplane Board - BPAC ........................................................................................... 27 Power Supply Assemblies ............................................................................................................. 28 MC3 DC Power Cables............................................................................................................... 28 MC3 DC Power Cable Details .................................................................................................... 30 Power Receptacle and Switch............................................................................................ 30 Display Assembly .......................................................................................................................... 32 LCD Board ................................................................................................................................. 32 Brightness and Contrast Adjustments.................................................................................... 32 LCD Display ............................................................................................................................... 33 Replacing Backlight Assembly ............................................................................................... 33 Touch Keypad ........................................................................................................................ 33 Touch Screen Location Codes................................................................................................... 34 MC3 Troubleshooting ..................................................................................................................... 35 MC³ Crash screens .................................................................................................................... 35 Start-Up Crash ....................................................................................................................... 35 Parameter Corruption ......................................................................................................... 35 Controller Firmware Upgrade ............................................................................................. 35 Fatal Error Crash.................................................................................................................... 36 Forcing a Parameter Reset ................................................................................................ 37 Controller Reboots and Displays Ram Reset Screen ........................................................ 37 Unit does not power up – ........................................................................................................... 37 LCD too dark/light or out – ......................................................................................................... 38 No Belt Load or Weight.............................................................................................................. 38 No Speed Detected.................................................................................................................... 39 Analog Output Problem.............................................................................................................. 39 Analog Inputs ............................................................................................................................. 39 MC3 Flashloader Programming (appLication upgrade) ................................................................ 41 Procedure for Rev 10 or earlier CPU boards............................................................................. 42 Procedure for Rev 11 or Later CPU boards............................................................................... 43 Sample Session ......................................................................................................................... 44 STORAGE ..................................................................................................................................... 45 STORAGE ON RECEIPT FROM FACTORY ............................................................................ 45 Storage Longer than 6 Months............................................................................................... 45 Storage up to 6 Months .......................................................................................................... 45 MC3 Hardware Manual ii Storage Following Use............................................................................................................... 45 Operation After Storage ............................................................................................................. 45 SPARE PART LIST ....................................................................................................................... 46 MC³ Controller Spare Parts List ................................................................................................. 46 MC³ Panel Mount A30685 ...................................................................................................... 46 MC³ Wall Mount A30833, A31534, A37244 ........................................................................... 46 MC³ Door Mount A33432 (Hitachi) ......................................................................................... 47 MC³ Door Mount A39307 (Hantronix) .................................................................................... 47 Accessories................................................................................................................................ 47 I/O System.............................................................................................................................. 47 Options (Communication)....................................................................................................... 48 Spare I/O Plugs and Miscellaneous ....................................................................................... 48 Feeder Connection Board (FCB)............................................................................................ 48 APPENDIX A ................................................................................................................................. 49 Panel Mount (A30685) – Dimensions ........................................................................................ 49 Wall Mount (A30833, A31534) – Mounting Dimensions ............................................................ 51 Wall Mount – Mounting Dimensions cont .................................................................................. 52 Door Mount (A33432, A39307) - Dimensions............................................................................ 53 Door Mount Power Supply Mounting Dimensions (S60213, 19-102-32402)............................. 54 Door Mount Power Supply (VL30) Mounting Dimensions (A36539) ......................................... 54 Backplane Mounting Dimensions (M21882, M22108, M22535)................................................ 55 Watchdog Timer Board Mounting Dimensions (N41215) .......................................................... 55 IOC Input Connection Board (M22536) ..................................................................................... 