Operation & Maintenance Manual For Model 475ez Belt Scale: Sigsig Ltda (Tecnagent Chile) Santiago, Chile

Operation & Maintenance Manual
for
Model 475EZ Belt Scale
SigSig LTDA (Tecnagent Chile)

Santiago, Chile
Customer Purchase Order Number: 12-MERR-01

Serial Number: 32045
MERRICK Sales Order Number: M13500-000
Merrick Industries, Inc.

10 Arthur Drive
Lynn Haven, FL 32444 USA
+1 850.265.3611 Worldwide
+1 850.271.7834 En Espanol
www.merrick-inc.com
PROPRIETARY NOTE
The information in this manual, including technical data and copies of drawings, embodies
information proprietary to Merrick Industries, Inc. This manual is provided to the user of equipment
purchased from Merrick Industries, Inc. for use only in the operation and maintenance of such
equipment. Such information in this manual is not to be used, disclosed, copied or reproduced in
whole or in part for any other use 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
SECTION 1 CONTACT AND SPARE PARTS INFORMATION

A. Customer Support
B. Recommended Spare Parts
SECTION 2 BELT SCALE

A. Model 475EZ Belt Scale; Operation and Maintenance
Instructions
B. Speed Transmitter
SECTION 3 CONTROLS
A. Genetix Belt Feeder Control with LCD User Interface;
Safety, Installation, Operation and Maintenance
Manual
B. Programming Data Sheets
SECTION 4 REFERENCE INFORMATION

A. 475EZ Mechanical Arrangement Drawing; Drawing
No. IB107261
B. Unit & Customer Connection Diagram; Drawing
No. A-49789
C. Feeder Connection Board Assembly; Drawing
No. A-31196
CUSTOMER SUPPORT
Technical Support
Jack Dehner - Customer Service Business Manager
Phone: +1.850.271.7844 Email: [email protected] Fax: +1.850. 271.7886
In House Customer Technical Support – Willie Allen

Phone: +1.850.271.7893 Email: [email protected] Fax: +1.850.271.7906
Emergency Number +1.850.271.7878 Available 24 Hours/Day
Field Service Technicians
Ken Allen Marvin Allen

Florida Georgia
Willie Allen Ron Deleon

Florida Florida
Chuck Hall Larry Helsene

Oklahoma Florida
John Ingalls Walter Kukyciak

Georgia Missouri
John Roberts Randy Schoolcraft

Florida West Virginia
Daryl Strickland Tom Gongloff

North Carolina Pennsylvania
Spare Parts Sales Department

Jayne Rice Dena Adams
[email protected] [email protected]
+1.850.271.7818 +1.850.271.7815
Customer Support Assistance

Kathy Selbe – Service Administrator
Phone: +1.850.271.7827 Email: [email protected] Fax: +1.850.271.7886
Please contact Kathy Selbe for customer support, recommended spare parts lists, the O&M manuals and to schedule
service or leave a message for a field service technician.
RECOMMENDED SPARE PARTS
475 EZ Belt Scale Assembly
Customer: SIGSIG LTDA (Tecnagent Chile)

User: SIGSIG LTDA (Tecnagent Chile)
AV. Presidente Arrazuriz # 3262, Las Condes
Casilla 25 – Santiago 35
Chile
Machine S/N: 32045
Merrick No.: M13500-000
Date: March 28, 2012
PART DESCRIPTION PART NUMBER QUANTITY LEADTIME
Genetix GCM Module M22633-1 1 6 Weeks

Genetix LCD User Interface A46753-2 1 6 Weeks
Genetix Power Supply 24VDC M22746-1 1 6 Weeks
Load Cell, 100Lb (Dual) N39188-112 2 6 Weeks
Feeder Connection Board M21911-5 1 2 Weeks
Coupling Half, .75 Bore BF212390-7 1 4 Weeks
Coupling Half, .625 Bore BF212390-6 1 4 Weeks
Insert Coupling, 4JE BF200573-2 1 4 Weeks
Digital Speed Pick-UP DSP-825 A46772-1 1 6 Weeks
DA
OPERATION AND MAINTENANCE
INSTRUCTIONS
FOR
MODEL 475EZ BELT SCALE
MERRICK INDUSTRIES, INC.

10 ARTHUR DRIVE
LYNN HAVEN, FL 32444
USA
(850) 265-3611
www.merrick-inc.com
SAFETY CONSIDERATIONS FOR MERRICK BELT FEEDERS AND BELT SCALES
SAFETY
Merrick manufactures units in a range of sizes. The following precautions are basic to all machinery and
the principles apply to all Merrick equipment, although the sizes differ.
No unusual hazards are associated with Merrick equipment and controls. However, all machinery with
electric drives and controls and moving parts requires the observance of basic precautions. Some of
these principles bear repeating.
AS A GENERAL RULE:
1. OBSERVE ALL STANDARD PRECAUTIONS, WHICH PERTAIN TO MOVING MACHINERY.
2. OBSERVE ALL STANDARD PRECAUTIONS, WHICH PERTAIN TO ELECTRIC DRIVES AND

ELECTRICAL CONTROLS.
3. PAY PARTICULAR ATTENTION TO THE SPECIAL "CAUTIONS" AND "NOTES" WHICH

OCCUR THROUGHOUT THIS MANUAL.
MECHANICAL PRECAUTIONS:
1. When working on Merrick equipment (whether for installation, cleaning, maintenance or

lubrication) take positive steps to close off all infeeds and discharges. This is to prevent material
from falling on personnel.
2. Use canvas tarpaulins to protect openings and to keep tools and loose parts from falling into
machinery.
3. Take positive steps to prevent machinery from being started while personnel are at work.
Conveyor pull cords or Main Disconnect Switches should be opened. Merrick recommends that
the boxes be padlocked by maintenance personnel who keep the keys in their possession while
at work. Or remove fuses in the Main Disconnect Box and hang signs which indicate personnel
are at work.
4. Do not attempt to remove chain guards and other protective elements of the equipment while
machinery is being operated.
5. When work must be performed on machinery in motion, caution personnel to remove all loose
clothing and jewelry such as rings, wrist watches, bracelets, etc.
6. Whenever possible do not allow personnel to work alone. There should be other people
available to stop a machine in the event of a mishap and to summon help.
7. Always stop machinery before opening doors or inspection ports to prevent material from flying
out of the enclosures.
8. Heavy components such as pulleys and motors must be cribbed or braced from below, or lashed
from above, to prevent them from falling. When dismantling equipment, use good rigging
procedures.
9. Stop machinery immediately in the event of unusual vibration, erratic operation, or runaway and
uncontrollable motor speed.
1
10. Personnel working on machines should wear safety goggles, hard hats, steel-toe shoes and
heavy gloves.
ELECTRICAL PRECAUTIONS:
1. Before undertaking work on the electrical control or drive systems, open Main Disconnect
Switches and lock boxes. Or remove the fuses in the Main Disconnect and attach a sign to the
box indicating that work is in progress.
2. Verify that all necessary grounds called for in the wiring diagrams are in place and are solid. Do
not disable or disconnect grounding.
3. When working in live areas (high voltage) always keep one hand clear of the machine, cabinet
and other conductors to avoid the possibility of shock from one arm across the chest to the other.
4. Never impair the function of a fuse.
5. Never undertake electrical work when the floor is wet or flooded.
IF PERSONNEL ARE IN DOUBT ABOUT A PROCEDURE, CALL THE MERRICK SERVICE

DEPARTMENT.
2
STORAGE OF MERRICK BELT FEEDERS AND BELT SCALES (AS APPLICABLE)
(NOTE SEPARATE INSTRUCTIONS FOR MECHANICAL AND ELECTRICAL)
STORAGE
MECHANICAL EQUIPMENT - STORED ON RECEIPT FROM FACTORY:
A. Storage up to 30 Days: Keep all equipment dry and store well above the ground. A warehouse
is preferred. No other special precautions apply.
B. Storage 1 to 12 Months:
1. Grease-lubricated Gear Boxes: No special requirements.
2. Oil-lubricated Gear Boxes: Fill the Gear Box completely with recommended lubricant and
plug the vents.
OR
Fill the Gear Boxes to operating level with a rust-preventative oil (NP-20 or equivalent).
Plug the vents. At approximately one-month intervals, rotate the Input Shaft a sufficient
number of times to insure that all internal components remain coated with oil.
3. Coat the Chain and Sprockets liberally with a heavy-consistency grease and inspect or
renew covering every six months.
4. Protect the Shafts and other exposed ferrous metal parts with a heavy-consistency
grease and inspect or renew coating every six months.
5. Slacken the Belt fully.
6. Install adequate amounts of desiccant in Feeders. A minimum of ten pounds is

recommended. The more, the better.
7. Remove all pressure from belt Scraper Blades (If furnished).
8. Locate the Suspension in the raised (shipping) position.
C. Storage Longer Than 12 Months: (Observe all of the above plus these additional precautions):
1. Change oil in Gear Boxes yearly.
2. Remove all Conveyor Belts and store indoors on a large-diameter core to prevent the belt
from taking a "set".
MECHANICAL EQUIPMENT - STORAGE FOLLOWING USE:
(Observe all of the above instructions for storage prior to use plus these additional instructions)
A. Empty the machine completely of conveyed material.

B. Neutralize units. Flush all surfaces with clean water and dry thoroughly.
C. Remove rust as necessary. Touch-up all painted surfaces where necessary to cover all bare
metal surfaces.
3
MECHANICAL OPERATION AFTER STORAGE:
A. Grease-lubricated Gear Boxes: Add half of the recommended quantity of new grease as shown
in Lubrication Section of this manual.
B. Oil-lubricated Gear Boxes:
1. Drain the rust-preventative or operating oil completely.
2. Flush unit with the recommended operating oil as shown in the Lubrication Section of this
manual.
3. When flushed clear, fill the unit to the proper oil level with the recommended lubricating
oil.
C. Reinstall and re-tension the Conveyor Belt.
D. Re-grease all bearings.
E. Remove desiccant.
F. Reposition belt scrapers.
ELECTRICAL EQUIPMENT - STORED ON RECEIPT FROM FACTORY:
A. Storage Up to Six Months: Keep all equipment dry and well above the ground. A warehouse is
preferred. If the equipment has been in transit for two months or longer, replace the factory-
supplied desiccant before storing. The use of Vaporizing Corrosion-Inhibitors is recommended
but not required.
B. Storage Longer Than Six Months:
1. In a heated warehouse with temperatures ABOVE FREEZING.
a. All equipment must be kept dry. Vaporizing Corrosion-Inhibitors MUST be used

inside all electrical enclosures and panels.
b. Operate all electrical and electronic equipment at least once a year for a
minimum of two to three hours, preferably during a low humidity season.
Operate all switches at least ten times. Operate transformers and motors at
least once a year and allow them to rise 20 degrees C (36 degrees F) above the
ambient temperature.
2. In a warehouse with temperatures BELOW FREEZING.
a. Prior to storage, remove all pen and ink elements from Recording Instruments,
and thoroughly clean all inking mechanisms.
3. Outside Storage IS NOT RECOMMENDED. If it is unavoidable, then damage from

dampness must be prevented. The use of Vaporizing Corrosion Inhibitors and
Desiccants affords some protection. Equipment must be operated periodically as above.
4
ELECTRICAL EQUIPMENT - STORAGE FOLLOWING USE:
A. Clean all equipment and enclosures thoroughly inside and out.
B. Remove rust as necessary. Touch up all painted surfaces as necessary to cover all bare metal
surfaces.
C. Observe instructions for storage and care of electrical equipment prior to use (see above).
D. Keep panels dry with anti-condensation heaters if possible.
ELECTRICAL EQUIPMENT - OPERATION AFTER STORAGE:
GENERAL INSTRUCTION:
A. When equipment has been stored at either high humidity and/or low temperatures, DO NOT
APPLY POWER until the equipment has been allowed to stand at ambient conditions for a
minimum of three hours.
B. Remove all packing and protective materials.
C. Remove all desiccants. Vaporizing Corrosion-Inhibitors may be left in the equipment only if this
is permitted by local fire regulations.
GENERAL DESCRIPTION
Merrick Belt Scales consist of electrical and mechanical components for weighing the material load on a
conveyor belt and for measuring the belt travel. They also include electronic instrumentation for
calculating the flow rate and the total weight of conveyed material. (This instrumentation is described in a
separate section or document).
BELT LOAD MEASUREMENT
Merrick Type 475EZ Belt Scales are modular in design, meaning that a scale is made up of one or more
Weigh Units, which replace an equal number of conveyor idlers. If more than one Weigh Unit is used,
they are installed one after the other. The scale span is defined as the distance along the belt where the
material load is measured. See Figure 1 and Figure 2 for illustrations of how the scale span is measured.
5
Figure 1
L/ 2 L/ 2
L L
Weighing Section
Figure 1
Belt Scale with Single Weigh Unit
L/ 2 L L L/ 2
Weighing Section
Figure 2
Belt Scale with Multiple Weigh Units
Each Weigh Unit is self-contained with its own load cells and weigh sensor (idler set). The number of
Weigh Units used in a scale is usually determined by the accuracy required and the belt speed. The
longer the weighing span, the more accurate the scale because of the reduced influence of errors due to
idler roll misalignment. The weigh span can be increased, to a certain point, by spacing the idlers farther
apart, or by adding Weigh Units.
Proper positioning of the Belt Scale on the conveyor is essential for accurate belt load measurement.
Refer to Installation, Positioning Considerations, for the necessary considerations.
Alignment of the individual Weigh Units with the two conveyor idlers before and after the Belt Scale is
also essential for accurate belt load measurement. Refer to Installation, Weigh Unit Adjustment, for the
necessary considerations.
Also, along the portion of the conveyor where the Belt Scale is installed the stiffness of the conveyor
frame and the conveyor idlers are very important to accurate belt load measurement. Refer to
Installation, Weighing Unit Installation, for the necessary considerations.
6
WEIGH UNIT DESIGN
The Merrick Model 475EZ Weigh Unit consists of two independent frames across which a conveyor idler
is supported.
Scale Frame Conveyor Idler Scale Frame
The two frames each consist of an idler support bracket, load cell and load cell bracket. The idler support
bracket is bolted to the load cell. The opposite end of the load cell is bolted to the load cell bracket which
is in turn bolted to the conveyor frame.
Idler Support Bracket
Load Cell Bracket
Load Cell
The precise adjustment of the idlers on the Weigh Unit is critical, so that it will conform to the geometry of
the adjacent conveyor rollers. On conveyors with troughed belts, the proper trough angle is set by
adjusting the angles of the arms holding the outer (wing) rollers.
Note: Commercial conveyor idlers are all slightly different, even though they are designed for
the same belt width. For this reason, proper selection of the Merrick precision idler set for
your conveyor depends on knowing the dimensions of the actual conveyor idlers being
used. Otherwise, correct idler alignment may not be achievable.
For Belt Scales not requiring the highest accuracy, Merrick can also supply an adapter for mounting a
standard commercial idler to the Model 475EZ Weigh Unit.
BELT TRAVEL AND SPEED MEASUREMENT
Conveyor belt movement can be measured by the electronics using a conveyor-mounted tachometer.
The tachometer has a shaft, which is normally coupled to an idler or pulley on the conveyor. The
tachometer rotates at a rate proportional to the movement of the belt.
7
The rotation of the tachometer generates electrical pulses, each of which is equivalent to a fixed unit of
belt travel. These pulses in conjunction with an accurate measurement of the belt length will provide the
information needed by the electronics to calculate belt travel distance and belt speed.
Merrick specifies various type of tachometers based on the physical installation and the process
specifications. A separate section in the Operators Manual will contain detailed information on the
tachometer supplied with the 475EZ.
8
INSTALLATION
INSPECTION
Inspect the equipment for shortages or evidence of physical damage and report it to the independent
carrier. If the weighing system consists of more than one Weigh Unit, the belt width, range, and serial
number of each unit should be checked against the specification sheets to ensure that all required
components have been supplied and identified.
POSITIONING CONSIDERATIONS
The Weigh Unit or Units, the two conveyor idlers on each side of the Weigh Units, and the conveyor
structure constitute the actual Belt Scale. Correct conveyor location and installation involving these
components and the considerations below are essential for accurate scale operation.
The guidelines given below are based on accepted installation practices and Merrick experience for
satisfactory Belt Scale performance. If a Belt Scale is to be Certified (licensed for legal commerce), the
scale must be installed in accordance with the guidelines of the regulating handbook (O.I.M.L., NIST
Handbook 44, etc.). In all cases involving certification the regulating handbook has priority over any
installation and positioning guideline stated in this manual.
A. The conveyor in which the Weigh Unit is to be installed may be either horizontal or inclined;
however, the angle must be constant within the portion of the conveyor, which accommodates
the Weigh Units. The inclination must not be so great that the material tends to roll or slip on the
belt (generally less than 20 degrees from horizontal).
B. The Weigh Units should never be placed in the vicinity of horizontal or vertical conveyor curves,
nor located too close to pulleys, turning rollers or training idlers where belt pressure on the Weigh
Units may vary with the stiffness of the belt (see Figures 3, 4, 5, and 6).
C. The conveyor should be equipped with some form of weather protection, if necessary, to prevent
weighing errors caused by snow, ice, wind forces, etc.
D. If a short conveyor has a troughed belt, the distance from the head pulley to the first Weigh Unit
must be at least 12 to 15 feet (3.7 to 4.6 meters) and must include at least 3 idlers to assure that
full troughing is attained at the first idler after the Weigh Unit. If the conveyor has a flat belt, at
least 2 idlers are required between the head pulley and the Weigh Unit to prevent errors due to
head pulley crowning.
E. Material should never be loaded onto the belt over the weigh span area. The distance between
the feeding point and the Weigh Units must be great enough to permit the material to fully come
to rest before it reaches the weigh span.
For an inclined conveyor, this must correspond to an area of minimum initial belt tension and
minimum changes in belt tension. Generally speaking, the Belt Scale should be located as close
as possible to the infeed, but at a distance far enough from it that the material is conveyed for 2-5
seconds (see figure 3).
For a conveyor that is horizontal or has a downward slope, the scale position is not as critical as
with an inclined conveyor. Since roller friction only affects belt tension in these conveyors, the
scale can be located up to 165' (50 meters) from the loading point. Again, however the material
must have come fully to rest before entering the scale area. On a downward sloping conveyor,
this can take longer than on an upward sloping conveyor.
F. If the conveyor has side skirting above the weigh span area, it must be located so as not to touch
the belt. Clearance between the bottom of the skirt plates and the belt must increase in the
direction of material flow so that material cannot become trapped between the skirt and belt.
9
G. Belt scrapers, training idlers, or monitoring devices which require contact with the belt must not
be used within the weigh span. Do not locate magnetic iron removal devices near the scale or
over the scale area. Training idlers must be located a minimum distance from scale required for
the material to be conveyed in 2-5 seconds.
Figure 3 Figure 4
Suitable Weighing Area On Inclined Conveyor Conveyor with Concave Type Vertical Curve
Figure 5 Figure 6
Conveyor with Convex Type Vertical Curve Conveyor with Tripper
10
WEIGH UNIT INSTALLATION
Ideally, the Weigh Units should be installed in the conveyor before the belt is fitted. If the belt has already
been fitted, the conveyor drive motor and belt tensioning device must be disconnected and the belt
hoisted to expose at least 3 idlers both upstream and downstream of the weigh span area.
Guidelines are given below for conveyor and idler stiffness in the scale area if weighing accuracy better
than 1% is required. Excessive or harmful deflections are a common occurrence when the idler load is
greater than 50 lbs. (23kg). If your loading exceeds this value and you need additional assistance in
evaluating modifications to stiffen the conveyor or idlers in the scale area, see Merrick technical brochure
entitled "Belt Scale Design and Installation Guidelines".
1. Dismantle and remove the existing idler or idlers from that section of the conveyor, which is to
serve as the weigh span.
Note: Sometimes more idlers are removed than Weigh Units installed. This is often
done in an effort to increase the scale span. The distance between idlers is an
important aspect of Belt Scale accuracy, and all things considered should be as
great as possible. This can greatly reduce the errors due to belt effects and mis-
alignment.
2. If the two conveyor idlers on each side of the Weigh Unit(s) are structurally weak, they must be
reinforced so that their deflection under full loading does not exceed 0.02% of the idler width.
Their roller concentricity must not exceed 0.012" (0.3 mm). Scale quality idlers can be purchased
for these locations, or idlers can be specially selected from the inventory of conveyor idlers for
these locations.
Note: "Offset" idlers (those with the wing rollers not in-line with the center roller) are not
acceptable in the weigh area. They must be replaced with conventional in-line
idlers. Offset idlers shouldn’t be within 2 idlers before or 2 idlers after the scale.
3. If the conveyor framework itself is structurally too weak, the part of the frame supporting the
Weigh Units including the two idlers before and after the Weigh Units must be reinforced to
prevent deflection or deformation. As a general rule, deflections must not exceed 0.025" (0.6
mm) under full load, between idlers. However, with Merrick Weigh Units, the amount of
deflection is not as critical as making sure that all the Weigh Units deflect an equal amount as
shown in Figure 7.
4. Check the two conveyor idlers on each side of the Weigh Units to ensure that they are aligned to
within 1/32" (2 mm) including side rolls. Use shims to adjust the idlers to this positioning where
necessary.
5. In most installations each of the two independent assemblies which support the conveyor idler
are bolted to the conveyor. The conveyor idler is then mounted across those two assemblies. In
most cases modifiecations for mounting might include a few bolt holes and a slot being cut into
the conveyor for mounting. The 475 EZ is designed to be installed in varying types of conveyors.
Specific installation instructions and drawings are normally included in the Seciton 3 of the
manual.
6. The Weigh Unit must be mounted parallel to the plane of the conveyor. The unit must be
oriented so that the test weight pegs are pointing opposite of belt travel.
7. The Weigh Unit must be installed spaced equally between the adjacent idlers. In multiple Weigh
Unit applications, all Weigh Units must be equally spaced and be centered between the adjacent
idlers.
11
A
-NO-
B
-YES-
= The shape of the beam at loading
C
-YES-
D
-YES-
Figure 7
Reinforcement of Conveyor Frames
12
Weigh Module Adjustments
The conveyor idler height can be adjusted on both ends by using adjusting screws supplied with the
Model 475EZ
The load cell support is slotted to allow the scale frames to be adjusted back and forth along the rails of
the conveyor. This ensures that the conveyor idler on the 475EZ can be made parallel to the conveyor
idlers on each side of the 475EZ scale. This, in conjuntion with the conveyor idler height adjustment,
ensures that the Model 475EZ can be precisely aligned within the conveyor for optimal weighing
accuracy.
1. After the Weigh Units have been properly positioned, stretch two thin nylon lines from both ends
of the second idler upstream of the weigh module to both ends of the second idler downstream of
13
the weigh module. The nylon lines should be weighted at each end and positioned as close to
the outer edges of the rollers as possible.
2. Perform fine adjustments by first loosening the jam nuts on the screws which are supporting the
shaft ends of each weigh roller. Carefully adjust the screws so that the horizontal roller just
touches the nylon lines without lifting them. Carefully re-tighten the adjusting screw jam nuts.
Weigh Module Too High.