56 MC3 Hardware Manual iii Graphical Display and Touch Screen. There are three different versions. The MC³ hardware is a platform for different Firmware Applications. Printed circuits boards in a standard PC/104 configuration. • I/O racks for digital I/O The controller is scalable and configurable by means of cards in the card stack and I/O racks. Power Supply. Special Isolated Load Cell inputs. Panel. with support for: • • • • Isolated Analog I/O. The major components in the MC³ are • • • • Mechanical enclosure. Card Stack. inputs and outputs.10V.20 ma or 0. providing +5. typically handling a material feeder. which can be changed and upgraded in the field. +12 and -12V DC to components.. • Special outputs for External Totalizers. Special inputs for Quadrature Encoders. MC3 Hardware Manual 4 . Digital I/O..INTRODUCTION Merrick MC³ controllers are used in industrial weighing applications. It is a microprocessor based system. conveyor belt scale or flow meter. This manual describes the MC³ hardware. Wall and Door mount. 4. dry contacts or 110V AC. and can be mounted most anywhere. NEMA-4X or NEMA-12 boxes. It must be protected from water or significant dirt or dust. The wall mount enclosure is available in NEMA-4. The slide tray allows the Card Stack Assembly to be slid out of the back of the enclosure for easier maintenance while the controller is mounted into a panel. It is suitable for use in environments that are generally clean. MC3 Hardware Manual 5 . a system-grounding bar and a sliding tray. The panel mount enclosure consists of a rectangular box with a hinged door on the rear covering the I/O connections. a removable top cover. Merrick recommends that the controller should be located out of direct sunlight and away from dripping water and must be protected from heavy rain. The top cover may be removed for easier access to the boards. Access to the terminal blocks for interconnection with other equipment is obtained by unscrewing the rear cover. The Display assembly is mounted on the front bezel.CONTROLLER ENCLOSURES PANEL MOUNT The Merrick MC³ Panel Mount Controller is designed for mounting in a control cabinet. The temperature range of this controller is within 14o to 122oF (-10o to 50oC). and within the temperature range of 32o to 104o F (0o to 40o C). WALL MOUNT The Merrick MC³ Wall Mount Controller is designed to be weatherproof. NEMA-4 box includes gaskets and a window kit over the touch screen to provide extra protection. See the drawings provided in Appendix A (page 49) for exact specifications on the controller enclosure. NEMA-4X will provide a stainless steel enclosure and window kit. Refer to the drawing in Appendix A on page 51 for detailed specifications of the controller enclosure. DOOR MOUNT The Merrick MC³ Door Mount Controller is designed for mounting on the door of a control cabinet. This style includes a window for protection from the elements. The door mount enclosure is mounted separately from the power supply and Backplane boards of the controller. See the drawings provided in Appendix A (page 53) for exact specifications on the controller enclosure. It is suitable for use in environments that are generally clean. It also adds two fans to the cover of the enclosure to improve air circulation for better cooling for use in warm environments. MC3 Hardware Manual 6 . and within the temperature range of 32o to 122o F (0o to 50o C). It must be protected from all but incidental water or significant dirt or dust. Make sure the cable supplied is long enough to reach the intended mounting location. Also. It is recommended to penetrate the enclosure from the bottom. following the instructions on the electrical connection diagram. MC3 Hardware Manual 7 . to keep the back of the board from shorting against plate. Insure there is adequate clearance around the controller for maintenance and ventilation. A31534) – Mounting Dimensions) on page 51 for placement of hardware used to secure enclosure to surface. Route the ribbon cables away from any power cables or switching circuits. Mount any Backplanes on the cabinet panel. Install the controller into cabinet door using the mounting brackets provided. Use dimensions provided in APPENDIX A (Wall Mount (A30833. There are two screws on each side of the top cover. NOTE: Before any deviation from the supplied wiring diagrams. The Power Supply should be mounted on the Cabinet panel in the cabinet. See cover page for contact information regarding the Merrick Support. which could induce a signal into the ribbon cables. PHYSICAL INSTALLATION Panel Mount Cut panel to dimensions provided in APPENDIX A (Panel Mount (A30685) – Dimensions) on page 49. In order to maintain the weatherproof integrity of the Wall Mount enclosure. Wall Mount Mount the controller on a vertical surface. liquid-tight conduit and conduit connectors must be used when running the wires. using standoffs. Insure that the power is disconnected from the power supply. Again. contact the Merrick Service Department for assistance. Remove them before putting the controller in the panel if you will not be able to get to them because of space restrictions. Install the controller into panel using the mounting brackets provided.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. Merrick must first be consulted to insure safe and proper operation of the controller. Door Mount Cut cabinet door to dimensions provided in APPENDIX A (Door Mount (A33432. insure there is adequate clearance around the controller for maintenance and ventilation. Make the wiring connections to the controller. Care must be used when cutting due to tight tolerances for the panel mount bezel. This will insure a watertight environment for the electronics. Make sure there is adequate clearance around the unit for swinging open the door and for maintenance. Verify all wiring connections before applying power to the controller. A39307) Dimensions) on page 53. make sure the ribbon cables are long enough to go from the controller to the boards. In the wall mount and door mount enclosures. with additional optional boards in the card stack. one (1) or two (2) PCIO boards and one (1) LTI board. CONNECTIONS The MC³ is capable of processing many different types of inputs and outputs. The diagram below shows the card stack as seen from the back. the Card Stack Assembly is securely attached to the mounting plate. MC3 Hardware Manual 8 .CARD STACK ASSEMBLY The Card Stack is a grouping label for the primary boards of the controller which consists of one (1) CPU Board. one (1) or two (2) HPAD boards. then the diagram on the following page should be used. If an older revision CPU is present. All boards are connected electronically by way of an industry standard PC-104 interface bus. The slide tray is kept in place by a pair of guides that are mounted on the enclosure and with catch screws on the back of the enclosure. The Card Stack Assembly in the panel mount enclosure is mounted to the slide tray. Most of the connections necessary for the inputs and outputs are located on the Backplane Boards which are plugged into the PCIO boards at the connectors labeled “Racks”. Card Stack with Revision 11 or newer CPU Board G LEGACY NOT USED N D ENC 1 A B A ENC 2 B + 12 V D C + 5 V D C DC EMT + LTI BOARD AC EMT ISOLATED ANALOG OUT 3 + OUT 4 + IN 2 + RACK 4 DIGITAL I/O RACK 3 DIGITAL I/O PCIO #2 (OPTIONAL) OUT 1 + - ISOLATED ANALOG OUT 2 IN 1 + + - RACK 2 DIGITAL I/O RACK 1 DIGITAL I/O PCIO #1 S H L D + E X C + S E N + S I G S I G S E N E X C N / C HPAD #2 (OPTIONAL) LOAD CELL #2 SIMM SOCKET (PROGRAMMING) S H L D + E X C + S E N + S I G S I G S E N E X C N / C LOAD CELL #1 HPAD #1 CPU + DB9-S (FEMALE) COMM 2 TX - + RX - + TX - + RX DB9-P (MALE) COMM 1 DC POWER CABLE Back Panel Rear View MC3 Hardware Manual 9 . Card Stack with Revision 10 or older CPU Board COMM 1 G N D ENC 1 A B ENC 2 A B + 12 V D C + 5 V D C DC EMT + LTI BOARD AC EMT ISOLATED ANALOG OUT 3 OUT 4 IN 2 + + + - RACK 4 DIGITAL I/O RACK 3 DIGITAL I/O PCIO #2 (OPTIONAL) ISOLATED ANALOG OUT 1 OUT 2 IN 1 + + + - RACK 2 DIGITAL I/O RACK 1 DIGITAL I/O PCIO #1 S H L D + E X C + S E N + S I G S I G S E N E X C N / C LOAD CELL #2 HPAD #2 (OPTIONAL) SIMM SOCKET (PROGRAMMING) S H L D + E X C + S E N + S I G S I G S E N E X C N / C HPAD #1 LOAD CELL #1 CPU DB9-S (FEMALE) COMM 2 RESET BUTTON DC POWER CABLE PROGRAMMING JUMPER Back Panel Rear View MC3 Hardware Manual 10 . make sure the pins all line up and the standoffs are lined up with the holes. Replace the ribbon cable and cover. and the standoffs from the top board (LTI). Remove the ribbon cable going to the Display. Again make sure the pins and the holes line up properly.CONTROLLER DISASSEMBLY • • • • • • • Remove the top enclosure or door for access to the Card Stack. Add the 5 additional standoffs to secure the board. CONTROLLER REASSEMBLY MC3 Hardware Manual 11 . Remove the top board (LTI) from the card stack gently. Replace the LTI board and the 5 small standoffs. Insert the new board (PCIO #2) on top of the existing PCIO board. taking care not to bend the pins. CPU BOARD The CPU Board contains the Intel 386EX Embedded Microprocessor and associated support circuitry for a bus interface. 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 DF-1 and Modbus. The CPU board is the bottom board of the card stack. but may float ± 50 V with respect to MC³ ground. see http://www. EtherNet/IP and Profbus. The newest CPU board includes two serial ports providing RS-232 and RS422/485 for both ports. For more information on MC³ connectivity.com/mct NEW CPU BOARD (REV 11 OR NEWER) SIMM SOCKET (PROGRAMMING) CPU DB9-S (FEMALE) COMM 2 + TX - + RX - + TX - + RX - DB9-P (MALE) COMM 1 DC POWER CABLE Communication Ports COM 1 RS-232 J7 Pin Signal 2 Rx 3 Tx 4 DTR (+5VDC) Not Fused 5 Com (DC GND) 7 RTS (OUT) 8 CTS (IN) The RS-232 serial port is not isolated. serial interface and memory support.merrick-inc. MC3 Hardware Manual 12 . COM 1 RS-485 4 WIRE J6 Pin Signal 1 TX + 2 TX 3 RX + 4 RX The 4 wire RS-485 serial port is not isolated. and adapters for DeviceNet. BOARD FEATURES 10/J 9/I 8/H 7/G 6/F 5/E 4/D 3/C 2/B 1/A J8 IrDA J9 J2 J1 T E K C O S M I S G N I M M A R G O R P U16 U11 U7 COM 2 RS-232 Flashldr.exe Printer Port DF-1 DNI ENI RS-485 U54 U14 SRAM DALLAS COM 1 RS-485 WinMerik Scalenet Modbus ASCII Modbus RTU Anybus Ehthernet IP Profibus RS-232 U53 1 JP1 ON OFF SW4 SW1 J4 COM2 RS232 J5 COM2 RS485 J6 COM1 RS485 J7 COM1 RS232 J3 F1 60HZ N L +5V RED PF GREEN +5V RED +12V YELLOW -12V BLUE COM BLACK COM BLACK MC3 Hardware Manual 13 . but may float ± 50 V with respect to MC³ ground. COM 2 RS-485 4 WIRE J5 Pin Signal 1 TX + 2 TX 3 RX + 4 RX The 4 wire RS-485 serial port is not isolated.COM 2 RS-232 J4 Pin 2 Signal Tx 3 Rx 5 Com (DC GND) 6 DSR (+5VDC) NONFUSED 7 RTS (IN) 8 CTS (OUT) The RS-232 serial port is not isolated. JTAG/Service Port (J8) Pin 1 2 3 4 5 6 7 8 Description +5VDC Test Pin 1/LED 5/E GND Test Pin 2/LED 6/F TCK Test Pin 3/LED 7/G TDO Test Pin 4/LED 8/H MC3 Hardware Manual 14 . or that SW2 is in incorrect position. If it is on during normal operation. • • Two blinks start the sequence (normal) A third blink indicate an application fault condition • A fourth blink indicates a problem with the LCD display. Test pin 4 has a status blink pattern with most firmware applications. this is an indication that the DC power fail cable between the Power Supply and the CPU board is not connected.Option Switch Settings SW1 Flash Programming Lockout OFF – Program when SIMM installed ON – Normal Operation Power Fail Detection Level ON – High Level Detection (Old Style) Modified Power Supplies OFF . 9/I The Power Fail indicator Blinks once momentarily when the MC³ is powered off.Low Level Detection Unmodified Power Supplies Test Pin 1 (Led 5/E) Test Pin 2 (Led 6/F) SW2 SW3 SW4 LED Display LED # 1/A 2/B 3/C 4/D 5/E 6/F 7/G 8/H 9/I 10/J Description Com 2 Receive Com 2 Transmit Com 1 Receive Com 1 Transmit Test Pin 1 Test Pin 2 Test Pin 3 Test Pin 4 Power Fail Power ON 8/H. MC3 Hardware Manual 15 . This port is isolated from the rest of the MC³ circuits. The Com 1 serial interface has a 4 wire RS485 port located on the LTI Board (page 23). There is no RS-232 port for Com 1.Pin 9 10 11 12 13 14 15 16 Description TDI NMI (/Debug Break) TMS CPU Reset TRST# (Normal operation 13/14 are jumpered) PWRGD (Normal operation 13/14 are jumpered) No Connection Flash Lockout (see SW1) OLD CPU BOARD (REV 10 OR OLDER) SIMM SOCKET (PROGRAMMING) CPU DB9-S (FEMALE) COMM 2 RESET BUTTON DC POWER CABLE PROGRAMMING JUMPER Communication ports Comm 2 (RS-232) Pin # 1 2 3 4 5 6 7 8 9 Description N/C TX Data RX Data N/C Ground N/C Clear to send N/C N/C The RS-232 serial port is not isolated. There is no RS485 port for Com 2. MC3 Hardware Manual SALL A D MA RS RESET TO LTI BOARD PF GREEN +5V RED +12V YELLOW -12V BLUE COM BLACK COM BLACK U14 16 . Call Merrick for details to verify your CPU board configuration.Board Features JP3 J2 JP4 J1 JP5 PROGRAMMING SIM SOCKET JP6 U53A CR1 JP1 COM 1 RS-232 COM 2 RS-485 FLASHLDR JUMPER Jumper Settings Jumper JP1 Description FLASH PROGRAMMING Strap to program Un-strap for Normal operation Memory Size Strap 1 & 2 for 1 to 2 Meg Simm Strap 3 & 4 for 4 to 8Meg Simm Strap 5 & 6 for 16+ Meg Simm (may not recognize larger) NMI INPUT Older power supplies connect power fail to pins 3 & 4 JP4 JP6 Printer Operation (Old CPU Only) MC³ CPU board must be specifically configured for Printer operation. MC3 Hardware Manual 17 . If the second HPAD board is not marked in this manner. The load cell cable shield should be grounded at one point. including the Guard terminal. The Analog to Digital Converter (A/D) used on the HPAD Board is a 20-bit converter. There is one (1) set of jumpers to select Zener Barrier Protection and Normal Operation of the HPAD. There is a strap (S1) on this board to switch between normal operation and Zener Barrier operation. the chip (U1) labeled in blue “E2” should be labeled “2nd”. If a “second” HPAD Board is added to the card stack. Zero Offset or Electronic Calibration. MC3 Hardware Manual 18 . are isolated from the rest of the MC³ circuitry. There are no switches on the HPAD Board for setting parameters such as Gain. it is most likely a first board and will not work with another first board. the MC³ Controller has the ability to utilize two (2) HPAD boards. All load cell connections. Connect the load cell cable shield to the guard terminal.000 counts.HPAD BOARD The High Performance Transducer A/D Board (HPAD) contains the circuitry needed to convert the analog input (mV) signal from the load cells into digital data.000. not to the ground strip. HPAD 1/2 DETERMINATION Note the chips in sockets on the image below. with a resolution of about 1. as close to the load cell as possible. The HPAD Board contains specialized circuitry for dynamically adjusting these parameters through software. STRAPS The transducer (load cell) connections are on the HPAD Board. As an option. G U A R D 1 + E X C I T E 2 + S E N S E 3 + S I G N A L 4 S I G N A L 5 S E N S E 6 E X C I T E 7 N O C O N N E C T G U A R D 8 1 + E X C I T E 2 + S E N S E 3 + S I G N A L 4 S I G N A L 5 S E N S E 6 E X C I T E 7 N O C O N N E C T 8 4 WIRE LOAD CELL 6 WIRE LOAD CELL Connection points and signals of the HPAD Board NOTE: In all cases the Sense (3 & 5) pins must be connected. MC3 Hardware Manual 19 . If a 4 wire load cell is connected directly to the HPAD board. jumpers must be placed between pins 2 & 3 and 6 & 7 as illustrated above. If a “second” PCIO Board is added to the card stack. one (1) isolated analog input. Two (2) racks of digital inputs and outputs can be connected to one (1) PCIO board or four (4) can be connected if there are two (2) PCIO Boards. are 6 potentiometers. sixteen (16) digital outputs and eight (8) digital inputs. the chip labeled in blue “F1” should be labeled “2nd”. as pictured to the left. two (2) isolated Analog Inputs. used to adjust zero and span. PCIO 1/2 DETERMINATION Up to two PCIO boards may be a part of the MC³ controller. If the second PCIO board is not marked in this manner. Note the socketed chips on this image. thirty-two (32) Digital outputs and sixteen (16) Digital inputs.PCIO BOARD The PCIO Board provides the circuitry for two (2) isolated analog outputs. An additional PCIO Board is available as an option giving the controller a capability of having four (4) isolated Analog Outputs. Located on the left side of the board. There are also jumpers to switch between current and voltage. MC3 Hardware Manual 20 . it is most likely a first board and will not work with another first board. .CONNECTIONS The backplane connections on the PCIO Board. This is set for Current input and output ANALOG INPUT There is one isolated analog input per PCIO board..10V.1V to 0. MC3 Hardware Manual 21 . to change the analog signals from current to voltage. provide the customer with logical on/off signals to the MC³ Controller. If the T15 is jumper installed (current input) the typical input impedance is 50Ω.20 mA. If jumper is removed (voltage input) they typical impedance is 200kΩ. The first backplane board plugs into Backplane 1 on the right. ISOLATED ANALOG OUT 1 OUT 2 IN 1 + + + 1 2 3 4 5 6 BACKPLANE 2 1 2 15 16 1 2 BACKPLANE 1 15 16 1 O U T 1 O U T 8 2 3 O U T 2 O U T 7 4 5 O U T 3 O U T 6 6 7 O U T 4 O U T 5 8 9 I N 1 I N 4 10 11 13 I N 2 I N 3 G N D + 5 V 15 G N D + 5 V 16 12 14 DIGITAL I/O PINOUT PCIO BOARD ANALOG I/O CURRENT/VOLTAGE STRAPPING On the PCIO board are jumpers. and the range is adjustable 0. They also provide digital outputs for controls and status indicators. The default is current out (straps in top row) and current in (strap in place at T15). and the range is 0.. When switching an analog output between current and voltage all three straps must be moved. In voltage output mode. Remove the short and supply your full scale signal Adjust AIS for 1. you can adjust them. contact Merrick for the correct part. The factory adjustment is 0 – 1.. The suggested procedure goes like this: • • • • • • • Map the analog output you want to adjust to something you can control easily such as the setpoint or Manual Speed control. If it is not.1 V. The maximum load resistance is 750Ω in current output mode and the range is 0.. usually design feedrate Adjust AO#S (Span) for 20mA.000 A/D counts for 0.10 V. and the range is 0.. Adjust AO#Z (Zero) for zero output {where # is the AOUT channel. 10V output. so any negative value will be displayed as Zero.20 mA. The first and second board have different U4 addressing chips (see PCIO 1/2 Determination on page 20). MC3 Hardware Manual 22 . The input is unipolar. This part is not field programmable. use the analog diagnostic screen. Set the setpoint to full scale. If you feel that you must. Adjust AIZ for slightly above Zero reading. the minimum load resistance is 5KΩ. or to the value needed for the particular application.20 mA. With the standard 50Ω shunt resistance. to be adjusted. ADDING AN ADDITIONAL PCIO BOARD TO A MC3 CONTROLLER Refer to drawing for card stack details on pages 9 & 10 and installation instructions found on page 11 for more information.. AO1Z AO1S AO2Z AO2S AIZ AIS CURR\VOLT SELECTOR Analog Potentiometers ANALOG OUTPUTS There are two isolated analog outputs on each board. Make sure that the board you are adding has 2nd marked on the board or the socketed PLCC marked U4.000 A/D counts for 0. To trim the analog input. Restore the original mapping for the analog output.AIN Adjustments The input trimmers may have to be adjusted if you change between Voltage and Current.20 mA/0.000 counts reading. this will give you 0 – 1..000. AOUT Adjustments The trimmers associated with the analog outputs (AO#XX) have been set at Merrick as a part of the shipment checkout using calibration grade instruments.000. • • • • Short the input terminals. 1 or 2.000.10V. Set the setpoint to Zero. There is very little trim space available.. Set the output type to 0. parity. +12VDC and Ground available for the encoders. outputs for an AC and DC Electromechanical Totalizer (EMT).Rx+ Rx1 2 3 4 GND 1 1A 2 TACHOS 1B 3 2A 4 2B 5 +12V +5V 6 7 TOTALIZERS DC EMT 8 + +24V COM (5-24VDC) (110VAC) LINE AC EMT 10 11 9 - NEUTRAL EMT (DC & AC) Speed Encoder 2 Channel HMS AB7000 Speed Encoder 1 Channel Serial Communications (for Older CPU Boards) Serial Channel COMM #1 is a four wire RS-485 port. an RS-485 Serial Port (legacy connector for older CPU boards) and an interface to the Display assembly. For more information regarding communications.merrick-inc. There is +5VDC. Supply voltages of +5V and +12V are located on the terminal block for the speed encoders. CONNECTIONS There are 3 types of connections available on the LTI Board: Communication. this port is no longer used. Encoder and Totalizer connections. this communication port has been moved to the CPU. For further information on configuring the Serial Communications Board and its interface to different types of serial equipment. These signals are detailed on the next page.com/mct. For users of the updated CPU board. stop bit settings and protocols of the ports are setup in the software.LTI BOARD The LTI Board contains the circuitry required to process up to two (single or dual channel) speed encoders. refer to the website http://www. The baud rate. see Communications found in the Software Manual. MC3 Hardware Manual 23 . RS-485 Tx+ Tx. Both AC and DC pulses are available. The outputs are dry contact relay outputs. EMT The EMT outputs are provided to you for connection to a remote totalizer. ex.Encoder If only one (1) encoder input channel is to be used it must be in the “A” position. MC3 Hardware Manual 24 . The mode should be No .. The second encoder connects to would connect to 2A and 2B for 2 channels or 2A for single. 