(Adjust Lower)
Weigh Module Too Low.

(Adjust Higher)
Weigh Module In Line.

(No Adjustment)
W
14
MAINTENANCE
MECHANICAL INSPECTION
Material build up on the Weigh Unit and adjacent idler rollers will affect scale accuracy. Inspect the
rollers frequently for cleanliness. A further check should be made at that time to ensure that they are
undamaged and run smoothly. Type 475EZ Weigh Units have an overload protection bolt to protect the
load cell under the middle of the Weigh Unit roller set. This area must be kept clean. Suitable inspection
intervals may range from once a week to once a month, depending upon operating conditions.
Also check to ensure that the idlers on either side of the Weigh Unit have not shifted from the positions
they occupied when the scale was installed and calibrated. If this is the case, and the correct positions
cannot be identified with certainty, the scale must be realigned and recalibrated.
LUBRICATION
Merrick Precision Weigh Unit rollers are permanently lubricated. No other parts of the weighing set
require lubrication.
15
TEST CHAINS
(OPTIONAL)
TEST CHAINS IN CALIBRATION
DESCRIPTION
The Merrick Roller Test Chain is designed and used for the Calibrating of Merrick Weigh Feeders and
Belt Scales. Constructed to simulate actual material loading conditions, the Test Chain consists of a
series of cast-iron or steel Rollers linked together and constructed so the chain will roll in place on a
moving conveyor.
Each chain is designed to a specific weight per unit length (i.e., pounds per foot, or kilograms per meter),
and belt width, and it is selected on the basis of the idler spacing, belt speed and the capacity of the unit
with which it will be used.
In use, the Test Chain is placed on the Belt and fastened to fixed Points on the Conveyor structure.
When the Belt is started the Test Chain Rollers rotate, allowing the Test Chain to remain in position, but
loading and depressing the belt as it would be when under actual load. The weight-per-length multiplied
by the length traveled by the belt gives a true weight against which the Totalizer or Controller must check.
USING THE TEST CHAIN
The Test Chain furnished has been selected specifically for each machine. Consideration has been given
to weight, (in pounds or metric), pitch, working width, actual width, roller diameter and construction.
Rollers may or may not be bushed, may be double-decked and may or may not have heavy side links.
Therefore, never calibrate with any chain other than the one furnished for your machine by Merrick.
If your machine is rerated, (to perform a different task or operate in a different weight range), check
whether the old Test Chain can be used. Otherwise, order a new test chain specifically designed for the
new range of your Merrick unit. Merrick will furnish this information.
POSITIONING THE TEST CHAIN LATERALLY
For maximum accuracy the Test Chain must run down the center of the belt. Measure carefully from the
centerline of the belt to the centerline of the Test Chain, both at the head pulley end and the tail pulley
end. If the Test Chain is properly secured at both ends, it should maintain its position.
Note: If a Test Chain shows a tendency to track to one side or the other, rather than run in the center,
try turning the chain over.
POSITIONING THE TEST CHAIN ON THE WEIGH UNIT
The proper positioning of the Test Chain along the belt is critical to its accurate use. The length of the
chain has been engineered so that it will cover the weigh unit(s) PLUS at least one fixed Idler at each end
-- the approach end and the retreat end. (Covering two fixed Idlers is ideal, if possible).
Merrick builds machines of various lengths. On machines which are shorter, there may be only one fixed
idler before and after the weigh unit(s). Longer units may have more than one fixed idler before the
weigh unit and following the weigh unit. In this instance, position the Test Chain so that the ends toward
the tail pulley lies fully over the first fixed idler. The end towards the head pulley (drive or discharge end)
will then lie fully over the fixed idler following the weigh unit. If extra Test Chain extends over the head
pulley, this is satisfactory. However, do not permit the Test Chain to lie over the tail pulley.
17
SECURING THE TEST CHAIN IN POSITION
Merrick Test Chains are equipped with shackles at both ends. At the center point of each shackle there
is a clevis and clevis pin. This creates an articulated "eye" from which anchor rope or cable can extend to
solid anchorage’s at each side of the machine. The anchor points need not be in the same plane as the
belt, but may be in a structural member above the belt. They need not be further apart than the width of
the belt, although they can be. With a troughed belt, raise the anchor points so the cables are clear of
the belt. It is important, however, that the points formed by the "eye" and the anchor points form a
symmetrical triangle. The lines are then of the same length.
On smaller machines these anchor lines may be of manila rope or Nylon or Polypropylene rope. These
can be tied at the machine end to any convenient point, or they can be equipped with hooks.
For heavier chains on large machines, use of 1/4 inch cable is recommended. Sheathed aircraft cable
can also be used. Rigid wire or rods may be used, as well.
If the Test Chain is to be used frequently or is very heavy, Merrick recommends that it be fitted as shown
in Figure 8. Use a thimble to prevent wear where the cable passes through the eye. Fit the other ends
with safety shank hooks and secure the cable to itself with cable clips.
Use a turnbuckle in the system as shown. This facilitates making minor adjustments if the Test Chain is
not tracking properly. Install screw-eyes at the anchor points.
On large installations, where larger chains are used, Merrick can furnish a Test Chain Reel or Rack for
ease in placing and removing the chain from the belt.
MAINTENANCE
Lubricate Test Chains with light machine oil.
Store Test Chains in a dry place.
MERRICK TEST CHAIN STORAGE REELS
(OPTIONAL ACCESSORY)
GENERAL DESCRIPTION
Merrick Test Chain Storage Reels are designed to store Test Chains, used to simulate actual load
conditions on a conveyor belt scale or weigh-feeder. They must be mounted in a convenient location for
easy positioning of the roller chains on the conveyor belt, and for easy retrieval and storage when they
are not in use.
The Test Chain Storage Reel consists of a hub and a number of discs which form the storage chambers,
and in the case of manually-operated reels, one disc serves as a brake.
Each storage chamber is fitted with a wire cable which is also stored on the reel. The cable is fixed to the
reel by passing the reel-end through a hole in the outer disc, the diameter of the cable. The cable is
18
Figure 8
Test Chain Tie Downs
19
then doubled back and held with a U-Bolt Shackle which cannot pass through the hole. The chain-end of
the cable is doubled back over a thimble and clamped, forming a eyelet to which the Roller Chain is
attached with an easy-opening shackle.
There is sufficient cable to permit the lowering of the Roller Chain to the proper position over the weigh
unit, where it is used in calibration procedures.
The Roller Chain is located along the center-line of the belt and it must over-lap two fixed idlers at each
end of the weigh unit. It is held in this position by a bridle affixed to both sides of the conveyor.
Merrick Test Chain Storage Reels are made in two configurations:
MANUALLY OPERATED
In these models the chain is let out by releasing a brake and controlling the hand-wheel. It is raised by
turning the hand-wheel and it is locked in storage position by the brake and a safety block described later.
Some models are direct drive, that is, the hand-wheel is attached directly to the reel axle. Some models
employ a reduction gear system, usually a 6 to 1 ratio, to facilitate turning the hand-wheel.
MOTORIZED
On these models there is a drive motor and reduction gear arrangement. The motor is reversible, and the
chain is let out or taken up by operating the motor in the correct direction. No brake is necessary. The
gearing of the reducer is sufficient to hold stored chains in place.
OPERATING THE MANUAL CHAIN STORAGE REEL
TO LOWER THE CHAIN INTO POSITION FOR TESTING
1. Remove the U-Safety Block form the edge of the Brake Disc. (The outer edges of the Brake Disc
are not painted, as this will decrease the locking power). DO NOT OIL THIS SURFACE. DO
NOT PAINT IT.
The Slotted Safety Block is a rectangular block of steel with a slot where it fits over the Brake
Disc, and with a square-headed locking bolt. Loosen the Locking Bolt.
CAUTION: The Main Brake must be engaged when the Safety Lock is removed. This will prevent
the chain from running-away.
2. Unlock the Main Brake slowly by turning the Main Brake Crank counter-clockwise. This releases
the pressure on the Brake Disc created by the squeezing of the Disc between the two brake
surfaces. The rate of chain release can be controlled by manually restraining the Hand-wheel,
and by maintaining some tension on the Brake.
3. When the Roller Chain is in position on the weigh unit, tighten the Brake.
4. Affix the Bridle which will hold the chain in correct position. Unshackle the Test Reel Cable and
wind the cable back onto the reel.
TO RETRIEVE THE CHAIN FOR STORAGE
1. Let out the cable until it reaches the bridle which holds the chain in its correct test position. Lock
the brake.
2. Shackle the cable to the chain, and remove the bridle which holds the chain in its test position.
20
3. Wind the chain back onto the reel. This should be done by two men. One must hold the hand-
wheel to keep the chain from running away when the second man releases the Brake. (In the
case of a level conveyor this may not be necessary).
4. When the Chain is completely in the storage position on the Reel, lock the Brake by turning the
Crank clockwise.
5. Apply the Safety Block by passing it over the edge of the Brake Disc and tightening the Square-
headed bolt.
OPERATING THE MOTORIZED CHAIN STORAGE REEL
TO LOWER THE CHAIN INTO POSITION FOR TESTING
1. Close the Main Disconnect, applying power to the Motor Control.
2. Set the Motor Control in reverse.
3. Run the motor until the Test Chain is in proper position on the weigh unit. (The chain must over-
lap two fixed idlers at each end of the weigh unit).
4. Attach the bridle which will hold the chain in test position.
5. Unshackle the Test Reel Cable. Put the Motor Control in Forward and wind the cable back onto
the reel.
TO RETRIEVE THE CHAIN FOR STORAGE
1. With the Motor Control in reverse, let out the Test Reel Cable until it reaches the bridle which
holds the chain in test position.
2. Shackle the cable to the chain and remove the bridle which holds the chain in its test position.
3. With the Motor Control in forward, wind the cable back onto the reel.
4. There is no manual brake needed.
5. Disconnect power to the motor.
LUBRICATION
The zerk-fittings on the main bearings of the reel must be kept filled with grease appropriate to the
ambient temperature of the installation.
Lubricate the Hand Brake Crank with heavy machine oil.
On motorized models, follow instructions which accompany the speed reducer.
21
DSP-825
SPEED
T RAN S M I T T E R
INSTALLATION
AND PARTS
MANUAL
MERRICK Industries, Inc.

10 Arthur Drive
Lynn Haven, FL 32444
+1.850.265.3611
www.merrick-inc.com
Model DSP-825 Speed Transmitter DSP-825
General Description
The Model DSP-825 detects the motion of a belt via an optical encoder that is mechanically coupled to
an appropriate rotating shaft. The rotating shaft can be, for example, the tail pulley of a belt conveyor, or
a specially mounted “bend pulley”. By using an idling pulley such as these a true representation of the
belt motion can be delivered, unaffected by slippage. The output of the DSP-825 is normally connected
to a microprocessor controller that then uses it to calculate belt speed and distance.
The DSP-825 was designed specifically for use on conveyor belt scales and is electronically identical to
the model F-25 speed sensor.
Specifications
Operating temperature range: 0 to 70ºC (32 to 158ºF)
Input voltage: 5 to 15 VDC
Protection class: IP66
Painted carbon steel enclosure, SS 304 shaft
Weight: 5 lbs. (2.26 Kg.)
Resolution (Pulses Per Revolution) 25 PPR
For other resolutions, consult Merrick
Installation
The scale installation drawing provided with your order includes an installation diagram
which is most appropriate for your application based on the information you provided to
us at the time you placed the order.
The DSP-825 can be supported directly by its input shaft, which is connected rigidly to the
rotating shaft, or it can be mounted separately and connected to the rotating shaft via a
flexible coupling. If mounted directly to the shaft, the DSP-825 must be constrained from
rotating by means of an appropriate anti-rotation device or bracket. Merrick provides a
complete array of mounting devices if required. Consult Merrick for more information.
TYPICAL BELT SCALE APPLICATION
Flexible Coupling
Mounting Bracket
SAFETY,
INSTALLATION,
OPERATION AND
MAINTENANCE
MANUAL
BELT FEEDER CONTROL

with LCD User Interface
MERRICK Industries, Inc.

10 Arthur Drive
Lynn Haven, FL 32444
+1.850.265.3611
www.merrick-inc.com
Revision History
Rev No. Date Comments

0 11 April, 2008 Initial publication
1 9 May, 2008
2 15 May, 2009 GCM Rev 1.5.x
PROPRIETARY NOTE
The information in this manual, including technical data and copies of drawings, embodies information proprietary to
MERRICK Industries, Inc. and 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.
Genetix® and WinMerik® are registered trademarks of Merrick Industries, Inc.