1A.Direction. For the door mount. MC3 Hardware Manual 25 . The Backplane Board mounts vertically in the rear access cover on the Panel mount type enclosure. Each Back plane board is termed a Rack in the MC³ controller. Relay 8 can be jumpered for normally open or normally closed operation. A standard controller consists of one PCIO and one Backplane board. the boards are mounted directly below the Card stack assembly. Relays 1-7 are normally open types. The BKPN card has four dry contact inputs and 7 relay (N/O) outputs. On the Wall mount enclosure. a dry contact closure input card (BKPN) and an AC input card (BPAC). The BPAC card has four AC inputs and 8 Relay outputs. the boards are mounted on the panel in the cabinet.BACKPLANE BOARDS Most of the Digital I/O connections to the MC³ will be made through the Backplane Board. There are two types of Back plane cards available. Up to four Backplane boards may be connected to the MC³ Controller when two (2) PCIO boards are present in the card stack assembly. .DC STYLE BACKPLANE BOARD . The inputs are to be dry contact type.BKPN Each DC Style Back plane board consists of four (4) inputs and seven (7) outputs.12 13..6 7.14 Inputs 1 2 3 4 Terminals 15/19 16/20 17/21 18/22 MC3 Hardware Manual 26 . All outputs (terminals 1.10 11.22 are all connected to the MC³ digital ground. with a resistance value of 650Ω. Care must be taken not to exceed these values.2 3. Terminals 19. Ribbon Cable to PCIO Board Digital Outputs Digital Inputs Outputs 1 2 3 4 5 6 7 Terminals 1.4 5.14) are floating. The outputs are N/O relay contacts with a rating of eight amps at 125 VAC or five amps at 30VDC.8 9. 18 19.14 15.24 MC3 Hardware Manual 27 .8 9.16 Inputs 1 2 3 4 Terminals 17. All inputs and outputs are floating with respect to MC³ ground.2 3.20 21. The outputs are N/O relay contacts with a rating of 5 amps at 250 VAC.6 7.4 5. Care must be taken not to exceed these values. Output 8 is jumper selectable between N/C and N/O.AC STYLE BACKPLANE BOARD .10 11.BPAC Each AC Style Back plane board consists of four (4) inputs and eight (8) outputs.22 23. which causes the contact to be derated. The inputs are to be designed for 110VAC.12 13. Ribbon Cable to PCIO Board Digital Outputs Digital Inputs Outputs 1 2 3 4 5 6 7 8 Terminals 1. so that parameters can be saved before the power is lost. there will be an open pin near the F1 fuse on the board when mating the connector to the board as shown below. if the newer cable is plugged into the older CPU board. the power supply is mounted under a protective metal panel. have 7 wires with a 7 position connector.POWER SUPPLY ASSEMBLIES The MC3 Power Supply is a switching power supply that converts the 90/240 AC voltage input to DC voltages. With the Door Mount unit. Likewise. MC3 Hardware Manual 28 . had 6 wires and a 6 position connector. The additional wire is an additional +5V signal. Both types of power supplies have built in Power Fail Detect circuits that send a warning to the processor when the input voltage begins to fail. The MC3 Power Supply has no user serviceable parts. such as fuses. If an older cable is used with this new CPU board. the fuse is located in the switch assembly. The older cables (REV 8 or older) used with Rev 10 or older CPU boards. WARNING: Connecting these incorrectly will damage the CPU board and other boards in the card stack. Below is a drawing that details how the different Cable revisions affect connecting to the CPU Revisions. see the wiring diagram for fuse located in the panel. On the Wall Mount enclosure. the power supply is normally attached to the cabinet away from the controller. In the Panel and Wall Mount controllers. The newer cables (Rev 9 or later) used with Rev 11 or newer CPUs. and some of these are based on MC3 CPU Revisions. the additional socket of the connector will hang over the header next to the LED on the CPU board. without the use of any jumpers. For the Door Mount controller. added to improve the +5V supply to the CPU Board. The power supply is mounted on the front of the slide tray on the Panel Mount enclosure. MC3 DC POWER CABLES There have been numerous revisions to the DC Power Cable. MC3 Hardware Manual 29 . MC3 DC POWER CABLE DETAILS Panel Mnt and Wall Mnt DC Power Cable (REV 9) COM +12V +5V +5V COM +12V -12V POWER FAIL POWER FAIL COM -12V Panel Mnt and Wall Mnt DC Power Cable (Previous Revision) +5V Door Mnt DC Power Cable Fan Power Door Mnt DC Power Cable For VL30 Power Receptacle and Switch The Power Receptacle and switch assembly is the same on both the Panel Mount and Wall Mount enclosures. MC3 Hardware Manual 30 . On the top above the switch. is the fuse holder. Push up on the small catch to release this holder from assembly. The fuse is a 1A 250V 5X20mm fuse. MC3 Hardware Manual 31 . If the brightness needs to be adjusted. avoid contact with the inverter boards next to the pot. Brightness and Contrast Adjustments Brightness Adjust Contrast Adjust Most of the adjustments will be made with the contrast pot. LCD BOARD This board is used to interface the LCD Display and the Touch Keypad to the LTI Board and provides the proper voltage for the backlight of the LCD Display. LCD Board and LCD Display (Shown here with out bezel or enclosure). on there is a Brightness Adjust potentiometer on the left top corner of the board. There is a potentiometer for adjusting the contrast of the LCD Display located on the top right corner. In addition. MC3 Hardware Manual 32 . It is a high voltage. low current circuit and could produce a shock or burn if contact with a non-insulated adjustment tool is made. An alignment tool is needed to make adjustments. The Door Mount uses gaskets for sealing. the display assembly is sealed against dust with silicone around the touch screen to the bezel or enclosure. With the Panel Mount and the Wall Mount.DISPLAY ASSEMBLY The Display Assembly consists of a Touch Keypad. Replacing Backlight Assembly Removal of LCD Board (shown on top below) is the first step in replacing the Backlight.LCD DISPLAY The LCD Display is a 240 horizontal by 128 vertical pixel resolution monochrome graphical display. Remove the plastic pins that secure the metal plate over the backlight diffuser panel. It consists of a four by eight touch cell array. Next remove the LCD Display Board. The display works in conjunction with the Touch Screen to provide a Graphical User Interface (GUI). The Touch Keypad works with the LCD Display to provide a way for you to interface with the controller. Reassemble in reverse order. In some MC3 Hardware Manual 33 . Touch Keypad The Touch Keypad is mounted directly to the bezel of the MC³ Panel Mount and Wall Mount enclosure. Take care in handling the LCD Display board to avoid damaging the screen. Next remove the plastic sockets that hold the pins and then slide out the old diffuser panel. A1 B1 C1 D1 E1 F1 G1 H1 A2 B2 C2 D2 E2 F2 G2 H2 A3 B3 C3 D3 E3 F3 G3 H3 A4 B4 C4 D4 E4 F4 G4 H4 MC3 Hardware Manual 34 . TOUCH SCREEN LOCATION CODES The touch screen has 32 pressure sensitive pads. a different display is used that has a touch screen attached to the display. They can be used as physical inputs for testing and demonstration purposes. This table shows the names of the physical inputs. The board also has a different LCD Board. but has the same functionality.controllers. The information displayed should always be recorded.) with the current. if you upgraded from 35. you can download them from a previously uploaded file. Parameter Corruption If the non-volatile memory in the MC³ that holds controller parameters is corrupt. Controller Firmware Upgrade If the controller firmware has been changed or upgraded. the parameters in the non-volatile memory will typically not be compatible with the new firmware. or with unreliable or inaccurate operation. Start-Up Crash If the crash screen occurs during controller boot-up.B to 35.00. Resetting to factory default will