Bluetooth® and the Bluetooth logo are the propery of the Bluetooth SIG, Inc.
All other registered trademarks are the property of their respective owners.
Page 2 of 104
Table of Contents
INTRODUCTION ..................................................................................................5
SAFETY................................................................................................................6
OPERATION.........................................................................................................7
LCD User Interface ...............................................................................................7
Numeric Entry .......................................................................................................8
Entering Passwords ..............................................................................................8
Menu System ......................................................................................................10
Feeder Control ....................................................................................................10
Start [Stop] Feeder ..........................................................................................11
Setpoint ...........................................................................................................11
Jog Forward ....................................................................................................11
Jog Reverse ....................................................................................................11
Calibration...........................................................................................................12
Zero Procedure ...............................................................................................13
Weight Procedure............................................................................................13
Chain Procedure .............................................................................................15
Speed Span ....................................................................................................16
Material Test....................................................................................................17
ECal Procedure ...............................................................................................18
Weight Factor ..................................................................................................18
Chain Factor....................................................................................................18
ECal Factor .....................................................................................................19
Numeric Data ..................................................................................................19
Warnings.............................................................................................................23
Faults ..................................................................................................................24
Display Settings ..................................................................................................25
Upper ..............................................................................................................25
Lower ..............................................................................................................26
Damping ..........................................................................................................26
Basic Setup.........................................................................................................27
Units ................................................................................................................27
Decimal Points ................................................................................................27
Design Capacities ...........................................................................................28
Advanced Setup..................................................................................................28
Feeder Control ................................................................................................29
Limits...............................................................................................................34
Load Cells .......................................................................................................42
Tachos ............................................................................................................46
Process Control...............................................................................................52
Analog I/O .......................................................................................................55
Inputs ..............................................................................................................56
Outputs............................................................................................................60
Digital I/O ........................................................................................................63
Totalizer ..........................................................................................................66
Feeder Peripherals..........................................................................................67
Page 3 of 104
Communications..............................................................................................75
Date & Time ....................................................................................................85
Passwords.......................................................................................................85
GCM Name .....................................................................................................85
Direct Param Edit ............................................................................................86
Configuration ...................................................................................................87
Reset Totals........................................................................................................94
DNA Key .............................................................................................................94
Save to Key .....................................................................................................95
Restore from Key ............................................................................................95
Diagnostics .........................................................................................................96
Drag Chain Control .............................................................................................96
Start [Stop] Drag Chain ...................................................................................97
Jog Forward ....................................................................................................97
Jog Reverse ....................................................................................................97
Appendix A .........................................................................................................98
Logical Inputs......................................................................................................98
Appendix B .......................................................................................................100
Logical Outputs .................................................................................................100
Appendix C .......................................................................................................103
GCM Connections.............................................................................................103
Appendix D .......................................................................................................104
GCM Specifications ..........................................................................................104
Page 4 of 104
INTRODUCTION
The Genetix Belt Feeder controller is designed to be a complete belt feeder control
system. It can control almost any conceivable belt weigher or feeder application from
the very simple to the very complex. Examples are:
• Belt Scales (also known as Wild Flow Weighers).
• Basic Belt Feeder (simple PID control of feedrate)
• Batching Belt Feeder
• Belt Feeder with Pre-Feeder
In addition, the Genetix Belt Feeder control has the ability to accept input from a variety
of optional sensors, such as:
• Belt Tracking Switches
• Material on Belt Switch.
• Discharge Pluggage Switch
• Second Encoder
• Infeed Flow Monitor
• Inclinometer
This is not a complete list of all available inputs. If, after reading the appropriate
sections of this Manual, you cannot find an input appropriate to your needs consult
Merrick Customer Support for other possibilities.
Also, the Genetix controllers support a high degree of connectivity for use with Industrial
Networks or other forms of serial communication.
Despite the many modes of operation and the variety of external sensors supported, the
Genetix remains very simple to configure and use. For example, those options that are
not required are not visible if they are not enabled. In this way the controller and its User
Interface is only as complex as your application requires.
The central module for all Genetix controllers is the Genetix Core Module (“GCM”) which
contains all the basic feeder control and connections for the standard I/O and peripheral
equipment. This is a standalone device and can operate with no User Interface (i.e. as a
“blackbox”). Alternatively the GCM may be connected to one of the available Merrick
User Interface assemblies (including wireless options), providing the user direct
interaction with the feeder.
The following sections in this Manual will instruct you in the proper configuration and use
of the Genetix Belt Feeder Controller and the LCD User Interface.
Page 5 of 104
SAFETY
The Genetix Belt Feeder Controller is used for the control of process weighing
equipment. As such, it is normally responsible for the control of a process and is not
intended as a motor control device. To insure personnel safety please read the following
instructions and precautions carefully.
In General
Observe all standard precautions that pertain to moving machinery.
Observe all standard precautions that pertain to electrical drives and electrical controls.
Pay particular attentions to special notes and precautions that appear throughout this
manual.
Please read and become familiar with this entire manual before attempting service or
repair of the Genetix Controller. If you have any questions or problems, please call the
Merrick Customer Support Department for assistance.
Electrical Precautions
Before undertaking work on the electrical system, the drives, or the Controller, insure
power is disconnected and locked out. Work should never be performed on the
Controller with power on the unit.
Verify that all grounds called for on the wiring diagrams are in place and are securely
connected. Proper grounding not only helps ensure your personal safety, but is also
necessary for the proper operation of the controller.
If it is necessary to 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.
NEVER impair or disable the function of a fuse or a circuit breaker.
CAUTION: IF PERSONNEL ARE IN DOUBT ABOUT ANY PROCEDURE
CONTACT THE MERRICK CUSTOMER SUPPORT DEPARTMENT.
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 Time. During normal hours call 1-888 MERRICK (637-7425) and ask for
service. The call will be routed to the next available phone support technician.
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 phone 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.
Page 6 of 104
OPERATION
LCD User Interface

The LCD User Interface assembly is one of many User Interface options for the Genetix
controller. It consists of a small, backlit LCD display and a membrane keypad as shown
in the photo below.
There are two lines of process information shown on the screen, and these may be
configured by the user. The text in the upper right corner shows the current feeder
control mode (if enabled). The text in the upper left is the “friendly” name of the feeder,
which may be set by the user.
The user interacts with the controller through a multi-level menu system that is designed
such that parameters are easy to find and change. The most commonly accessed
features are found at the top of menus, and only those menus that are relevant to the
specific feeder application are visible.
Navigation through the menu system is managed by the 6 tactile feedback keys to the
right of the screen. To enter the menu system, the user presses the “Menu/Esc” key,
To select an item from a displayed menu, the user navigates up or down the list with the
Up/Down arrow keys until the item desired is highlighted. Once highlighted, the item is
selected by pressing the “Enter” key,
Page 7 of 104
Moving up one menu level, or aborting an operation is accomplished by pressing the
Menu/Esc key. Ultimately, if you continue to press the Menu/Esc key, you will arrive
back at the Main Screen.
Numeric Entry
Various numeric parameters are set and/or changed using the common Numeric Data
Entry screen. An example is shown below:
To enter or change a value, you scroll to the appropriate digit with the left/right arrow
keys, and then increment or decrement the digit with the up/down arrow keys. To add a
new digit to the left, scroll left to the blank space. You may only scroll left to a new a digit
one digit at a time. To change the sign of a number, scroll left to the sign position and
scroll up/down until the correct sign appears. To enter a decimal point, scroll up/down
until the decimal point appears.
Once the desired number is displayed, press the Enter key to accept. Note that there is
limit checking on these parameters; the limits being shown in the lower portion of the
display. If the Min or Max limit is exceeded, the value will be limited appropriately. You
will see an error message and the value will change to the Min or Max value as
appropriate. You may either accept this value or enter a new value that is within the
limits.
Entering Passwords
Several areas of the Menu system require entry of a Password, for security. These
passwords are 4 digit numbers and have factory default settings. They can be changed
by the user and you should do this for extra security (see Main Menu > Advanced Setup
> Passwords). In addition the password security can be turned off by setting the
respective password to all zeroes (“0000”). Once thus set, that password will no longer
be requested.
When you are asked for a password, you must enter the correct code, from left to right,
using the Up/Down arrow keys to increment or decrement the digits. Once a digit is set,
you use the Right arrow to move to the next digit, at which time the previous digit is
obscured by a star (*) (see below) . Once all digits are set, press the Enter key to
proceed.
Page 8 of 104
Page 9 of 104
Menu System
When you first enter the Menu system by pressing the Enter key, you will see the
following Main Menu:
Feeder Control… ↑
Calibration…
Warnings…
Faults…
Display Settings…
Basic Setup…
Advanced Setup…
Reset Totals…
DNA Key…
Diagnostics…
Drag Chain Control… ↓
Note: Not all the of the above entries will necessarily appear in the menu, depending on
how the controller is configured (see Advanced Set-up > Configuration ).
Feeder Control
(Main Menu)
Note: The items presented in the Feeder Control menu will vary depending on the
current control method and source. Also “Feeder Control” only appears in the Main
Menu if “Feeder Control” is configured (see Main Menu > Advanced Set-up >
Configuration).
The following is a list of all Feeder Control items and their functions:
Start [Stop] Feeder… ↑
Setpoint…
Jog Forward
Jog Reverse ↓
Page 10 of 104
Start [Stop] Feeder
If Local control has been selected for the control Source (see Main Menu > Advanced
Set-up > Feeder Control > Source), this menu item allows you to start and stop the
feeder. If the feeder is not running, this item will read “Start Feeder”. If the feeder has
already been started, this item will read “Stop Feeder”.
If either “Network” or “Remote” have been selected as the control source, then you
will not have local control over starting and stopping, and this menu item will read
“Remote Start/Stop”.
If “Manual” has been selected (see Main Menu > Advanced Set-up > Feeder Control
> Control) then this will allow you to start and stop the feeder with few restrictions.
This mode is normally used only for maintenance or initial set-up of the feeder.
Setpoint
If Local control has been selected for the control Source (see Main Menu > Advanced
Set-up > Feeder Control > Source), this menu item allows you to enter and/or change
the current Setpoint. Highlighting this item and pressing the Enter key will bring up the
Numeric Data Entry screen allowing you to enter the desired setpoint. This value is
entered in units of Feedrate if the control method has been selected as “Rate
Control”, units of Speed if the control method has been selected as “Speed Control”,
or units of percent if in Manual (“Open Loop”) (see Main Menu > Advanced Set-up >
Feeder Control > Method). If in Manual control (see above), this value will be entered
in percent.
If either “Network” or “Remote” have been selected as the control source, then you
will not have local control over Setpoint, and this menu item will display the current
Setpoint (as received from the Remote source). You may not select the item to
change it.
Jog Forward
This menu item allow you to run the feeder forward briefly, only as long as the Enter
key is pressed. You must be in Manual control for this option to be available (see
above). Also “Jog OK” must be enabled (see Main Menu > Advanced Set-up >
Feeder Control > Settings).
Jog Reverse
This menu item allow you to run the feeder backward briefly, only as long as the
Enter key is pressed. You must be in Manual control for this option to be available
(see above). Also “Jog OK” must be enabled (see Main Menu > Advanced Set-up >
Feeder Control > Settings), and “Belt Reversible”. Note: There is a settable parameter
for a delay between running the belt forward and running the belt backward (see Main
Menu > Advanced Set-up > Feeder Control > Settings > Numeric Data). This is to
prevent damage to the motor or motor contactor.
Page 11 of 104
Calibration
(Main Menu)
Selecting this item from the Main menu will present a screen asking you to enter a
Password. The default factory setting for the Calibration password is “1234”. Upon
successful entry of the password, you will be presented with the following list of options:
Zero Procedure… ↑
Weight Procedure…
Chain Procedure…
Speed Span…
Material Test…
ECal Procedure…
Weight Factor…
Chain Factor…
ECal Factor…
Numeric Data… ↓
Page 12 of 104
Zero Procedure
(Main Menu > Calibration > Zero Procedure)
This procedure “zeroes” the feeder calibration, accounting for all the dead load
represented by the suspension, the belt, etc. Selection of this procedure from the
above menu presents a screen that advises you to “Verify belt is empty”, and the
current status of the test (0.0%).
Note: The Calibration procedures do not start the belt automatically. Before starting
this procedure you must start the belt and see that it is empty. Also the belt should be
allowed to run for at least 30 minutes if starting from cold.
From this screen, you simply press the Enter key to start the procedure, or the
Menu/Esc key to cancel. Once the procedure is started, the percentage indicator will
begin to increment, and the horizontal progress bar at the bottom of the screen will fill
from left to right.
Once the procedure is complete (100.0%), a new screen will be displayed with the
following data:
Diff [x] 00.00%
Curr: [x] 00.00 lb/ft (or kg/m)
New: [x] 00.00 lb/ft (or kg/m)
Press to Accept test

Press “Menu/Esc” to reject test
Note: The subscript [x] refers to the load cell number, i.e. 1 or 2 (if two load cells are
configured)
The percentage difference (“Diff”) is shown on the first line, and represents the
difference between the current Zero Load, and the results of this procedure, relative
to Design Load.
The current Zero Load (“Curr”) is shown on the next line.
The new Zero Load (“New” is shown on the third line. This value will become the
current Zero Load if the results of this procedure are accepted.
To accept the results of this procedure, press the Enter key. If you do not wish to
accept the results, and leave the zero value un-changed, press the Menu/Esc key.
Whichever key is pressed at this point, you will be returned to the Zero Procedure
start screen so that you may easily run another procedure if desired. It is
recommended that you run more than one test to verify that the feeder is repeatable.
Weight Procedure
(Main Menu > Calibration > Weight Procedure)
This is one of the available procedures that “span” the feeder calibration, or set its
Scale Factor. Scale Factor is the parameter that relates counts from the Load Cell
A/D (analog to digital) converter to belt load units (i.e. lb/ft or kg/m). Scale Factor will
vary from feeder to feeder, depending on load cell size, weigh span, etc.
Page 13 of 104
The Weight Procedure requires the placement of certified test weights directly to the
scale suspension, usually as provided by Merrick. For assistance with correct use of
Test Weights refer to the feeder Instruction Manual and/or the mechanical drawings
provided by Merrick.
Note: The Weight Procedure requires that the correct Weigh Span value be entered
prior to running the test (see Main Menu > Calibration > Numeric Data > Weigh
Span).
Selection of this procedure from the above menu presents a screen that advises you
to verify that the correct Calibration weights are applied to the feeder and the current
status of the test (0.0%). The value of the Test Weights is shown and should be
verified. To change this value see Main Menu > Calibration > Numeric Data > Test
Weights.
this procedure you must start the belt and see that the test Weights are in position.
Also the belt should be allowed to run for at least 30 minutes if starting from cold.
from left to right.
following data:
Diff [x] 00.00%
Curr: [x] 10000.00
New: [x] 10000.00

configured)
difference between the current Scale Factor, and the results of this procedure,
relative to the current Scale Factor.
The current Scale Factor (“Curr”) is shown on the next line.
The new Scale Factor (“New” is shown on the third line. This value will become the
current Scale Factor if the results of this procedure are accepted.
accept the results, and leave the Scale Factor value un-changed, press the Menu/Esc
key.
Whichever key is pressed at this point, you will be returned to the Weight Procedure
Page 14 of 104
Chain Procedure
(Main Menu > Calibration > Chain Procedure)
This is one of the available procedures that “span” the feeder calibration, or set its
Scale Factor. Scale Factor is the parameter that relates counts from the Load Cell
A/D (analog to digital) converter to belt load units (i.e. lb/ft or kg/m). Scale Factor will
vary from feeder to feeder, depending on load cell size, weigh span, etc.
The Weight Procedure requires the placement of a certified test chain onto the feeder
belt, usually as provided by Merrick. For assistance with correct use of a Test Chain
refer to the feeder Instruction Manual and/or the mechanical drawings provided by
Merrick.
Selection of this procedure from the above menu presents a screen that advises you
to verify that the correct Test Chain is applied to the feeder and the current status of
the test (0.0%). The value of the Test Chain is shown and should be verified. To
change this value see Main Menu > Calibration > Numeric Data > Test Weights.
this procedure you must start the belt and see that the test Weights are in position.
Also the belt should be allowed to run for at least 30 minutes if starting from cold.
from left to right.
following data:
Diff [x] 00.00%
Curr: [x] 10000.00
New: [x] 10000.00