require you to enter your parameters again. either by hand from the spec sheet. Continuing with the existing parameters is risky – you may end up with a fatal error. the crash screens will look like this: Checksum Error Crash Screen You will then be given the opportunity to either reset all parameters (Reset Ram) to their factory default values or continue operation (Cont.C: MC3 Hardware Manual 35 . or if you have WinMerik. The crash screen will look like this. The newer applications screens are shown on the left and older applications on the right. the two most likely problems are parameter corruption and controller firmware upgrade. The information displayed should always be recorded. None of these alternatives are attractive. possibly corrupt parameters.00.MC3 TROUBLESHOOTING MC³ CRASH SCREENS The Crash Screen is the firmware’s last attempt to communicate a fatal error in the controller. Here are some of the Crash Screens that are available. The background image looks like this: Crash Background Image The available space is then used to display additional information. Please Report A fatal error should always be reported to Merrick Technical Support.EX. See below. In this example. you should reset the parameters (Reset Ram) to factory default (unless instructed otherwise by Merrick Customer Support). The only way out of this situation is to cycle the MC³ power. The crash screen looks something like this Example of Fatal Error Crash Fatal Error Indicates the nature of the crash. The most common reason is that an invalid parameter has been entered into the controller by means of serial communications or by using the Register Editor. Fatal Error Crash The crash screen caused by a fatal error can occur anytime. Parameters Version: 56. including controller boot. you can attempt to force a Reset to Factory Default. and then enter the new parameters either from the spec sheet or from a prepared parameters file. This may restore controller operation.Parameter Compatibility Crash Firmware Version: 56.C. but the most likely scenario you will see a new Crash Screen at controller boot. and then re-enter all controller parameters. If you have been working with communications or using the register editor recently. If that is the case. 66 Firmware ID and Version ID before upgrade. you may have an idea of what happened. an attempt was made to perform a division with a zero value in the denominator. The last line normally will contain additional information. In this case. 67 Firmware ID and Version ID of 35.00. using WinMerik. MC3 Hardware Manual 36 . press and hold the touch-pads. check the fuse on the power receptacle (wall mount and panel mount only). or the controller may boot up normally. The boot sequence will then go directly to the crash screen. the CPU does not have a proper warning that the power is going away and therefore can not safely shutdown processes and save parameters. If you see a fatal error crash screen before the count-down starts. • If the DC voltages are not present. If this happens. UNIT DOES NOT POWER UP – • • Check the supply power to the unit: is there supply power.Forcing a Parameter Reset It is possible to invoke the Parameters Crash Screen at controller boot by the upper left and right touch-pads on the screen during the boot-count-down. If supply voltages are good. and then turn the controller power off and on. you may see the Ram Reset Screen. Although short circuit protection is part of this circuitry. Ram Reset Touch-pads You can then reset all parameters to factory default. then the power supply or cable is defective. check the DC voltages as marked on the drawing below. are all cables connected? If no supply voltage. in some cases the +5V of the controller’s power supply may overloaded which will reboot the controller. Controller Reboots and Displays Ram Reset Screen If the +5V connection on the LTI Board is shorted to ground during startup or troubleshooting. When the +5V is shorted in this manner. o Without +12VDC the display will not light up MC3 Hardware Manual 37 . it is possible that the controller will reboot. check fuses in cabinet or breakers. If the fuse is good. if the connections are disconnected. do they blink? LED Test indicator 8/H (see CPU Layout): o If none of the LEDs blink or are all on. o If the display is okay and the CPU seems to be processing data. If there is no light at all or is not adjustable.o • Without +5VDC. o If the LED blinks 2 times then 1 time. the first terminal is shield or make the measurements at the Feeder Connection Board. touch the screen to make sure that the screen saver is not engaged and causing the blank or dark screen. If the signal is greater than 30 mV or less than 0 mV. such as the LTI boards. this could produce a large signal or even a negative signal. o If the signal is too large or too small. o If the excitation voltage is good. LCD TOO DARK/LIGHT OR OUT – • First. it should be a 0 . one of the boards could be defective. • • NO BELT LOAD OR WEIGHT • • • • MC3 Hardware Manual 38 . the controller will not boot at all If all voltages are present. o If the signal from the load cell is a voltage (not millivolt) or negative millivolt. o If LED blinks 3 times. The controller must be rebooted. there is a fault in the controller. the CPU board may be defective. o Check the display board or display assembly. so it may be necessary to disconnect the signal output from the load cell to the HPAD to isolate the signal from the controller. the back light may need to be replaced A replacement kit can be purchased from Merrick. it may be the result of changing temperatures and can therefore be adjusted by the contrast pot R3 on the LCD Board. The screen saver function turns off the backlight to increase its life span. 30 mV signal and be close to the values indicated on the specification sheet for that machine. Remember to validate connection from FCB to controller. measure the voltage being applied to the load cell. is it wired correctly? If the load cell was wired so that one of the excitation wires and signal wires were swapped. if present . o The backlight may be out on the controller and the screen maybe only partially visible. then the CPU has a problem. then processing is okay. the load cell is wired in backwards or damaged. then there are LCD Board problems. Next check the output signal from the load cell. if easier. It should be +10VDC. If no counts are present go to the next point. o If there are lights on the CPU board (l1).. If no counts. o If no excitation voltage or it is low. the HPAD board may be bad. o If LED blinks 2 times. measured from terminal 2 and 7 of the PCAD board. the HPAD board may be loading down the signal. If the screen is only a little light or dark.was an incorrect calibration performed. go to the next step. Disconnect the load cell from the board and re-measure. to make sure the load cell was not pulling the excitation voltage down. excitation voltage. Go to the HPAD Diag Screen and check for A/D counts. are there any lights on the CPU board? If not. Consult Merrick for more information. o The cable may have gotten damaged from heat or excessive stress. check the supply voltage at the FCB board or pins 1 and 7 of the LTI board. If there is still no speed detected. Also check the scaling units in the analog input settings. • ANALOG OUTPUT PROBLEM Go to the Analog Diagnostic screen. The device may be