configured)
key.
Whichever key is pressed at this point, you will be returned to the Chain Procedure
Page 15 of 104
Speed Span
(Main Menu > Calibration > Speed Span)
The Speed Span procedure is the process by which the controller relates the length
of the belt (which you must enter) to the number of tacho pulses representing one belt
revolution. It is very important for the accuracy of the speed calculation, for
totalization and for the repeatability of Calibration procedures.
Note: Before you perform a Speed Span procedure, you must measure the belt
accurately and enter the Belt Length into the Genetix controller (see Calibration >
Numeric Data > Belt Length). Also the Speed Span procedure must be performed
before all other calibration procedures.
The objective of this test is to allow the controller to count the number of pulses
representing one belt revolution. To do this, either a switch on the Feeder Connection
Board is used, or this User Interface. For this test, you should place a mark on the
belt and select a suitable reference point to establish when the mark passes by. The
belt must be running.
When you select the Speed Span procedure from the above menu, you will be
presented a screen that shows the number of pulses from Tacho 1 (and Tacho 2, if
configured). At the top of the screen you will also see a note showing you how many
revolutions of the belt the controller is expecting you to run. Generally, more than one
revolution of the belt is used, for accuracy (see Main Menu > Calibration > Numeric
Data > Test Revs to set this parameter). The controller will divide total number of
pulses counted by the number of revolutions to arrive at the number of pulses per rev
(“Pulses/Belt Rev”, see Main Menu > Calibration > Numeric Data > Pulses/Belt Rev
x).
If your feeder is equipped with a Merrick Feeder Connection Board, with a switch,
then you should turn the switch OFF. When you do this, the pulse counters on the
display should stop incrementing. Press the Enter key to start counting pulses, and
the display(s) should reset to zero.
When your mark on the belt passes your reference point, you should turn the switch
to the ON position. Try to be as accurate as possible. While ON, the controller display
should be incrementing pulses.
Allow the required number of belt revolutions to take place (see above), and when the
mark again passes the reference point, again turn the switch OFF. Pulses should now
stop.
At this point, press the Enter key to allow the controller to make the calculation of
Pulses/Belt Rev. A new screen will be presented that shows the Current value and
the New value. Press the Enter key again to accept the new value or the Menu/Esc
key to exit without making any changes.
If your feeder is not equipped with a feeder connection board, or a switch, then use
the following procedure to perform a Speed Span:
With the belt running, and the controller incrementing pulses, press the Enter key
when your mark on the belt passes the reference point.
Allow the required number of belt revolutions to take place (see above), and when the
mark again passes the reference point, press the Enter key to stop counting pulses
and calculate Pulses/Belt Rev. A new screen will be presented that shows the
Page 16 of 104
Current value and the New value. Press the Enter key again to accept the new value
or the Menu/Esc key to exit without making any changes.
Material Test
(Main Menu > Calibration > Material Test)
When you select this procedure you will see another screen as follows:
GCM Total ↑
Actual Total
Run Procedure… ↓
The purpose of a Material Test is to run a quantity of material over the scale (or
feeder) and weight that quantity on a reference scale for comparison. The reference
scale must be in known good condition and have an accuracy better than the desired
accuracy of the Genetix. For example, if the Genetix controlled feeder is to have an
accuracy of +/- 0.25%, the reference scale should have an accuracy of +/- 0.10%.
Note: Running a proper material test is complicated and can be very expensive, but is
arguably the best way to calibrate your scale (or feeder). If you would like assistance
organizing a well-run test, please contact the Merrick Customer Support department.
To run a Material Test procedure, first reset the Sub-Total totalizer (see Main Menu >
Reset Totals > Reset Sub-Total). Then run a quantity of material over the scale that
has either been pre-weighed or can be post-weighed on the reference scale.
Go to the Material test screen and the material will be totalized on the first line that
says “GCM Total”.
After the material has been weighed on the reference scale, that total should be
entered by highlighting the line that reads “Actual Total” and entering the actual total.
Once both values are persent, highlight the line that reads “Run Procedure” and
press the Enter key. A new screen will be displayed with the following data:
Diff [x] 00.00%
Curr: [x] 10000.00
New: [x] 10000.00

configured)
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key.
Whichever key is pressed at this point, you will be returned to the Material Test
screen so that you may easily run another procedure if desired. It is recommended
that you run more than one test to verify that the feeder is repeatable.
Note: It is also possible to use the Material Test procedure to directly affect a change
to the Calibration by entering numbers for both parameters that you select. You may
enter arbitrary values for both “GCM Total” and “Actual Total” and run the procedure.
The error displayed is calculated as follows:
Error, % = (GCM Total – Actual Total) / Actual Total x 100%
So, if for example you believe the Genetix is reading 1% low, you can correct it
directly by selecting appropriate numbers and running the Material Test procedure. In
this example a set of numbers can be selected by entering a GCM total that is exactly
1% lower than the Actual total, for example GCM Total = 198, Actual Total = 200.
(Note: All numbers must be greater than 100).
After you run the procedure and accept the results the Genetix should now agree with
your reference.
ECal Procedure
(Main Menu > Calibration > ECal Procedure)
This procedure allows you to “span” the feeder calibration without having to use
weights, a test chain or any other kind of load. Instead a calibration is performed
based on the electrical signal that should be present under a given load. Before
performing this procedure this value must be calculated ahead of time and entered in
the Genetix controller (see Main Menu > Calibration > Numeric Data > ECal Value).
To perform this procedure, select it from the menu by pressing the Enter key.
Weight Factor
(Main Menu > Calibration > Weight Factor)
This procedure will calculate and store a new gravimetric Weigh Span (see Main
Menu > Calibration > Numeric Data > Weigh Span) and should only be performed
after an accurate Material Test (see Main Menu > Calibration > Material Test) or
Chain Procedure (see Main Menu > Calibration > Chain Procedure). It is performed
with Test Weights, exactly like a Weight Procedure.
Once the test is complete, and accepted, a change is made to the Weigh Span; it
does not change the calibration (i.e. Scale Factor) of the feeder.
Chain Factor
(Main Menu > Calibration > Chain Factor)
This procedure will calculate andd store a new Test Chain value (see Main Menu >
Calibration > Numeric Data > Test Chain) and should only be performed after an
accurate Material Test (see Main Menu > Calibration > Material Test). It is performed
with a Test Chain exactly like a Chain Procedure.
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Once the test is complete, and accepted, a change is made to the Test Chain value; it
does not change the calibration of the feeder. Once the new Test Chain value is
stored it is used for all future Chain Procedures.
ECal Factor
(Main Menu > Calibration > ECal Factor)
This procedure will calculate and store a new ECal Value (see Main Menu >
Calibration > Numeric Data > ECal Value) and should only be performed after an
accurate Material Test (see Main Menu > Calibration > Material Test) or Chain
Procedure (see Main Menu > Calibration > Chain Procedure). Once the test is
complete, and accepted, a change is made to the ECal Value; it does not change the
calibration of the feeder.
It is performed exactly like an ECal Procedure. The feeder does not need to be
running.
Numeric Data
(Main Menu > Calibration > Numeric Data)
In this menu you will find the following parameters that relate to the Calibration
procedures. Most of these parameters must be correctly set before any Calibration
procedures are performed.
Belt Length
Before the Calibration procedures can be performed correctly, the feeder belt must
be measured accurately and the length entered here. This length should be
measured to the nearest 1/8 inch (3mm), and entered in the units of length.
Pulses/Belt Rev 1
This is the number of pulses emitted by Tacho 1 for one revolution of the feeder
belt. It can be estimated depending on the length of the belt, type of tacho,
diameter of the pulley, etc. However, it will be accurately determined by the
Genetix controller during a Speed Span procedure (see Calibration > Speed
Span). You do not have to make an accurate calculation of this parameter and
enter it, but you may refer to it here.
Pulses/Belt Rev 2
Note: This parameter will only appear in this menu if Tacho 2 is enabled (see
Advanced Set-up > Configuration)
This is the number of pulses emitted by Tacho 2 for one revolution of the feeder
belt. It can be estimated depending on the length of the belt, type of tacho,
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diameter of the pulley, etc. However, it will be accurately determined by the
Genetix controller during a Speed Span procedure (see Calibration > Speed
Span). You do not have to make an accurate calculation of this parameter and
enter it, but you may refer to it here.
Test Revs
This is the number of revolutions of the belt that will be counted for any and all of
the Calibration procedures. It should normally be at least 2, but may be set higher
for feeders with very high belt speed.
Weigh Span
This value represents the “Gravimetric Weigh Span”, which is a factor that relates
load on the Load Cell(s) to Belt Load, as follows:
Load Cell load (lb, kg) = Belt Load (lb/ft, kg/m) X Weigh Span (ft, m)
The units are those of length, but this parameter cannot always be directly
measured. On a conveyor with equally spaced idlers it will usually be equivalent to
the distance between idlers, however, on some scales there are pivots and ratios
involved that complicate the calculation. Normally this parameter is calculated and
entered at the factory.
Note: This value will be updated (changed) if a Weight Factor (see Calibration >
Weight Factor) procedure is performed, for example after a Material Test (see
Calibration > Material Test). In this way, future Weight Procedures (see Calibration
> Weight Procedure) that are performed will check or update the controller
calibration based on the results of the Material Test.
This value must be correct if a Weight Procedure is to correctly calibrate the
controller.
Test Weight
This is usually the total value of the test weights applied to the scale during a
Weight Procedure (see Calibration > Weight Procedure). If weights are applied to
both sides of the scale or feeder, the sum of all weights should be entered here.
The units are those of weight (lb, kg) and the test weights should be stamped with
their correct value by the factory.
Note: Removable brackets, pegs, etc. that are used to hang the test weights must
be included in the sum. Normally all such pieces will be stamped with their correct
weight by the factory.
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Test Chain
This is usually the total value of the test chain applied to the scale during a Chain
Procedure (see Calibration > Chain Procedure). The units are those of load (lb/ft,
kg/m) and the test chain should be stamped with its correct value by the factory.
ECal LC1 Value
This is the calculated output of the weighing mechanism in mV/V (millivolts per
volt) at Design Load, for loadcell number 1. This can be difficult to calculate
accurately and will usually be done by Merrick. However, in general, it can be
calculated as follows
ECal, mV/V = Ld x WS x SLc / WLc
Where
Ld = Design Load (i.e. lb/ft or kg/m)
WS = Gravimetric Weigh Span (i.e. ft or m)
SLc = Actual output of loadcell (or loadcells) at rated capacity (mV/V)
WLc = Rated capacity of loadcell (or loadcells) (i.e. lb or kg)
When performing this calculation, it is important to use the actual output of the
loadcell (SLc) as certified by the manufacturer, as this can be very different than
the nominal output. Also, the determination of Weigh Span can sometimes be
tricky (see Main Menu > Calibration > Numeric Data > Weigh Span). Contact the
Merrick Customer Support department for assistance if required.
ECal LC2 Value
This is the calculated output of the weighing mechanism in mV/V (millivolts per
volt) at Design Load, for loadcell number 2. It is calculated the same as for loadcell
number 1, above. This value only appears in the menu, if 2 loadcells are
configured (see Main Menu > Advanced Setup > Configuration).
Zero Tracking
(Main Menu > Calibration > Numeric Data > Zero Tracking)
Note: This item will only appear in this menu if Zero Tracking is enabled (see
Advanced Set-up > Configuration).
Zero Tracking (also known as “Auto-Zero”) is a process by which a belt feeder or
belt conveyor can be allowed to zero itself, while running, if certain conditions are
met. Errors in Zero are the most significant source of poor accuracy and so this
can be a very powerful means to improve your performance of your belt scale (or
feeder).
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Good candidates for Zero Tracking are those feeders or conveyors that
occasionally run empty for the period of time necessary to perform a Zero test, and
those belt scales that require the utmost accuracy (i.e. certified scales).
Following are the list of parameters involved in Zero Tracking, and how to properly
set them.
To enable Zero Tracking, you must first select Zero Tracking from the
Configuration menu, and enable it (set it to “Y(es)”. Once enabled, the following
settings will be found:
Load Limit ↑
Wait Time
Increment Limit
Absolute Limit
Start Delay
Splice Allowance ↓
Load Limit
This value is used to determine whether or not the belt is truly empty. If the
measured belt load drops below this value, the “Wait Time” timer starts (see
below). If the belt load exceeds this value anytime during the “Wait Time”, then
the current Zero Track process is abandoned. Once the belt load drops below
this limit again another “Wait Time” period is started. The units for this
parameter are those of Load (i.e. lb/ft, kg/m).
Note: An exception can be made for belts with a bad section (i.e. a mechanical
splice) that might normally cause abandonment of a Zero Track process (see
“Splice Allowance” below).
Wait Time
The “Wait Time” value is the delay time that the controller will wait after all
conditions have been met before actually beginning a Zero Tracking sequence.
For example ,the belt must be running empty (see “Load Limit” above) and the
“Start Delay” (see below) must have expired before the process of zeroing the
belt will begin. Units are seconds.
Increment Limit
This parameter is the maximum allowed incremental change of the Zero Load,
as the result of any one Zero Tracking process. If the calculated correction is
above this parameter then no change is made. The units for this parameter are
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those of Load (i.e. lb/ft, kg/m). To prevent zeroing a belt when material may
actually be present, this value should be set very low.
Absolute Limit
This parameter is the maximum allowed total change of the Zero Load. As
successive Zero Tracking processes are performed, the sum of all tests is
accumulated. If this sum exceeds the “Absolute Limit” then no change is made.
The Logical Output “Zero Track Fail” will occur if the change is within the
increment limit but outside the absolute limit. Limits are minimum of 0 and
maximum of <later> % of the Design Load. To prevent
Start Delay
This parameter is the hold off time at power up (coldstart) to keep controller
from starting and running Zero Tracking on a cold belt. The units are seconds.
Splice Allowance
On some belts there is a section around the splice that causes the measured
belt load to “spike” (rapidly increase) then fall back to normal just as quickly.
This spike can be high enough to abort the Zero Tracking process, prohibiting it
from ever completing. The Splice Allowance parameter allows the controller to
ignore a spike in belt load if it occurs for less than the specified amount of belt
travel. That section of the belt is not used in the zero calculation
The units of the Splice Allowance are those of length (i.e. ft or m). Setting this
parameter to zero defeats this allowance.
Warnings
Warnings are logical conditions that may occur of which you wish to be notified.
Warnings are informational only and will not affect the process. Any Logical Input or
Output can be used to trigger a Warning. To set a Logical I/O point as a Warning, see
Main Menu > Advanced Setup > Digital I/O > Warnings/Faults.
If any Warning occurs, you will see the text “WARNINGS!” on the bottom of the main
display, like this:
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Selecting “Warnings” from the Main Menu will present a screen that shows a list of all
Logical Inputs and Logical Outputs that have had their “Warning” property set. Next to
each input or output, you will see one of the following labels,
Label Meaning
<blank> No Warning has occurred (since last

reset)
“Warn-Off” Warning occurred, but is not now

present (may be reset)
“Warn-ON” Warning occurred and is still present
If a Logical I/O point shows the label “Warn-Off”, that means that condition did occur but
is no longer present. You may scroll to that item, select it and then press the Enter key to
Reset.
If a Logical I/O point shows the label “Warn-ON”, then this means the condition is still
repsent and it may not be Reset. The logical condition must no longer be present before
a Warning can be reset.
When all Warnings have been reset, the text “WARNINGS!” will disappear from the main
display.
Faults
Faults are logical conditions that may occur and which will stop the feeder. Any Logical
Input or Output can be set to trigger a Fault. To set a Logical I/O point as a Fault, see
Main Menu > Advanced Setup > Digital I/O > Warnings/Faults. Note: you should use
careful judgement in setting Faults; if they occur, they will cause the feeder to stop.
If any Fault occurs, you will see the text “FAULTS!” on the bottom of the main display,
like this:
Note: In the example shown, there are also Warnings present (see above)
Selecting “Faults” from the Main menu will present a screen that shows a list of all
Logical Inputs and Logical Outputs that have had their “Fault” property set. Next to each
input or output, you will see one of the following labels,
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Label Meaning
<blank> No Fault has occurred (since last reset)
“Fault-Off” Fault occurred, but is not now present