loading down the output. If it is correctly mapped. There should be +5VDC. try changing the output to SCR and see if you can generate the output. If voltage is present. changed the LTI board. the PCIO board my need replaced. MC3 Hardware Manual 39 . If the output is not proportional to the rate or condition. check to see that it is mapped correctly under the analog output settings. This will let you receive pulses if only one channel is out. check the signals coming into the LTI board to see that they measure around 2.NO SPEED DETECTED • Check and see if the belt is moving. try removing the wire and see if the voltage comes back. A01 S & A02 S is the span or maximum setting pot. It the +5VDC signal still isn’t present. you should see either 0V or 5V If not the encoder or cabling is the problem. • If the setpoint indicated on the screen does not equal the desired setpoint being sent by an analog signal. If not.5VDC RM. Adjust here if the 0% output is too high. The encoder could be loading the signal. without the device being driven. then the rate output will not be correct. the input may not have been calibrated properly. You can quickly verify this in the analog diagnostic screen. Try connecting a milliamp meter to it. Adjust here if the 100% output is too high. If the voltage isn’t present. If the design rate does not equal the speed * the load. A01 Z & A02 Z is the zero or minimum setting pot. make sure the design capacities are correct. • If the output is low or high it can be adjusted at the PCIO board at the appropriate pot. If there is no output present. • • ANALOG INPUTS Go to the Analog Diagnostic screen. It is also important to make sure that the encoder is still coupled to the shaft by way of the setscrew.S. If so check the Tacho Setup and change it to ‘No Direction’ detected. or if the wiring has been changed. If the belt is not moving. When the belt is moving. MC3 Hardware Manual 40 . changing position of SW1 and inserting and extracting the SIMM. FLASHLDR. running on your PC.EXE is a DOS application. used to load the MC³ application (HEX file) into the MC³ Flash EPROM. memory SIMM. It must be started from the directory that contains the HEX file you want to load. you may have to go as low as 4800 baud. NOTE: Do not erase other programs in flash memory unless specified to do so by the factory. See Figure 1 on next page. For Windows 2000 and XP. CAUTION: It is recommended to turn off power and remove the power cord from the controller before setting or removing the JP1 jumper. USB serial adapters will not work. NOTE: There are 2 procedures. Windows 95. 98 and ME. use 38400 or 57600 baud.EXE cannot be used from a network drive. which consists of a serial cable. The PC serial port must be native to the PC. A straight serial DB9-P to DB9-S cable between the serial port on the PC and COM 2 serial port on the MC³ Controller must be used. After programming the MC³ controller the SIMM memory must be removed. choose the procedure that matches your CPU Board revision. FLASHLDR. A 1 to 16 Mbyte 72 pin SIMM must be connected into the SIMM socket on the CPU board before installation of application software. The usable baudrate depends on the CPU speed and operating system. It is recommended you use a Merrick Programming Kit (S60234-1). For DOS.MC3 FLASHLOADER PROGRAMMING (APPLICATION UPGRADE) This instruction details the procedure to use when loading (new or revised) application firmware into the Flash EPROM of an MC³ Controller. application and firmware. MC3 Hardware Manual 41 . Start Flashldr C:\3000software> type: flashldr (. copy them to a directory on the computer hard disk. Turn off power to the controller. FLASH CMD: type: pr r3000c (or whatever the new file is) <ENTER> After the application has been loaded. FLASH CMD: type: dir (take not of the app name) <ENTER> Delete the current application FLASH CMD: type: del 3000exr (or whatever the app name is) <ENTER> Program the new application version. This will update the flash tables appropriately. You may need long needle nose pliers to get to this.PROCEDURE FOR REV 10 OR EARLIER CPU BOARDS SIMM Socket JP1 Programming Serial Port NMI SMI RESET Insure that the power cord is disconnected from the controller (for safety). FLASH CMD: type: q <ENTER> Wait for FLASHLDR to update the flash tables and shut down. Remove power cord. Watch screen for normal MC³ countdown.exe not needed<ENTER> Set the baud rate for communications. Insert SIMM memory into SIMM socket and make sure it is seated properly. The LCD screen should be blank (no display) or blink random characters. Plug in your power cord and turn on power. JP1 is located near the power supply connector. so (with power off) re-check those items and try again. Reinstall power cord. Remove JP1 jumper. If they are on a floppy disk. MC3 Hardware Manual 42 . Make sure you know which com port you are using on the computer. Turn on power. FLASH CMD: type: baud=57600 (or lower baud based on UART) <ENTER> Initialize communication on the serial port. if not. FLASH CMD: type: init com2 (or the correct port on computer) <ENTER> Get a listing on what is currently in the flash memory. Jumper JP1 on the CPU card.exe and the hex file are located. the controller may not see the SIMM (poor seating) or the jumper may not be in place. Connect the serial cable to the controller and to the PC com port to be used. Find the correct directory on the computer where flashldr. FLASH CMD: type: sb <ENTER> Quit Flashldr. tell flash to boot from application. Remove SIMM memory. Touch the upper left and right corners of the screen to perform a ram reset. Make sure you know which com port you are using on the computer. FLASH CMD: type: init com2 (or the correct port on computer) <ENTER> Get a listing on what is currently in the flash memory. Remove power cord. FLASH CMD: type: dir (take not of the app name) <ENTER> Delete the current application FLASH CMD: type: del 3000exr (or whatever the app name is) <ENTER> Program the new application version. Reinstall power cord. The LCD screen should be blank (no display). Turn off power to the controller. tell flash to boot from application. FLASH CMD: type: baud=57600 (or lower baud based on UART) <ENTER> Initialize communication on the serial port. Connect the serial cable to the controller and to the computer com port to be used. Move SW1 to the OFF position (away from simm). Turn on power. This will update the flash tables appropriately. You may need to switch the position back and forth to clean the switch. Touch the upper left and right corners of the screen to perform a ram reset.PROCEDURE FOR REV 11 OR LATER CPU BOARDS SIMM Socket SW1 Programming Port Insure that the power cord is disconnected from the controller (for safety). Watch screen for normal MC³ countdown. FLASH CMD: type: sb <ENTER> Quit Flashldr. FLASH CMD: type: pr r3000c (or whatever the new file is) <ENTER> After the application has been loaded.exe not needed) <ENTER> Set the baud rate for communications.exe and the hex file are located. Start Flashldr C:\3000software> type: flashldr (. Remove SIMM memory. If they are on a floppy disk. Find the correct directory on the computer where flashldr. the controller may not see the switch so re-check those items and try again. Insert SIMM memory into SIMM socket and make sure it is seated properly. Plug in your power cord and turn on power. MC3 Hardware Manual 43 . if not. Return SW1 to On Position. copy them to a directory on the computer hard disk. FLASH CMD: type: q <ENTER> Wait for FLASHLDR to update the flash tables and shut down. ------. Addr: 00080000 . ver = 2..4K baud . prog = 1.--. Inc. 24 FEB 95 ***** Copyright (c) 1994...---------. Target system on-line (board = 00010102..SAMPLE SESSION C:\MC3\APPS\2496EN\V003C>flashldr ***** CQi Flash Loader ..000BDFFF Size: 253952 Total: 253952 Hex file OK Process flash blocks .0009FFFF Size: 1024 Total: 131072 Program 28F400BX-T flash block #1 . Download . Download .95 Cyber Quest....-------2496EXR 07/16/96 16:41 00080000 253952 B1.0167458B 07/16/96 16:44 000BDFFF 253952 FLASH CMD: del 2496exr Program name set to 2496EXR Program 2496EXR deleted FLASH CMD: pr 2496exr Program file set to .V2...-------------..... Process hex file . Addr: 0009FC00 .----.HEX Program name set to 2496EXR File format set to HEX Start flash programming . Flash blocks OK Flash programming complete FLASH CMD: sb 2496exr Program name set to 2496EXR Boot program set to 2496EXR (start vector = 8000:0000) FLASH CMD: q Start shutdown .. FLASH CMD: baud=38400 Baud rate set to 38.4K FLASH CMD: init com2 Port set to COM2 VT Port set to COM2 Establish link to target system on COM2 at 38. Read .95 Intel Corporation Copyright (c) 1994.HEX .-------..000BDFFF Size: 1024 Total: 253952 Program 28F400BX-T flash block #2 .\2496EXR. Flash tables OK Shutdown complete C:\MC3\APPS\2496EN\V003C>exit MC3 Hardware Manual 44 .\2496EXR..0. Addr: 000BDC00 ...00) Flash tables OK Initialization complete FLASH CMD: dir Flash directory of I386EX-EVAL board (TARGET system): File/Program Strt/End Log/Phy Name Group Ver Date/Time Address Size Flg Checksum -------.... Update flash tables . Operate all switches at least ten (10) times and allow the equipment to obtain normal operating temperature before turning off. Protect electrical and electronic components from painting operations. Remove all packing and/or protective materials. do not apply power until the equipment has been allowed to stand at ambient conditions a minimum of three (3) hours. Remove all desiccants. Allow units to cool before repackaging and returning to storage. replace the factory supplied desiccant (if so equipped) before placing in storage. The use of evaporative corrosion inhibitors is recommended. but not mandatory. Place desiccant or evaporative corrosion inhibitors inside control enclosures. above freezing temperatures. OPERATION AFTER STORAGE When electrical equipment has been stored at either high humidity or low temperature. Clean all equipment and enclosures thoroughly inside and out. Remove rust as necessary. If the equipment has been in transit for two months or longer. 4. MC3 Hardware Manual 45 . 3.STORAGE STORAGE ON RECEIPT FROM FACTORY Storage Longer than 6 Months Outside storage is NOT recommended. Storage up to 6 Months Keep all equipment dry and well above the ground. Operate all electrical and electronic equipment at least once (1) a year for a minimum of two hours. STORAGE FOLLOWING USE 1. 2. Observe storage instructions as above for storage before use. If possible. preferably during a low humidity season. store electrical equipment in a heated warehouse. Touch up painted surfaces as necessary to protect bare metal surfaces. A37244 Name Power Supply Assembly Fuse 1A 5X20MM CPU Board HPAD Board #1 HPAD Board #2 PCIO Board #1 PCIO Board #2 LTI Board Display Assembly LCD Board LCD Graphic Display Backlight Assembly Touchpad Keypad Part Number M21912-1A Q-73 M21746-1A M21701-1A M21701-2A M21735-1A M21735-2A M21689-1A M21729-2A M21684-1A 19-411-00002 13-903-79001 M21733-1 MC3 Hardware Manual 46 . A31534. MC³ CONTROLLER SPARE PARTS LIST MC³ Panel Mount A30685 Name Power Supply Assembly Fuse 1A 5X20MM CPU Board HPAD Board #1 HPAD Board #2 PCIO Board #1 PCIO Board #2 LTI Board Display Assembly LCD Board LCD Graphic Display Backlight Assembly Touchpad Keypad Part Number M21912-1A Q-73 M21746-1A M21701-1A M21701-2A M21735-1A M21735-2A M21689-1A M21729-1A M21684-1A 19-411-00002 13-903-79001 M21733-1 MC³ Wall Mount A30833. should a problem develop with your MC³ Controller unit or a part become lost or damaged. it is possible that not all parts shown will be present in this particular unit. contact the Merrick Spare Parts Department.SPARE PART LIST This section contains typical parts lists to assist in identifying necessary parts. or would like to place a parts order. Depending on the options ordered with the unit. If you need further assistance. 2.3 ACCESSORIES I/O System Name Backplane Board Backplane Board (AC) Cable .MC³ Door Mount A33432 (Hitachi) Name CPU Board HPAD Board #1 HPAD Board #2 PCIO Board #1 PCIO Board #2 LTI Board LCD Board Hitachi LCD Graphic Display Backlight Assembly Touchpad Keypad Map80 Power Supply VL30 Power Asy Door Mt MC³ Door Mount A39307 (Hantronix) Name CPU Board HPAD Board #1 HPAD Board #2 PCIO Board #1 PCIO Board #2 LTI Board LCD Board Hantronix LCD Graphic Display Backlight Assembly Map80 Power Supply VL30 Power Asy Door Mt Part Number M21746-1A M21701-1A M21701-2A M21735-1A M21735-2A M21689-1A M21684-2A 19-411-00004 13-903-79001 S60213-1A A36539-1.9 inch Cable 12 inch Cable 18 inch Cable 22 inch Cable 48 inch (door mount) Watchdog Timer Board IOC Input Board BPACIN AC Input Board Part Number M21882-1A M22108-1A M20184-6 M20184-5 M20184-3 M20184-4 09-600-20001 N41215-1A M22536-1A M22535-1A MC3 Hardware Manual 47 .2.3 Part Number M21746-1A M21701-1A M21701-2A M21735-1A M21735-2A M21689-1A M21684-1A 19-411-00002 13-903-79001 M21733-1 S60213-1A A36539-1. LTI 6 Pin PCIO 8 Pin PCAD 11 Pin LTI Grounding Bar Power Cord AC Cable (panel mount) AC Cable (wall mount) DC Cable (wall & panel) Door Mount DC Cable Door Mt DC Cable VL-30 Door Mt AC Cable VL-30 Feeder Connection Board (FCB) Name Feeder Connection Board Only Feeder Connection Board Only FCB Assembly FCB Assembly FCB Assembly FCB Assembly Part Number M21911-1 M21911-4 A31196-1 A31196-2 A31196-3 A31196-4 Description 1 Load Cell 4 Load Cells NEMA 4 SS Enclosure 1 Load Cell NEMA 4 SS Enclosure 4 Load Cell NEMA 4 Std Enclosure 1 Load Cell NEMA 4 Std Enclosure 4 Load Cell Part Number 09-204-40401 09-204-40601 09-204-40801 09-204-41101 FE11887 FE11270 M21731-1 M21731-2 M21732-2 09-600-06001 M22520-1 M22523-1 Part Number S61118-1 S61118-2 S61118-3 S60234-1 S60234-2 MC3 Hardware Manual 48 .Options (Communication) Name WinMerik MC3 Kit – Disk Only WinMerik MC3 Kit – Disk & MC3 only Cable WinMerik MC3 Kit – Disk & MC3/MC2 Cable MC3 Programming Kit – 3 ½ Floppy w/Cable MC3 Programming Kit – CD w/Cable Spare I/O Plugs and Miscellaneous Name 4 Pin Plug CPU. APPENDIX A PANEL MOUNT (A30685) – DIMENSIONS BEZEL FRONT PANEL CUTOUT MC3 Hardware Manual 49 . TOP VIEW SIDE VIEW MC3 Hardware Manual 50 . WALL MOUNT (A30833. A31534) – MOUNTING DIMENSIONS FRONT VIEW MC3 Hardware Manual 51 . WALL MOUNT – MOUNTING DIMENSIONS CONT SIDE VIEW MC3 Hardware Manual 52 . DIMENSIONS FRONT VIEW SIDE VIEW BACK VIEW MC3 Hardware Manual 53 .DOOR MOUNT (A33432. A39307) . 19-102-32402) DOOR MOUNT POWER SUPPLY (VL30) MOUNTING DIMENSIONS (A36539) MC3 Hardware Manual 54 .DOOR MOUNT POWER SUPPLY MOUNTING DIMENSIONS (S60213. M22108.BACKPLANE MOUNTING DIMENSIONS (M21882. M22535) WATCHDOG TIMER BOARD MOUNTING DIMENSIONS (N41215) MC3 Hardware Manual 55 . IOC INPUT CONNECTION BOARD (M22536) MC3 Hardware Manual 56 . 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