(may be reset)
“Fault-ON” Fault occurred and is still present
If a Logical I/O point shows the label “Fault-Off”, that means that condition did occur but
is no longer present. You may scroll to that item, select it and then press the Enter key to
Reset.
If a Logical I/O point shows the label “Fault-ON”, then this means the condition is still
repsent and it may not be Reset. The logical condition must no longer be present before
a Fault can be reset.
When all Faults have been reset, the text “FAULTS!” will disappear from the main
display.
Display Settings
These settings determine what is displayed on the main screen, and to a certain extent
how it is displayed.
Upper… ↑
Lower…
Damping… ↓
Upper
(Main Menu > Display Settings)
This item allows you to select what variable is displayed on the upper line of the main
screen. You may select from the following list
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Feedrate ↑
Speed
Load
Grand Total
Sub-Total
Belt Spd Demand
Time
Setpoint ↓
Lower
(Main Menu > Display Settings)
This item allows you to select what variable is displayed on the lower line of the main
screen. You may select from the same list as above.
Note: While at the main screen, it is also possible to scroll the lower display through
the available options with the Up/Down arrow keys. This allows you to quickly
observe different data. Whichever display option you last scroll to will remain the
selection for the lower display until you change it, either by scrolling or through the
Display Settings menu as described above.
Damping
These parameters allow you to “damp” (i.e. “smooth) the displayed values, causing
the display to be more stable and therefore more readable. The variables that may
thus be damped are selectable from the following list:
Feedrate ↑
Speed
Load ↓
The Speed and Load damping parameters are settable from 0 to 100, where 0 is no
damping, and 100 is maximum. Note: Damping is not linear, so a setting of 10 is
much greater than 1, and should usually be sufficient. Too much damping will cause
the display to respond so slowly that process changes may not be visible.
Feedrate damping is settable from 1 to 33, and behaves more linearly.
Damping affects the specific displayed value, and the value presented as an Analog
output (if configured), but does not affect the process.
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Basic Setup
These are the basic parameters for all Belt applications. Selecting this item from the
Main menu will present a screen asking you to enter a Password. The default factory
setting is “5678”. Upon successful entry of the password, you will be presented with the
following list of parameters:
Units… ↑
Decimal Points…
Design Capacities… ↓
These parameters must be set correctly before any other settings. If you later change
any of the above, other settings (i.e. Limits) may not behave correctly and also need to
be reset.
Units
(Main Menu > Basic Set-up)
This parameter refers to the Units in which data are displayed. There are imperial and
metric units for the following data: Belt Speed (i.e. ft/min, m/s, m/min); Belt Load (i.e.
lb/ft, kg/m); Totals (i.e. TN, kg, t); Lengths (i.e. ft, m); Feedrate (i.e. lb/min, lb/h, TN/h,
kg/min, kg/h, t/h). The most common combinations of the above units are presented
in groups. You should select the group that best suits your needs.
Decimal Points
These parameters select the number of digits to the right of the decimal point for the
following data: Weight/Load; Totals; Length; Feedrate; Speed. The maximum number
of decimal places for any of these data is four. They may be set individually and will
determine the precision with which the data are displayed or entered. For example if
the units of Length have been set to meters (m), and the number of decimal places to
3, then you may enter length data, and it will be displayed, to the nearest millimeter.
When you select Units from the Basic Setup menu, the current setting is highlighted.
You may scroll up or down to select a new group, then press Enter.
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Design Capacities
When you select this item, the following basic feeder design parameters are listed
with their current settings:
Design Load
(Main Menu > Basic Set-up > Design Capacities)
This parameter represents the belt loading that the feeder has been designed for
in normal operation. Typically it is set at the maximum load expected. It is set in
Load units (i.e. lb/ft, kg/m), and with the number of decimal places specified.
Design Feedrate
This parameter represents the feedrate that the feeder has been designed for in
normal operation. Typically this is specified by the buyer. It is set in Rate units (i.e.
lb/min, lb/h, TN/h, kg/min, kg/h, t/h), and with the number of decimal places
specified.
Design Speed
This parameter represents the speed that the feeder has been designed for in
normal operation. Typically it is slightly less than the maximum speed possible. It
is set in Speed units (i.e. ft/min, m/s, m/min), and with the number of decimal
places specified.
Advanced Setup
(Main Menu > Advanced Setup)
These are the more advanced settings for all Belt applications. These settings are
typically configured at the factory (by Merrick), and so it is possible you may not need to
change them.
Selecting this item from the Main menu will present a screen asking you to enter a
Password. The default factory setting is “3010”. Upon successful entry of the password,
you will be presented with the following list:
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Feeder Control… ↑
Limits…
Load Cells…
Tachos…
Process Control…
Analog I/O…
Digital I/O…
Totalizer…
Feeder Peripherals…
Communications…
Date & Time…
Passwords…
GCM Name…
Direct Param Edit…
Configuration… ↓
Note: Some of the above items may not appear, depending on the Configuration settings
(see Main Menu > Advanced Setup > Configuration)
Selection of one of the entries from the above list will present further selections in each
category as shown below
Feeder Control
(Main Menu > Advanced Setup > Feeder Control)
Note: This item will appear in the menu only if Feeder Control is enabled (see Main
Menu > Advanced Setup > Configuration > Feeder Control).
Selecting this menu item, you will be presented with the following menu:
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Control… ↑
Source…
Method…
Settings… ↓
Control
This refers to whether feeder control is to be automatic (uses feedback to control),
or manual (Belt Speed Demand is manually entered). The two choices for this
setting are:
Manual ↑
Auto ↓
Manual
With this control option selected, you must enter the desired Belt Speed
Demand from the keypad. This is signal is sent directly to the belt speed control
device, and there is no attempt to control it. This mode is generally used for
maintenance purposes as it allows you to control the belt speed in a
straightforward manner.
Once you set Control for “Manual”, the Feeder Control menu (see Main Menu >
Feeder Control) is used to start and stop the feeder and set the speed.
Note: “Manual” is equivalent to setting control source to “Local”, and control
method to “Open Loop” (see below).
Auto
With this control option selected various forms of automatic control become
available, such as Feedrate control and Speed control. These functions all
involve some sort of feedback and therefore control the process variable based
on control method (see below).
Source
This refers to the source from which the setpoint (control variable) will be obtained.
The choices for this setting are:
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Local ↑
Remote (Analog)
Network (Serial) ↓
Local
“Local” refers to control from the User Interface. Once you set the control
source to Local, the Feeder Control menu (see Main Menu > Feeder Control) is
used to start and stop the feeder and enter the setpoint.
Remote (Analog)
“Remote (Analog)” refers to control from an outside source as follows:
Setpoint is determined from an analog signal. Note: An analog input must be
mapped to the appropriate control variable (see Main Menu > Advanced Setup
> Analog I/O > Inputs > Function).
Feeder Start/Stop is controlled by the Logical input “Run Permission”. Typically
this is mapped to a Physical input for remote control (see Main Menu >
Advanced Setup > Digital I/O).
Network (Serial)
“Network (Serial)” refers to control from an outside source as follows:
Setpoint is determined from a Network source (i.e. PLC). Note: A Network input
must be mapped to the appropriate control variable (see Main Menu >
Advanced Setup > Analog I/O > Inputs >Network).
Feeder Start/Stop is controlled by the Logical input “Run Permission”. Typically
this is mapped to a Network input for remote control, but it could be a Physical
input instead (see Main Menu > Advanced Setup > Digital I/O).
Method
This refers to the method of control, or what the controlled variable is to be. The
choices for this setting are:
Rate Control ↑
Speed Control
Open Loop ↓
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Rate Control
If set for “Rate Control”, feedrate is the controlled variable. The controller will
attempt to maintain a feedrate setpoint.
Speed Control
If set for “Speed Control”, belt speed is the controlled variable. The controller
will attempt to maintain a speed setpoint.
Open Loop
If set for “Open Loop” the setpoint is mapped directly to Belt Speed Demand,
with no attempt at control.
Settings
These are settings that enable/disable or control various functions relative to
Feeder Control. The settings are:
Belt Reversible ↑
AutoStart
RP Start/Stop in Local
Jog OK
Lock Source
Lock Method
Clamp Setpoint to Limits
Clamp Spd Demand to Limits
Fast Start
Numeric Data… ↓
Belt Reversible
If belt is reversible, that is it is connected to a control device that can reverse
the belt direction through inputs, this should be turned on (set to “Y”). This will
enable certain additional Logic inputs that can be used to run the belt in
reverse.
AutoStart
If this feature is enabled, the feeder will start anytime the Logical input “Run
Permission” is on. If this is mapped to a Physical input and that Physical input is
on after a reset, the feeder will start automatically. This is not generally
recommended, but available.
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RP Start/Stop in Local
If enabled, this feature allows the Logical input “Run Permission” to start and
stop the feeder when the Feeder Control source is set to “Local”.
Jog OK
This feature enables “jogging” the belt, which refers to running the belt for brief
period, only as long as a button is pressed (see Main Menu > Feeder Control).
Also, if “Belt Reversible” is enabled (see above), jogging the belt in reverse is
also enabled by this setting.
Lock Source
If this is turned on you will not be able to change the Feeder Control source
(see Main Menu > Advanced Setup > Feeder Control > Source). This is to
protect the process from inadvertent changes that might cause a setpoint
change.
Lock Method
If this is turned on you will not be able to change the Feeder Control method
(see Main Menu > Advanced Setup > Feeder Control > Method). This is to
protect the process from inadvertent changes that might cause a setpoint
change.
Clamp SetP to Limits
If this feature is enabled, the setpoint (i.e. Feedrate or Speed) will be “clamped”
to its Limits, which are settable (see Main Menu > Advanced Setup > Limits).
This means no value outside of the limits will be accepted, regardless of
source, and the resultant value will be set to the appropriate limit. This can be
used for example to set the maximum rate that a feeder is allowed to run, or the
minimum.
Clamp Spd Dem to Limits
If this feature is enabled, the Belt Speed Demand will will be “clamped” to its
Limits, which are settable (see Main Menu > Advanced Setup > Limits). This
means no value outside of the limits will be accepted, and the resultant value
will be set to the appropriate limit.
Fast Start
If this feature is enabled, the belt feeder will attempt to “jump” at start to the
correct speed for the current setpoint. For this to happen, the following must be
true:
• This feature must be enabled
• The feeder control method must be “Feedrate” (see Main Menu >
Advanced Setup > Feeder Control > Method)
• The “Use Head Load” feature must be enabled (see Main Menu >
Advanced Setup > Configuration > Use Head Load)
• The current head load must be greater than 1% of Design Load
At start, the Genetix will calculate the desired Belt Speed Demand using the
Head Load (belt load), the Setpoint, and the Speed Factor. It will immediately
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start at this speed, limited only by the acceleration set by the user (see Main
Menu > Advanced Setup > Process Control > Accel/Decel). After jumping to
this initial speed, closed loop control takes over and regulates the speed
appropriately.
Numeric Data…
These are various data that affect feeder control.
Belt Reverse Delay
This is a time delay, set in seconds, that holds off reversing the belt if it is
running. This allows the motor to coast down before re-starting in a different
direction.
Limits
(Main Menu > Advanced Setup > Limits)
Limits provide alarm functionality for selected process parameters. If the actual value
moves outside of the limits set here, Logical outputs are set and/or clamping can take
place. All Limits have “Delay” settings to prevent nuisance alarms if the process
variable only momentarily exceeds its Limit. The process values that may have Limits
set are:
Feedrate… ↑
Load…
Speed…
Setpoint…
Belt Speed Demand… ↓
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Feedrate
The following settings are available for Feedrate limits:
High Feedrate ↑
Low Feedrate
High Feedrate Delay
Low Feedrate Delay
High Abs Deviation
Low Abs Deviation
High Rel Deviation
Low Rel Deviation
High Deviation Delay
Low Deviation Delay ↓
High Feedrate
If the actual feedrate exceeds this limit for duration longer than the High
Feedrate Delay value (see below) then the logical output “High Feedrate” is set.
Note that this setting is independent of setpoint, and will activate anytime the
limit is exceeded, even if the intended rate is higher than the limit. The High
Feedrate and Low Feedrate limits are usually used with Belt Weighers or Belt
Scales where there is no closed loop control over feedrate. This limit is set in
units of feedrate.
Low Feedrate
If the actual feedrate drops below this limit for duration longer than the Low
Feedrate Delay value (see below) then the logical output “Low Feedrate” is set.
This limit is set in units of feedrate.
Note this limit is only active under the following conditions:
• Feeder Control is enabled (see Main Menu > Advanced Setup >
Configuration > Feeder Control) and the belt is commanded to run.
• Feeder control is not enabled and the logical input “Belt Running” is on.
• No calibration routine is running.
High Feedrate Delay
This value provides a delay for the High Feedrate limit, in order to prevent
nuisance alarms. The feedrate must remain above the limit value for duration
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as long as this delay value for the logical output to be set. This delay value is
set in seconds.
Low Feedrate Delay
This value provides a delay for the Low Feedrate limit, in order to prevent
nuisance alarms. The feedrate must remain belwo the limit value for duration as
long as this delay value for the logical output to be set. This delay value is set in
seconds.
Note: The following feedrate limits will appear in the menu only if Feeder
Control is enabled (see Main Menu > Advanced Setup > Configuration >
Feeder Control ).
High Abs Deviation

If the actual feedrate exceeds the setpoint by this amount for duration longer
than the High Deviation Delay value (see below) then the logical output “High
Feedrate” is set. This limit is set in units of feedrate.
Low Abs Deviation
If the actual feedrate drops below the setpoint by this amount for duration
longer than the Low Deviation Delay value (see below) then the logical output
“Low Feedrate” is set. This limit is set in units of feedrate.
High Rel Deviation
If the actual feedrate exceeds the setpoint by this percentage for duration
longer than the High Deviation Delay value (see below) then the logical output
“High Feedrate” is set. This limit is set in units of percent.
Low Rel Deviation
If the actual feedrate drops below the setpoint by this percentage for duration
longer than the Low Deviation Delay value (see below) then the logical output
“Low Feedrate” is set. This limit is set in units of percent.
High Deviation Delay
This value provides a delay for the High Deviation limits, in order to prevent
nuisance alarms. The feedrate must remain above the limit value for duration
set in seconds.
Low Deviation Delay
This value provides a delay for the Low Deviation limits, in order to prevent
nuisance alarms. The feedrate must remain below the limit value for duration as
long as this delay value for the logical output to be set. This delay value is set in
seconds.
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Load
The following settings are available for Load limits:
High Belt Load ↑
Low Belt Load
High Belt Load Delay
Low Belt Load Delay ↓
High Belt Load

If the actual belt load exceeds this limit for duration longer than the High Belt
Load Delay value (see below) then the logical output “High Belt Load” is set.
This limit is set in units of belt load.
Low Belt Load
If the actual belt load drops below this limit for duration longer than the Low Belt
Load Delay value (see below) then the logical output “Low Belt Load” is set.
This limit is set in units of belt load.
High Belt Load Delay
This value provides a delay for the High Belt Load limit, in order to prevent
nuisance alarms. The belt load must remain above the limit value for duration
set in seconds.
Low Belt Load Delay
This value provides a delay for the Low Belt Load limit, in order to prevent
nuisance alarms. The belt load must remain below the limit value for duration
set in seconds.
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Speed
The following settings are available for Speed limits:
High Belt Speed ↑
Low Belt Speed
High Belt Speed Delay
Low Belt Speed Delay ↓
High Belt Speed

If the actual belt speed exceeds this limit for duration longer than the High Belt
Speed Delay value (see below) then the logical output “High Belt Speed” is set.
This limit is set in units of belt speed.
Low Belt Speed
If the actual belt speed drops below this limit for duration longer than the Low
Belt Speed Delay value (see below) then the logical output “Low Belt Speed” is
set. This limit is set in units of belt speed.
High Belt Speed Delay
This value provides a delay for the High Belt Speed limit, in order to prevent
nuisance alarms. The belt speed must remain above the limit value for duration
set in seconds.
Low Belt Speed Delay
This value provides a delay for the Low Belt Speed limit, in order to prevent
nuisance alarms. The belt speed must remain below the limit value for duration
set in seconds.
Setpoint
The following settings are available for Setpoint limits:
Note: The following setpoint limits will appear in the menu only if Feeder
Feeder Control ).
Page 38 of 104
Max Rate Setpoint ↑
Min Rate Setpoint
Max Rate SP Delay
Min Rate SP Delay
Max Speed Setpoint
Min Speed Setpoint
Max Speed SP Delay
Min Speed SP Delay ↓
Max Rate Setpoint

This is the maximum allowed setpoint, and the logical output “High Setpoint” will
be set if it is exceeded for longer than the duration set by the limit “Max Rate
SP Delay” (see below). This limit is set in units of feedrate.
Note also that if setpoint clamping is enabled (see Main Menu > Advanced
Setup > Feeder Control > Settings), the setpoint used by the controller will be
clamped to this limit value even if it exceeded. However, in this case the logical
output “High Setpoint” will still be set.
Min Rate Setpoint
This is the minimum allowed setpoint, and the logical output “Low Setpoint” will
be set if the setpoint drops below this limit for longer than the duration set by
the limit “Min Rate SP Delay” (see below). This limit is set in units of feedrate.
clamped to this limit value even if it drops below. However, in this case the
logical output “Low Setpoint” will still be set.
Note that the Max and Min Rate Setpoint limits are active only if the Feeder
Control Method is set to “Rate Control” (see Main Menu > Advanced Setup >
Feeder Control > Method)
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Max Rate SP Delay
This value provides a delay for the High Rate Setpoint limit, in order to prevent
nuisance alarms. The feedrate setpoint must remain above the limit value for
duration as long as this delay value for the logical output to be set. This delay
value is set in seconds.
Min Rate SP Delay
This value provides a delay for the Low Rate Setpoint limit, in order to prevent
nuisance alarms. The feedrate setpoint must remain below the limit value for
Max Speed Setpoint
This is the maximum allowed speed setpoint, and the logical output “High
Setpoint” will be set if it is exceeded for longer than the duration set by the limit
“Max Speed SP Delay” (see below). This limit is set in units of speed.
clamped to this limit value even if it exceeded. However, in this case the logical
output “High Setpoint” will still be set.
Min Speed Setpoint
This is the minimum allowed setpoint, and the logical output “Low Setpoint” will
be set if the setpoint drops below this limit for longer than the duration set by
the limit “Min SpeedSP Delay” (see below). This limit is set in units of speed.
clamped to this limit value even if it drops below. However, in this case the
logical output “Low Setpoint” will still be set.
Note that the Max and Min Speed Setpoint limits are active only if the Feeder
Control Method is set to “Speed Control” (see Main Menu > Advanced Setup >
Feeder Control > Method)
Max Speed SP Delay
This value provides a delay for the High Speed Setpoint limit, in order to
prevent nuisance alarms. The Speed setpoint must remain above the limit value
for duration as long as this delay value for the logical output to be set. This
delay value is set in seconds.
Min Speed SP Delay
This value provides a delay for the Low Speed Setpoint limit, in order to prevent
nuisance alarms. The Speed setpoint must remain below the limit value for
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Belt Speed Demand
The following settings are available for Belt Speed Demand limits:
Note: The following setpoint limits will appear in the menu only if Feeder
Feeder Control ).
Max Belt Spd Demand ↑
Min Belt Spd Demand
Max Spd Demand Delay
Min Spd Demand Delay ↓
Max Belt Spd Demand

If the actual belt speed demand (i.e. controlled variable, or “CV”) exceeds this
limit for duration longer than the Max Spd Demand Delay value (see below)
then the logical output “High PID CV” is set. This limit is set in units of percent.
Note also that if speed demand clamping is enabled (see Main Menu >
Advanced Setup > Feeder Control > Settings), the speed demand used by the
controller will be clamped to this limit value even if the PID calculation yields a
larger value. However, in this case the logical output “High PID CV” will still be
set.
Min Belt Spd Demand
If the actual belt speed demand drops below this limit for duration longer than
the Min Belt Speed Delay value (see below) then the logical output “Low PID
CV” is set. This limit is set in units of percent.
Note also that if speed demand clamping is enabled (see Main Menu >
Advanced Setup > Feeder Control > Settings), the speed demand used by the
controller will be clamped to this limit value even if the PID calculation yields a
smaller value. However, in this case the logical output “Low PID CV” will still be
set.
Max Spd Demand Delay
This value provides a delay for the Max Speed Demand limit, in order to
prevent nuisance alarms. The belt speed demand must remain above the limit
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value for duration as long as this delay value for the logical output to be set.
This delay value is set in seconds.
Min Spd Demand Delay
This value provides a delay for the Min Belt Speed Demand limit, in order to
prevent nuisance alarms. The belt speed demand must remain below the limit
value for duration as long as this delay value for the logical output to be set.
This delay value is set in seconds.
Load Cells
(Main Menu > Advanced Setup > Load Cells)
Function… ↑
Settings…
Numeric Data… ↓
Function
The following menu lists all the available functions for the load cell functionality.
Note: Some functions require two load cells and so will only appear if two load
cells have been configured (see Main Menu > Advanced Setup > Configuration >
Load Cell n)
First Only ↑
Second Only
Both
Auto Bypass
Inferred Load
Analog Input
From Network ↓
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First Only
Only one load cell, or group of load cells in parallel, is connected and they are
connected to Load Cell Channel 1 on the GCM. This is the most basic level of
functionality with no special features.
Second Only
Same as “First Only” above, except load cells are connected to Channel 2 on
the GCM.
Both
This requires load cells be connected to both GCM load cell channels. The load
will be determined by averaging the inputs from both channels.
Auto Bypass
This requires load cells to be connected to both GCM load cell channels. The
load will be determined by averaging the inputs from both channels, but in
addition, the two channels will be monitored individually and if a difference
greater than the allowable is observed, the Load Cell Function can be observed
to switch to “Bypassed”. This assumes that the difference is being caused by a
failure in the weighing system and the load cannot reliably be measured by the
load cells. “Bypassed” is a form of Inferred Load feeding (see below).
While in Inferred Load mode, the load is not being measured but rather is set to
a value that has been established by the Genetix controller based on history, or
can be set by the user. Once the problem is corrected, the controller can be
switched back to gravimetric mode by setting the Load Cell Function back to
“Auto Bypass”
Switching to “Bypassed” also turns the Logical output “Load Imbalance” on.
Typically this is set as a Warning to advise the user that a load balance has
occurred and that the feeder is using Inferred Load for control.
Inferred Load
The user may force the controller to Inferred Load mode if no load cells are
available. The belt load will be fixed and as set by the Inferred Load value (see
Main Menu > Advanced Setup > Load Cells > Numeric Data).
Note: If a Material on Belt switch is enabled (see Main Menu > Advanced Setup
> Configuration > Material on Belt Sw), then the Inferred Load value will be
controlled by this switch. When the switch is on, the load used will be as set by
the Inferred Load parameter, if the switch is off (no Material on Belt), then the
load value will be set to zero.
This feature is most often used for a volumetric belt feeder that does not feed
by weight.
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Analog Input
Load information is generated by an analog input. Note that the load value must
be calibrated using an analog input calibration procedure. Negative load values
on the analog input are not allowed and are replaced with zero.
This setting is most commonly used when there is a weight transmitter available
with a high level (i.e. 4-30mA) analog output representing belt load.
From Network
Load information is written to the GCM by means of communications. Note that
the load value must be written as a floating point number in engineering units.
This setting can be used when there are no load cells but there is a signal
available from the Network that represents belt load.
Settings
Inf Load AutoUpdate
This setting must be enabled to automatically update the Inferred Load value
while the feeder is running. If normal operation with load cells is maintained for
one belt revolution, within all limits and without any load related warnings or
faults, then the Inferred Load will be updated with the average load for that
revolution.
Numeric Data
The following menu lists numeric settings that affect load cell functionality.
Note: Some settings require two load cells and so will only appear if two load cells
have been configured (see Main Menu > Advanced Setup > Configuration > Load
Cell n)
Inferred Load ↑
LC to Headpulley
Difference Time
Max Difference
Scale Factor 1
Zero Load 1
Scale Factor 2
Zero Load 2 ↓
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Inferred Load
This is the value that will be used for belt load, if in Inferred Load mode. This
can be a result of either the user selecting “Inferred Load” as the load cell
function (see Main Menu > Advanced Setup > Load Cells > Function ), or as a
result of a load imbalance if “Auto Bypass has been selected as the load cell
function.
This value can be automatically updated if enabled (see Main Menu >
Advanced Setup > Load Cells > Settings ), or can be manually adjusted by the
user.
LC to Headpulley
This is the distance from the load cell to the headpulley, measured along the
belt, in units of length. To improve batching and/or short term accuracy, a
translational algorithm is used to calculate the load at the headpulley rather
than at the load cell. This feature must be enabled (see Main Menu > Advanced
Setup > Configuration > Use Head Load) for this algorithm to be employed.
Note if this distance is set to zero, that will effectively disable this feature.
Max Difference
This is the maximum allowed difference, in percent of Design Load, that if
exceeded for longer then the time set by “Difference Time” (see below) will
cause the logical output, “Load Imbalance” to be set. Also, if the load cell
function is set to “Auto Bypass”, a shift to “Bypassed” (Inferred Load) will occur.
Difference Time
This is the maximum allowed time, in seconds, that the load cells can be out of
balance (based on Max Difference above) before the logical output, “Load
Imbalance” is set.
Scale Factor 1
This is the calibration factor associated with load cell 1. This value is basically is
basically the number of A/D counts associated with one unit of belt load, and is
typically the result of a calibration procedure. It is not normally entered by the
user, but may be done if it is known.
Zero Load 1
This is the zero load (i.e. when belt is empty) associated with load cell 1. This
value is the average empty belt load as observed by the first load cell, and is
typically the result of a zero procedure. It is not normally entered by the user,
but may be done if it is known. This value is in units of belt load.
Note: If the feeder is re-calibrated then this value may change.
Scale Factor 2
Same as Scale Factor 1 (see above), but for load cell 2.
Zero Load 2
Same as Zero Load 1 (see above), but for load cell2.
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Tachos
(Main Menu > Advanced Setup > Tachos)
Function… ↑
Tacho 1
Tacho 2
Numeric Data… ↓
Note: Not all menu items will appear, depending on how many Tachos are configured
(see Main Menu > Advanced Setup > Configuration).
Function
This setting describes the functionality of the tacho or tachos, if more than one is
configured. The available options are:
First Only ↑
Second Only
First (Pri) Second (Slip)
Second (Pri) First (Slip)
First (Pri) Second (ZSpd)
Second (Pri) First (ZSpd)
Analog Input
From Network
Simulator
None ↓
First Only
This is the setting to use if you have only one tacho connected and it is
connected to the Tacho 1 port on the GCM. This is the tacho that will be used
for all functions within the controller. Note: This tacho may be a 2-channel (i.e.
quadrature), but it is still considered one tacho.
Note: The Configuration settings should bet set to enable only Tacho 1 (see
Main Menu > Advanced Setup > Configuration > Tacho 1).
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Second Only
This is the setting to use if you have only one tacho connected and it is
connected to the Tacho 2 port on the GCM. This is the tacho that will be used
for all functions within the controller. Note: This tacho may be a 2-channel (i.e.
quadrature), but it is still considered one tacho.
Note: The Configuration settings should bet set to enable only Tacho 2 (see
Main Menu > Advanced Setup > Configuration > Tacho 2).
First (Pri) Second (Slip)

This setting requires that tachos be connected to both tacho ports on the GCM.
They may each be any of the allowable types (see Main Menu > Advanced
Setup > Tachos > Tacho n).
With this setting, the First tacho (connected to port 1) will be used for all
process control functions and the Second (connected to port 2) will be used to
detect belt slippage. This is done by monitoring the ratio of the signals from the
two tachos. Nominally it should be constant regardless of belt speed. However,
if the belt slips on the driving pulley (i.e. the head pulley), the ratio will change
and this can be detected and used to set alarms. If the ratio exceeds a settable
amount then the Logical output “Belt Slippage” will turn on (see Main Menu >
Advanced Setup > Tachos > Numeric Data > Max Allowed Ratio Diff).
This setting is most commonly used when there is a tacho connected to port 1
that is mounted to a tail pulley or some other idling pulley and another tacho
connected to port 2 that is mounted on the driving motor.
Second (Pri) First (Slip)
This setting is the same as the one above except the roles of the two tachos
are reversed.
First (Pri) Second (ZSpd)

This setting requires that tachos be connected to both tacho ports on the GCM.
They may each be any of the allowable types (see Main Menu > Advanced
Setup > Tachos > Tacho n).
With this setting, the First tacho (connected to port 1) will be used for all
process control functions and the Second (connected to port 2) will be used to
detect “Zero Speed”. The primary tacho will be used to calculate belt travel and
all other process functions. Pulses from the second tacho will be counted and if
a certain amount of belt travel occurs before a pulse from the second tacho is
received, then belt speed will be assumed to be slipping.
This setting is most commonly used when there is a tacho connected to port 1
that is mounted to the driving motor. This tacho is not directly measuring belt
speed and therefore may not detect true zero speed. For example in this setup
if the belt was to break, the motor could keep turning and without an additional
sensor, a loss of belt speed would not be detected. However, if a second
encoder, or some kind of sensor can be arranged to sense belt motion (i.e. a
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proximity switch and target) then this can be connected to the second tacho
port and used to detect belt slippage or breakage.
Note: In conjunction with this setting, the parameter corresponding to how much
belt travel to allow without a pulse from the second tacho must be set (see Main
Menu > Advanced Setup > Tachos > Numeric Data > Zero Spd Distance).
Second (Pri) First (ZSpd)

This setting is the same as the one above except the roles of the two tachos
are reversed.
Analog Input
Speed information is generated by an analog input. Note that the speed value
must be calibrated using an analog input calibration procedure. Negative speed
values on the analog input are not allowed and are replaced with zero.
This setting is most commonly used when there is no real tacho available, but
there is an analog signal available that represents belt speed. This might be
from an output on the drive or a tach-generator on the motor.
From Network
Speed information is written to the GCM by means of communications. Note
that the speed value must be written as a floating point number in engineering
units. Negative speed values are not allowed and are replaced with zero.
This setting is most commonly used when there is no real tacho available, but
there is a signal available from the Network that represents belt speed.
Simulator
Speed information is derived from the feedrate PID controller’s Belt Speed
Demand signal. This makes it possible to run PID control of a feeder with no
tachos, usually for testing or diagnostic purposes. A parameter called “Speed
Factor” is used to adjust for the relation between Belt Speed Demand and belt
speed (see Main Menu > Advanced Setup > Tachos > Numeric Data > Speed
Factor).
Calculation:
Belt Spd = (Belt Spd Demand x Design Speed) / Speed Factor
None
If no tachos are connected and the belt speed can be assumed to be constant
this setting can be used. There is a Logical Input available called “Belt is
Running” that can be used to turn belt speed on and off. Typically this would be
mapped to a Physical input and connected to a motor starter that drives the
belt.
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Whenever this input is on, the belt speed will be set to a constant speed which
is determined by a user parameter called “Inferred Speed” (see Main Menu >
Advanced Setup > Tachos > Numeric Data > Inferred Speed).
Tacho 1
Each tacho that is enabled (see Main Menu > Advanced Setup > Configuration >
Tacho n) must be configured as to its type and direction detect ability. When you
select this tacho from the menu, you will two settings as follows:
Type… ↑
Direction.. ↓
Type
The type of tacho connected to this port must be set here. This is basically the
electrical characteristic of the specific tacho used. The options are:
Quad, Opt/TTL ↑
F-25/Mag, Ch-A
Quad, Opt/Line Drv
Frequency ↓
Quad, Opt/TTL
This setting is used with 2-channel encoders that have their outputs
arranged in a quadrature arrangement (one channel leads the other by 90°).
These types of encoders can be used to detect direction of belt travel as well
as distance, and travel in the reverse direction will not be counted. In this
scenario only forward travel will be measured, which can be useful if there is
significant vibration or encoder noise that might otherwise be interpreted as
belt travel.
The outputs of this encoder must be nominal “TTL” levels (i.e. 0-5 VDC).
This is the most common type of encoder used on Merrick belt feeders.
F-25/Mag, Ch-A
The setting is used with the Merrick F-25 or DSP-825 type 2-wire current
loop encoders, and certain other encoders of this style.
These encoders are single channel and therefore do not have the ability to
detect direction. Also, they may be connected to either tacho port on the
GCM, but they must be connected to channel A.
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Note:This setting turns on a bias current and therefore should not be used if
an optical encoder is connected. Damage to the encoder may result.
Quad, Opt/Line Drv

This setting functions the same as “Quad, Opt/TTL” (see above), but is used
with optical encoders that have “Line Driver” outputs. These types of
encoders are sometimes used if there is a great distance between encoder
and GCM.
Frequency
This is a generic setting for use with encoders that have a basic sinusoidal
output; that is an output swings both negative and positive at a frequency
that is proportional to speed.
Direction
Tachos that are able to detect direction (i.e. quadrature encoders) must have
this parameter set correctly so that this feature functions correctly. The
available options are:
Left Hand ↑
Right Hand
No Direction ↓
Left Hand
This typically refers to an encoder that is mounted on the left side of the belt
(facing direction of travel). However, more technically, it means that channel
B of the encoder is leading channel A.
Right Hand
This typically refers to an encoder that is mounted on the right side of the
belt (facing direction of travel). However, more technically, it means that
channel A of the encoder is leading channel B.
No Direction
Direction of tacho rotation is not detectable. The GCM will only look at
channel A of the tacho port for pulses.
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Tacho 2
All the same settings as for tacho 1 are available for tacho 2. Note: These settings
are only available if Tacho 2 is enabled (see Main Menu > Advanced Setup >
Configuration > Tacho 2).
Numeric Data
These are numeric settings that affect the operation of the tachos or the speed
detection algorithms of the GCM.
Note: Not all settings will appear in this list unless two tachos are configured (see
Main Menu > Advanced Setup > Configuration > Tacho 1,2).
The available settings are:
Zero Timeout ↑
Inferred Speed
Speed Factor
Max Allowed Ratio Diff
Zero Spd Distance ↓
Zero Timeout
This value determins how long to wait for a pulse from the primary tacho. If no
pulses are received within this time limit, the Logical output “No Belt Motion” is
turned on, providing the means for an alarm.
Note: This function is always enabled, regardless of feeder control mode. In
other words anytime pulses stop, for any reason, this Logical output will turn on.
Inferred Speed
This is the speed that will be inferred whenever the tacho function is set to
“None” (see Main Menu > Advanced Setup > Tachos > Function), and the “Belt
is Running” Logical input is on. The units are those of speed (i.e. ft/min or
m/min, etc.).
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Speed Factor
“Speed Factor” is used to calculate and set speed when the tacho function is
set to “Simulator” (see Main Menu > Advanced Setup > Tachos > Function >
Simulator).
Normally this parameter is automatically updated when a valid speed is
available from tachos. However, when in simulator mode, you may set this
parameter directly and it will then not be updated (changed).
Max Allowed Ratio Diff

This is the maximum allowable absolute value for the difference between
nominal tacho ratio and actual tacho ratio. The nominal ratio between of the
tachos is determined by the two BLT parameters “Pulses per Belt Rev 1” and
“Pulses per Belt Rev 2”, which are set during a Speed Span calibration. (see
Main Menu > Calibration > Speed Span and Main Menu > Calibration >
Numeric Data). If the difference exceeds this set amount, the Logical output
“Belt Slippage” is turned on. The units of this parameter are percent (%).
Zero Spd Distance

This parameter corresponds to how much belt travel to allow without a pulse
from the “Zero Speed” tacho (see Main Menu > Advanced Setup > Tachos >
Function). If a pulse from the tacho set as the “Zero Speed” tacho is not
received by the time the belt has moved this distance, then the Logical output
“Belt Slippage” is turned on. The units of this parameter are length (i.e. ft or m).
Process Control
(Main Menu > Advanced Setup > Process Control)
Note: This entire menu will not appear unless Feeder Control is enabled (see Main
Menu > Advanced Setup > Configuration).
PID… ↑
Accel/Decel
Filters… ↓
PID
Selection of this menu item shows you the list of parameters that are the settings
for conventional PID (Proportional plus Integral plus Derivative) control and their
current value. PID is the control action that enables the Genetix to maintain the
desired setpoint, by constantly striving to minimize the deviation between the
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setpoint and the process variable (i.e. Feedrate or Belt Speed). The PID algorithm
uses the deviation to calculate a new Belt Speed Demand to bring the feeder to
the setpoint.
A complete description of how PID control action works is beyond the scope of this
Manual, but a brief description of each term is provided below.
Proportional Gain ↑
Integral
Derivative ↓
Proportional Gain
The Proportional Gain (or sensitivity) is the closed loop gain, expressed in
percent (%). This setting affects all three PID components (Proportional,
Integral and Derivative). The higher the value of Proportional Gain, the harder
the controller will react to a deviation from setpoint.
Note: Proportional control by itself can result in stable control, but the feeder will
likely always be offset from the setpoint. Too much Gain and the control action
will oscillate. Too little Gain and the control action may be very slow to respond.
Integral
The PID Integral component uses the accumulated (integrated) deviation over
time to adjust the Belt Speed Demand signal. The Integral parameter,
expressed in units of s-1 (i.e. 1/s) determines how fast the accumulation takes
place. The Integral function will, over time, make the deviation go to zero,
assuming everything else is in steady state. Essentially this means that the
longer time passes with the feeder not at setpoint, the larger the sum of the
deviation becomes over time, and the more control action that is applied to the
Belt Speed Demand signal.
The Integral function may be disabled by setting this parameter to zero, but this
is not recommended as it will usually result in very poor control, or a feeder that
never comes to setpoint.
Derivative
The PID Derivative component uses the rate of change (the trend) of the
deviation to adjust the Belt Speed Demand signal. The Derivative parameter,
expressed in seconds determines the sensitivity to trend changes. The
Derivative function will react earliest to deviations.
The Derivative function can be disabled by setting this parameter to zero, but
this is not recommended as it will usually result in poor control. However, only a
little Derivative action is typically required, so this setting is normally fairly low.
Note: The effects of all three of the above terms are combined to produce the
total change to the Belt Speed Demand signal. Thus, they all interact to some
degree. Settings for all three parameters will vary from feeder to feeder and will
also depend on the nature of your process.
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Accel/Decel
Selection of this menu item shows you the settings that allow you to control how
rapidly the Belt Speed Demand signal is allowed to change, and therefore provide
a certain amount of dynamic output protection. These parameters are set in
percent/second (%/s). For example, a setting of 100 allows the Belt Speed
Demand signal to change from 0 to maximum in 1 second.
Max Accel ↑
Max Decel ↓
Note: Setting these parameters too low can defeat the settings of the PID control
and result in very slow response. Normally the factory settings should produce
reasonable results.
Also note that many drives (especially Variable Frequency Drives or Inverters)
have their own settings for Acceleration and Deceleration and these should always
be verified as part of the feeder setup process. Again, if the drive Accel/Decel
parameters are set too low, this can defeat the settings of the PID control.
Filters
Filters are a means of averaging certain process data to improve the smoothness
of the control or to compensate for “noisy” data. The averaging is performed by
means of a sliding average, and the extent of the averaging can be set by the
number of “slots”. The following process parameters have filtering available. They
are described along with their effects on the control system.
Speed ↑
Load
Setpoint
PID Feedrate ↓
Speed
In some cases the speed signal generated by the feeder tacho(s) is unusable to
calculate feedrate as-is because of mechanically generated noise, for example
an out-of-round pulley. In these cases, a sliding average algorithm calculates
an average speed with less noise. This parameter is settable between 1 and 33
slots, with 1 representing no averaging. The result of the averaging is used in
feedrate calculations.
Note: The Speed signal can be further “damped” for display purposes only (see
Main Menu > Display Settings > Damping > Speed).
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Load
In some cases the load signal generated by the feeder mechanics is unusable
to calculate feedrate as-is because of mechanically generated noise, for
example excessive ambient vibration. In these cases, a sliding average
algorithm calculates an average load with less noise. This parameter is settable
between 1 and 33 slots, with 1 representing no averaging. The result of the
averaging is used in feedrate calculations.
Note: The Speed signal can be further “damped” for display purposes only (see
Main Menu > Display Settings > Damping > Load).
Setpoint
In some cases the setpoint signal as received from the remote system is
unusable because it is too noisy. Therefore it also possible to average the
setpoint before it goes to the PID control algorithm. This is also a sliding
average, settable between 1 and 33 slots.
PID Feedrate
If, after Load averaging and Speed averaging, the calculated feedrate is still too
noisy, it can cause erratic control action as the PID algorithm tries to
compensate. Therefore it also possible to average the feedrate before it goes to
the PID control algorithm. This is also a sliding average, settable between 1 and
33 slots.
Note: It is very rarely necessary to set this parameter higher than 1 if Load
averaging and Speed averaging are used properly. Also, this is not the same as
the “actual” feedrate which can be damped for display purposes only (see Main
Menu > Display Settings > Damping > Feedrate).
Analog I/O
(Main Menu > Advanced Setup > Analog I/O)
This menu allows you to map the physical Analog Inputs and Analog Outputs to
specific logical functions, and to set certain properties for those IO. Physical inputs
are those that exist on the installed hardware. Physical inputs accept analog
information (such as current or voltage) from external sources, and physical outputs
present similar information. The exact number of physical Analog IO points and their
form depends on the installed hardware and the Configuration settings (see Main
Menu > Advanced Setup > Configuration).Selecting this menu item, you will be
presented with the following menu:
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Inputs… ↑
Outputs… ↓
Inputs
(Main Menu > Advanced Setup > Analog I/O > Inputs)
Selecting Inputs from the Analog I/O menu will present you with the following menu:
Analog In 1… ↑
Analog In 2…
Analog In 3… ↓
Analog In 1
Selection of one of the Analog Inputs above will allow the following settings to be
configured:
Function… ↑
Calibration…
Numeric Data… ↓
Function
This setting allows you to what process value will be received by this physical
input. The options are:
Feedrate SP ↑
Speed SP
Oloop SP
Load
Speed
Inclination
Available ↓
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Feedrate SP
If you select this parameter, the analog input received will be mapped to a
value representing the desired feedrate (i.e. the Feedrate setpoint). This will
be used to control the feeder if the Feeder Control Method is “Rate Control”
(see Main Menu > Advanced Setup > Feeder Control > Method), and the
Feeder Control Source is “Remote Analog” (see Main Menu > Advanced
Setup > Feeder Control > Source ). The data will be scaled according to the
Calibration of this analog input and the parameters under Numeric Data (see
below).
Speed SP
value representing the desired belt speed (i.e. the Speed setpoint). This will
be used to control the feeder if the Feeder Control Method is “Speed
Control” (see Main Menu > Advanced Setup > Feeder Control > Method),
and the Feeder Control Source is “Remote Analog” (see Main Menu >
Advanced Setup > Feeder Control > Source ). The data will be scaled
according to the Calibration of this analog input and the parameters under
Numeric Data (see below).
Oloop SP
If you select this parameter, the analog input received will be mapped
directly to the Belt Speed Demand output, bypassing all closed loop control.
This will be used to control the feeder if the Feeder Control Method is “Open
Loop” (see Main Menu > Advanced Setup > Feeder Control > Method), and
the Feeder Control Source is “Remote Analog” (see Main Menu > Advanced
Setup > Feeder Control > Source ). The data will be scaled according to the
Calibration of this analog input and the parameters under Numeric Data (see
below).
Load
value representing the actual belt load. This might be useful if the belt load is
being measured by a sensor that transmits an analog output. The data will
be scaled according to the Calibration of this analog input and the
parameters under Numeric Data (see below).
Speed
value representing the actual belt speed. This might be useful if the belt
speed is being measured by a sensor that transmits an analog output. The
data will be scaled according to the Calibration of this analog input and the
Inclination
value representing the angle of the feeder or conveyor. This value then is
used to correct the measured load according to the angle. This might be
useful if the scale or feeder is mounted in such a way that the angle relative
to earth is changeable, allowing automatic correction. The data will be scaled
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according to the Calibration of this analog input and the parameters under
Numeric Data (see below).
Note: For automatic angle correction to take place, the “Inclinometer” option
must be enabled (see Main Menu > Advanced Setup > Configuration).
Available
Selecting this parameter allows you to read the analog input via a network or
serial connection. It is not used by the GCM application. The value will
appear in a register in floating point format, which will be scaled according to
the Calibration of this analog input and the parameters under Numeric Data
(see below).
Note, the name of the register used is GLO.AnaInHijack, the number of
which will be dependent on the GCM firmware version. Contact Merrick
Customer Support for assistance if necessary.
Calibration
This menu allows you to calibrate the physical analog input for the signal to
which it is connected. The options are:
Snap Low Current ↑
Snap High Current
Snap Low Current

This allows you to set the GCM for the lowest value that the analog signal
will present. You should be connected to the analog signal and have it
sending its lowest value. If you select this menu item you will go to a screen
that shows the live value of the analog signal. Pressing the Enter key at this
point will accept this value as the input to scale to the low end. You must
press the Enter key again to confirm.
Snap High Current
This allows you to set the GCM for the highest value that the analog signal
will present. You should be connected to the analog signal and have it
sending its highest value. If you select this menu item you will go to a screen
that shows the live value of the analog signal. Pressing the Enter key at this
point will accept this value as the input to scale to the high end. You must
press the Enter key again to confirm.
Numeric Data
This menu contains numeric parameters that allow you to scale the analog
input to the process value it represents. The parameters are:
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High mA ↑
Full Scale
Low mA
Zero ↓
Selecting any of the above parameters brings up the Numeric Data Entry
screen that allows you to assign or edit the numeric value.
High mA
This is the value that represents the maximum analog signal that will be
received. If an analog input calibration has been performed then this value
will have been assigned automatically by that process. Alternatively it may
be entered directly here.
Full Scale
This is the maximum process value that will be assigned to the maximum
analog input value. The Full Scale value is entered in engineering units
representing the process value. For example if the analog input function is
set to Feedrate Setpoint, then this value would be set in units of rate (i.e.
lb/min, kg/min).
Low mA
This is the value that represents the minimum analog signal that will be
received. If an analog input calibration has been performed then this value
will have been assigned automatically by that process. Alternatively it may
be entered directly here
Zero
This is the minimum process value that will be assigned to the minimum
analog input value. The Zero value is entered in engineering units
representing the process value. For example if the analog input function is
set to Feedrate Setpoint, then this value would be set in units of rate (i.e.
lb/min, kg/min).
Analog In 2
For this analog input to be present in the menu, a second Expansion Analog Card
must be enabled (see Main Menu > Advanced Setup > Configuration > Expansion
Analog Card 1 ).
If present this analog input can be configured exactly as Analog Input 1, above.
Analog In 3
For this analog input to be present in the menu, a third Expansion Analog Card
must be enabled (see Main Menu > Advanced Setup > Configuration > Expansion
Analog Card 2 ).
If present this analog input can be configured exactly as Analog Input 1, above.
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Outputs
(Main Menu > Advanced Setup > Analog I/O > Outputs)
Selecting Outputs from the Analog I/O menu will present you with the following menu:
Analog Out 1… ↑
Analog Out 2...
Analog Out 3...
Analog Out 4...
Analog Out 5...
Analog Out 6... ↓
Analog Out 1
Selection of one of the Analog Outputs above will allow the following settings to be
configured:
Function… ↑
Numeric Data…
Function
This setting allows you to what process value will be transmitted by this
physical analog output. The options are:
Belt Spd Demand ↑
Feedrate
Belt Load
Belt Speed
Setpoint
Available
Always Zero ↓
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Belt Spd Demand
This output is used to set the desired speed of the belt, via the motor speed
control (i.e. VFD or SCR drive).
Feedrate
This output transmits the actual feedrate, i.e. to an analog rate meter or chart
recorder.
Belt Load
This output transmits the actual belt load.
Belt Speed
This output transmits the actual belt speed. This can be used, for example,
to control the rate of a pre-feed device such that it is always proportional to
the belt speed.
Setpoint
This output transmits the actual setpoint. Note that this setpoint may be
received from several sources (i.e. Local, Network, Remote Analog, etc.).
Available
Selecting this parameter allows you to write a value to the analog output via
a network or serial connection, which will then be sent out the physical
analog output. It is not used by the GCM application. The value is written to
a register in floating point format, which will be scaled according to the
Note, the name of the register used is GLO.AnaOutHijack, the number of
which will be dependent on the GCM firmware version. Contact Merrick
Customer Support for assistance if necessary.
Always Zero
This setting effectively “turns off’ the physical output, so that no power is
used.
Numeric Data
This menu contains numeric parameters that allow you to scale the analog
output to the process value it represents. The parameters are:
High mA ↑
Full Scale
Low mA
Zero ↓
Selecting any of the above parameters brings up the Numeric Data Entry
screen that allows you to assign or edit the numeric value.
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High mA
This is the value that represents the maximum analog signal that will be
sent. It is entered in mA (milliamperes). Note the range is nominally 4-20mA,
but it is possible to enter numbers outside this range if the connected device
cannot be calibrated.
Full Scale
This is the maximum process value that will be assigned to the maximum
analog output value. The Full Scale value is entered in engineering units
representing the process value. For example if the analog output function is
set to Feedrate, then this value would be set in units of rate (i.e. lb/min,
kg/min).
Low mA
This is the value that represents the minimum analog signal that will be sent.
It is entered in mA (milliamperes). Note the range is nominally 4-20mA, but it
is possible to enter numbers outside this range if the connected device
cannot be calibrated.
Zero
This is the minimum process value that will be assigned to the minimum
analog output value. The Zero value is entered in engineering units
representing the process value. For example if the analog output function is
set to Feedrate, then this value would be set in units of rate (i.e. lb/min,
kg/min).
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Digital I/O
(Main Menu > Advanced Setup > Digital I/O)
This menu allows you to map the physical Digital Inputs and Digital Outputs to
specific logical functions, and to set certain properties for those IO. Physical inputs
are those that exist on the installed hardware. Physical inputs accept digital
information (such as contact closures) from external sources, and physical outputs
present similar information. The exact number of physical IO points and their form
depends on the installed hardware and the Configuration settings (see Main Menu >
Advanced Setup > Configuration).
Logical inputs are events that occur within the Genetix controller that typically cause
some action to take place. An example of a Logical input for a belt feeder would be
“Run Permission”, which is required to make the feeder run. For this permission to
come from an outside source, this Logical input must be mapped to a Physical input,
and then that physical input connected to the external source.
Logical outputs are events that happen within the Genetix controller that are usually
the result of some action or process. An example of a Logical output for a belt feeder
would be “Running”, which indicates that the belt is actually moving. For an outside
source to be informed of this event, this Logical output must be mapped to a Physical
output, and then the Physical output connected to the outside source.
Note: Mapping of Digital I/O and settings will normally take place at the Merrick
factory based on your specific requirements and wiring details. Changes should be
made carefully, as there is generally external equipment involved that may start, stop,
open, close, etc. unexpectedly. No changes should be made unless all equipment is
secure and no personnel are at risk.
If you have any doubts about this process, contact the Merrick Customer Service
department for assistance.
When you select “Digital I/O” you will be presented with another menu as follows:
Inputs… ↑
Outputs…
Warnings/Faults…
Forces…
Inverted IO... ↓
Inputs
This menu item allows you to map the Logical Inputs to the available physical
inputs. One Physical input may be mapped to multiple Logical inputs, allowing one
external physical event to trigger many internal logical events.
Selecting “Inputs” will present you with a list of all the current Logical Inputs, along
with the Physical input they are currently mapped to, if any.
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Selecting a Logical input from the list, by pressing the Enter key, brings up the list
of available Physical inputs to which they may be mapped. Again, note that the list
of Physical inputs will depend on installed hardware and Configuration settings.
Note there are “special” Physical inputs that are used that don’t actually represent
hardware. In some cases it is desired to turn a logical function permanently on or
permanently off. Two special physical inputs are available for this, “Always On”,
and “Always Off”.
The list of all possible Logical inputs varies by application and so is not presented
here. Also, the Configuration settings will cause specific Logical inputs to appear
or disappear from this menu. Consult the Appendices to this Manual, or contact
the Merrick Customer Service department for assistance.
Outputs
This menu allows you to map the Physical outputs to the Logical outputs. One
Logical Output may be mapped to multiple Physical outputs, allowing one internal
event to be sent to multiple external processes.
Selecting “Outputs” will present you with a list of all the current Physical outputs,
along with the Logical output they are currently mapped to, if any. Again, note that
the list of Physical outputs will depend on installed hardware and Configuration
settings.
Selecting a Physical output from the list, by pressing the Enter key, brings up the
list of available Logical outputs to which they may be mapped.
Note there are “special” Logical outputs available. In some cases it is desired to
turn a Physical output permanently on or permanently off. Two special Logical
outputs are available for this, “Always On”, and “Always Off”.
The list of all Logical outputs varies by application and so is not presented here.
Also, the Configuration settings will cause specific Logical outputs to appear or
disappear from this menu. Consult the Appendices to this Manual, or contact the
Merrick Customer Service department for assistance.
Warnings/Faults
This menu item allows you to set a specific property for any Logical input or
Logical output.
Setting an input or output to “Warning” causes an annunciation (display) whenever
that logical event occurs. Warnings are displayed (see Main Menu > Warnings),
but cause no further action.
Setting an input or output to “Fault” causes the feeder to “trip” (stop) and an
annunciation. The feeder cannot resume until the fault condition is cleared (see
Main Menu > Warnings).
Selecting “Warnings/Faults” shows the following menu
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Logical Inputs… ↑
Logical Outputs…
Select one of the above items to show the desired list. Select a Logical I/O point
from the list by pressing the Enter key, and you will see the following options:
None ↑
Warning
Fault ↓
By selecting one of the above items, you may set the Logical I/O property as
described above.
Forces
Physical I/O points may be forced to be On or to be Off. An I/O point thus set will
be permanently set to that state overriding all other conditions. For example, if a
Logical output is mapped to a Physical output and the Physical output is forced to
be On, the physical state of the output will be on (“energized”), but the Logical
output is unaffected and may be On or Off depending on the process or other
conditions.
However, if a Physical input is mapped to a Logical input and the Physical input is
forced On, then the resulting Logical input will also be turned On. Likewise if a
Physical input is forced Off, then it will be off and all Logical inputs mapped to it will
be off, regardless of the physical state of the Physical input.
Any Physical I/O point that is forced On or Off will remain so until reset with this
menu.
If you select “Forces” you will be presented with the following menu:
Physical Inputs… ↑
Physical Outputs…
Select one of the above items to show the respective list. Select a Physical I/O
point from the list by pressing the Enter key, and you will see the following options:
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None ↑
Force OFF
Force ON ↓
By selecting one of the above items, you may set the Physical I/O property as
described above.
Note: Obviously the ability to force Physical I/O On or Off is a powerful tool, but
risky. Changes should be made carefully, as there is generally external equipment
involved that may start, stop, open, close, etc. unexpectedly. No changes should
be made unless all equipment is secure and no personnel are at risk.
If you have any doubts about this process, contact the Merrick Customer Service
department for assistance.
Inverted I/O
Physical I/O points may also be inverted. This simply reverses the logical function
of any particular input or output. For example if a Physical output is mapped to a
Logical output and the Physical output is inverted, then when the Logical output is
On, the Physical output will be Off, and vice versa.
If you select “Inverted I/O” you will be presented with the following menu:
Physical Inputs… ↑
Physical Outputs…
Select one of the above items to show the respective list. Select a Physical I/O
point from the list by pressing the Enter key, and you will see the following options:
None ↑
Invert ↓
By selecting one of the above items, you may set the Physical I/O property as
described above.
Totalizer
(Main Menu > Advanced Setup > Totalizer)
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Totalizer Cutoff ↑
Weight per EMT Pulse
EMT Pulse Length ↓
Totalizer Cutoff
This setting allows you to specify a value for Belt Load below which totalization will
not occur. Totalization is normally bi-directional, meaning that material can be
subtracted from the totalizer if belt load is negative. If you wish to prevent this from
happening, you may set this value at some reasonable value and any belt load
lower than the setting (including negative values) will not be totalized.
The units of this setting are those of Belt Load (i.e. lb/ft or kg/m). The lower limit is
-10% of Design Load and the upper limit is 50% of Design Load (see Main Menu >
Basic Setup > Design Capacities > Design Load)
Weight per EMT Pulse
This is the value for one pulse of the EMT (external mechanical totalizer) output.
The units are those of Weight (i.e. lb or kg). The lower limit is 0.01 and the upper
limit is 100,000.
Pulse Length
This is the “on” time in seconds for each pulse that is sent to the EMT (external
mechanical totalizer) output. This is settable to allow longer pulses for mechanical
totalizers versus electronic. The “off” time will never be less than the “on” time, but
may be longer depending on the actual rate of pulses.
Also note that output pulses are buffered so that none are lost. If the Pulse Length
and/or the rate of pulses are high enough, its possible that the external totalizer
will not be able to keep up with the internal totalizers. However, it will “catch up”
and no pulses should be lost. The rate of pulses will depend on the setting for
“Weight per EMT Pulse” (see above) and the actual feedrate.
The minimum setting for this parameter is 0.01 seconds and the maximum is 5.0
seconds.
Feeder Peripherals
(Main Menu > Advanced Setup > Feeder Peripherals)
Note: This menu item will only appear if at least one of the following feeder
peripherals is enabled (see Main Menu > Advanced Setup >Configuration).
Selection of this menu item will present you with a list of peripheral devices that have
been configured, and allow you to set certain parameters that control their
functionality.
Only those devices that have been enabled will appear in this menu.
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Pre-feeder… ↑
Drive Feedback…
Material on Belt Sw…
Discharge Monitor…
Drag Chain…
Infeed Flow Monitor… ↓
Pre-feeder (not available yet)

Note, there are many pre-feeder arrangements that can be accommodated with
the standard Genetix. If you have a pre-feeder application and require assistance,
contact the Merrick Customer Support department.
Drive Feedback
Note: To enable this item, see Main Menu > Advanced Setup >Configuration >
Drive Feedback
Many feeder drives (i.e. VFD, PWM, SCR) have extra digital outputs that can help
diagnose drive related problems. By enabling the Genetix “Drive Feedback”
feature, additional GCM inputs and outputs are turned on that can be used to
improve overall feeder diagnostics by including drive diagnostics. See below for
the menu of settings and parameters and descriptions of the I/O functionality.
Settings… ↑
Numeric Data… ↓
Settings
The following settings are available for Drive Feedback:
Overld Connected ↑
AtSpd Connected ↓
Overld Connected
This is a switch (Y/N) that tells the Genetix that the drive has an overload
output and that is connected to a GCM input, which has been mapped to the
Logical input “Belt Drv Overld.
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AtSpd Connected
This is a switch (Y/N) that tells the Genetix that the drive has an “At Speed”
output and that is connected to a GCM input, which has been mapped to the
Logical input “Belt Drive AtSp”.
Numeric Data
The following parameters are available for Drive Feedback:
Overld On Delay ↑
Not at Spd On Delay ↓
Overld On Delay
A time delay, in seconds, between the time the “Belt Drv Overld” input
comes on and the output “Belt Drive Ovld” comes on. This timer and the
output are active even if the drive is not enabled (commanded to run).
Not at Spd On Delay

The elapsed time, in seconds, allowed for the drive to come up to speed,
once enabled (commanded to run). The “Belt Drive AtSp” must come on
within this set time to prevent the output “Belt Drive NAS” from turning on.
Material on Belt Sw
Material on Belt Sw
A material on belt switch (MOB) is intended to provide an electromechanical
indication of the presence of material on the belt. Typical designs are: limit switch,
tilt switch, or capacitance probe.
Selection of this item will present the following menu, whose settings will
determine the functionality of this switch.
Settings… ↑
Numeric Data… ↓
Settings
The following settings are available for the Material on Belt Switch:
Blocking ↑
Jog while Blocking ↓
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Blocking
This is a switch (Y/N) that indicates whether or not it is okay to run the belt
forward in Manual mode, while the MOB is indicating that there is material on
the belt. If “Blocking” is enabled (“Y”), then this is not allowed. This is a
requirement of the NFPA for some coal feeders.
Jog OK while Blocking

This is a switch (Y/N) that indicates whether or not it is okay to jog the belt
forward while “Blocking” is enabled (see above). If this seting is turned on
(“Y”), and blocking is also enabled, then it will still be possible to jog the belt
forward (see Main Menu > Feeder Control) while the MOB is indicating that
there is material on the belt.
Numeric Data
The following numeric parameters can be set for the Material on Belt Switch:
MOB Off Delay ↑
MOB Off Delay

This parameter sets the time, in seconds, that the controller will ignore a
loss of material on the belt, before taking any action. This can be used to
prevent temporary loss of material from un-necessarily causing alarm
(nuisance trips).
Discharge Monitor
Discharge
A discharge pluggage switch is typically mounted below the head pulley of the
feeder and is intended to provide an indication of flow stoppage at the discharge.
Typical designs are: limit switch, paddle switch, or capacitance probe.
Selection of this item will present the following menu, whose settings will
determine the functionality of this switch.
Settings… ↑
Numeric Data… ↓
Settings
The following settings are available for the Material on Belt Switch:
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Blocking ↑
Blocking
This is a switch (Y/N) that indicates whether or not it is okay to start the belt
in Auto, while the discharge pluggage switch is indicating that there is
material in the discharge cavity. If “Blocking” is enabled (“Y”), and this switch
is on, the “Ready” condition will not be true and the feeder cannot be started.
Numeric Data
The following numeric parameters can be set for the Discharge Monitor:
Disch On Delay ↑
Disch On Delay
This parameter sets the time, in seconds, that the controller will ignore a
discharge pluggage condition, before taking any action. This can be used to
prevent temporary pluggages from un-necessarily causing alarms (nuisance
trips).
Drag Chain
“Drag Chain” can refer to any cleanout conveyor designed to clean out the feeder
body underneath the belt, moving any material that may have fallen off the belt into
the discharge area. Enabling this feature allows the GCM to control the cleanout
conveyor according to the following settings and parameters.
Drag Chain.
Settings… ↑
Numeric Data… ↓
Settings
The following settings are available for the Drag Chain:
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Linked with Auto Run ↑
Timed (No = Cont)
Reversible
Has Zero Spd Sw ↓
Linked with Auto Run

This is a switch (Y/N) that links the running of the cleanout conveyor with the
running of the belt. If this is set for “Y”, the drag chain will only run if the belt
is running, and will not run if the belt is not running. Note: If the drag chain is
set for “Timed” operation (see below), the drag chain will cycle while the belt
is running, even though the belt is running continuously.
If this option is set for “N”, the drag chain will only run when started from the
User Interface (see Main Menu > Drag Chain Control), and will only stop
when stopped from the User Interface.
Timed
This is a switch (Y/N) that indicates if the cleanout conveyor should cycle on
and off, or run continuously. A setting of “Y” indicates timed operation, and a
setting of “N” indicates continuous. See “Numeric Data” below for the timer
settings.
Reversible
This is a switch (Y/N) that indicates if the cleanout conveyor can run
backwards. If this is enabled, then it will be possible to run the drag chain in
reverse from the User Interface.
Has Zero Spd Sw

If a proximity (or other type) switch has been installed to monitor the motion
of the drag chain, this feature can be turned on to provide a Zero Speed
function. Enabling this feature adds an additional Logical Input called “Drag
Chain ZSS” and an additional Logical Output called “Drag Chain Jam”.
Numeric Data
The following numeric parameters can be set for the Drag Chain:
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On Time ↑
Off Time
Reverse Delay
ZSS Off Delay ↓
On Time
This is the time, in seconds, that the drag chain will run if set for “Timed”
operation ( see Main Menu > Advanced Setup > Feeder Peripherals > Drag
Chain > Settings).
Off Time
This is the time, in seconds, that the drag chain will be off if set for “Timed”
operation ( see Main Menu > Advanced Setup > Feeder Peripherals > Drag
Chain > Settings).
Reverse Delay
This is the time, in seconds, that the controller will wait after the drag chain
has run forward, before allowing the user to run it in reverse (from the User
Interface).
ZSS Off Delay

This parameter sets the time, in seconds, that the controller will wait after the
proximity (or other) switch is triggered. If the switch is not triggered again
within this wait period, the drag chain will be assumed to have jammed and
the appropriate output will be set.
Note: This parameter will not be visible unless the setting “Has Zero Spd Sw”
is enabled ( see Main Menu > Advanced Setup > Feeder Peripherals > Drag
Chain > Settings).
Infeed Flow Monitor

Infeed Flow Monitor refers to a device installed above the feeder, generally in a
downspout, that monitors the flow of material and indicates when flow has
stopped. Generally if the feeder is running and flow above the feeder stops, this is
an indication of a blockage, and in certain situations this can be very dangerous as
it may eliminate the seal between the feeder and the silo above, if the downspout
is allowed to completely empty.
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Loss of flow will be determined by two methods; a fixed turn-off time delay, and a
delay based on the amount of material that passes though the feeder after the
initial loss of flow is indicated. The intent is to provide a warning soon after a loss
of flow, and then a Fault (i.e. trip the feeder) before the pipe is completely empty
and a loss of seal occurs. Each method qualifies a specific Logical output and can
therefore be acted on independently.
Infeed Flow Monitor).
Numeric Data… ↑
Numeric Data
The following parameters control the functionality of the Infeed Flow Monitor:
Loss of Flow Delay ↑
Loss of Flow Weight ↓
Loss of Flow Delay

This is the amount of time, in seconds, that the controller will wait, after an
initial indication of loss of flow, before turning on the “No Flow” logical output.
Loss of Flow Weight

This is the amount of material, in units of weight (i.e. lb or kg), that must
pass through the feeder after an initial indication of loss of flow, before the
controller turns on the “Empty Pipe” logical output.
Note : It is common for the “No Flow” output to be set as a “Warning”

(annunciate only), and for the “Empty Pipe” output to be set as a “Fault”
(shuts down, or trips, the feeder).
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Communications
(Main Menu > Advanced Setup > Communications)
Selecting this menu item, you will be presented with a list of all the available serial
communications ports. Each is individually configurable for any of the available
communications protocols. The minimum list of available ports will like this:
GCM Port 0 (USB)… ↑
GCM Port 1
GCM Port 2 ↓
When you select any of the available ports you will be presented with another menu
like this:
Protocol… ↑
Baudrate…
Parity…
Data bits…
Stop Bits…
Exp Comm Bd Routing…
Numeric Data… ↓
Protocol
There are several different serial protocols available for different kinds of
communications tasks. Each is listed below with a brief description of its intended
use. Note, not all protocols are available on all ports.
Note: A complete discussion of these protocols details of how to use them for
communications with the Genetix controllers is beyond the scope of this Manual. If
you require assistance, contact the Merrick Customer Support department or see
www.merrick-inc.com/mct
Page 75 of 104
UI Protocol ↑
ScaleNet
DF1
Modbus RTU
Modbus ASCII
Modbus TCP
Monitor
None ↓
UI Protocol
This is a special protocol developed by Merrick for communications between a
User Interface and the GCM board. If you have a Merrick User Interface
connected to a serial port, then that port must be set to “UI Protocol”. This is a
binary protocol.
Note: If you change this setting via the User Interface, then you may lose
communication and not be able to change it back. Make sure you know which
port (if any) is connected to the User Interface and don’t inadvertently change
its settings.
ScaleNet
This is a protocol developed by Merrick for the exchange of information
between a computer and the Genetix controller. It is a “Master/Slave” protocol
wherein the master requests information or an action and the slave responds.
Typically the master is a computer (PC), and the slave is the Genetix controller.
It is also possible to use this protocol in a “multi-drop” configuration (i.e. RS-
422/RS-485) that allows one master to talk to several slaves (i.e multiple
Genetix controllers). Through ScaleNet, you may have access to all parameter
data in the Genetix controllers. ScaleNet is an ASCII protocol.
The ScaleNet protocol, although proprietary to Merrick, is published and can be
used to develop your own communications interface through programming. The
details of this protocol and programming examples are beyond the scope of this
manual, but if you require assistance contact the Merrick Customer Support
department.
Note: WinMerik® is a program developed by Merrick that runs on a PC and
uses the ScaleNet protocol to get parameter data for either logging or archival
purposes. If you intend to use WinMerik you must set the appropriate port’s
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protocol to “ScaleNet”. For more information on the WinMerik application,
DF1
DF1 is an Allen-Bradley protocol primarily used to communicate with Allen
Bradley devices such as PLC’s and DeviceNet interfaces (DNI’s).
Modbus RTU
Genetix controllers support the Modbus RTU communications protocols. They
will act as slaves, supporting the Modbus functions 3 (Read Holding Registers)
and 16 (Preset Multiple Registers). Function 8, sub function 0 (Return Query
Data) is also supported. The master is assumed to maintain a cyclic
conversation with the controller, which exposes the Merrick Common Interface
Table (CIT), making it possible monitor and supervise the Genetixcontroller
completely.
This protocol is commonly used to interface Genetix controllers with a variety of
industrial networks, often with the use of protocol converters. Modbus RTU is a
binary protocol.
Modbus ASCII
Genetix controllers also support the Modbus protocols as above, in its ASCII
form.
Modbus TCP
This protocol is again the Modbus protocol, supported in the Genetix as above,
encapsulated in TCP/IP format and transported over Ethernet networks. Use of
this protocol requires an optional Ethernet converter.
Monitor
Monitor is a special protocol developed by Merrick primarily for test and
diagnostic purposes. With it, any PC equipped with terminal emulation software
can connect to a Genetix controller and receive a tremendous amount of data
for diagnostic purposes.
None
Selecting “None” for a communications protocol effectively shuts off that port,
disabling all communications functions.
Baudrate
This is the communications data rate in bits per second. Master and slave devices
must have the same setting for communications to take place. Baudrate must be
selected from one of the following settings: 2400, 4800, 9600, 19200, 38400,
57600, 115200, and 230400.
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Parity
Parity provides basic error detection for serial communications. Master and slave
devices must have the same setting for communications to take place. Parity must
be selected from one of the following settings: None, Odd, Even.
Data bits
This is the number of data bits used to represent one byte of data. Master and
slave devices must have the same setting for communications to take place. Data
bits must be selected from one of the following settings: 7, 8.
Stop Bits
This is the number of stop bits used at the end of the data. Master and slave
devices must have the same setting for communications to take place. Stop bits
must be selected from one of the following settings: 1, 2.
Numeric Data
These are various numeric parameters that support or modify serial
communications. Not all the parameters in this list will appear depending on the
protocol selected.
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Unit Address ↑
Start Code
End Code
Communication Timeout
Comm Data Mapping
Write Protection
Byte (Word) Order
Integer/Frac FP
Register Tag 1
Register Tag 2
Register Tag 3
Register Tag 4
Register Tag 5
Use LRC ↓
Unit Address
The Unit Address is a number that uniquely identifies the controller. It is
typically embedded in communications telegrams so that each GCM knows
who is to respond to which telegram. The lowest address is always one (1), and
the highest depends on the protocol selected. The default address is 1, but this
may change if there are multiple controllers connected to one network or serial
communications bus (i.e. RS-485).
If multiple Genetix GCM’s are connected to one Genetix Color User Interface,
each GCM must have a sequential Unit Address, starting at one (1).
If multiple Genetix GCM’s are connected to one network protocol converter,
each GCM must have a uniquel Unit Address, but they need not necessarily
start at one (1), although this is typically the case.
The Unit Address is port and protocol specific. For example, it is possible to
have a Unit Address on port 1 that is different from the Unit Address on port 2,
along with different protocols.
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Selecting this parameter from the Numeric Data menu will bring up the Numeric
Data Entry screen that will allow you to enter the desired Unit Address. This
should be done after selecting the correct protocol (see above).
Start Code
Some protocols use Start Codes and End Codes to identify the beginning and
end of a telegram. The Start Code parameter will only appear in the Numeric
Data list if “ScaleNet” has been selected as the protocol. The default value for
this is 10, and this should probably not be changed. Certain Merrick
applications (i.e. WinMerik®) expect this parameter to be set to 10.
Data Entry screen that will allow you to enter the desired Start Code. This
End Code
Some protocols use Start Codes and End Codes to identify the beginning and
end of a telegram. The End Code parameter will only appear in the Numeric
Data list if “ScaleNet” has been selected as the protocol. The default value for
this is 13, and this should probably not be changed. Certain Merrick
applications (i.e. WinMerik®) expect this parameter to be set to 13.
Data Entry screen that will allow you to enter the desired Start Code. This
Communication Timeout
This is the maximum amount of time that the GCM will wait for a valid incoming
telegram (message). If a valid telegram is not received within this time period, a
communications timeout error will occur, and an appropriate logical output will
be set (i.e. “Port x Timeout”). This value is set in seconds. A value of zero (0)
will effectively disable this parameter and a timeout error will never occur.
This parameter is valid and will appear in the Numeric Data menu only if one of
the following protocols is selected:
• UI Protocol
• ScaleNet
• DF1
• Modbus RTU
• Modbus ASCII
• Modbus TCP
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Data Entry screen that will allow you to enter the desired Timeout period. This
Comm Data Mapping

There are two Common Interface Tables (CIT’s) available for communications
use, “Small” and “Large”. They represent a data structure containing some fixed
elements and some that you can configure. The small data map (CIT) is exactly
the same as previous Merrick controllers (i.e. MC³) to maintain compatibility.
The large data map exposes some additional data and can be used in more
complex systems. For a complete description of the CIT, please see our web-
site at www.merrick-inc.com/mct
• ScaleNet
• DF1
• Modbus RTU
• Modbus ASCII
• Modbus TCP
Selecting this parameter from the Numeric Data menu will bring up a screen
that will allow you to select either the small (default) or large data map. This
Write Protection
This parameter allows you to protect certain data in the data map from being
overwritten.The write protection property should be set when a register is
tagged for monitoring only. When writing to words that are write protected, the
corresponding Tag n W value changes accordingly, but the corresponding MC³
register (Tag n R Value) is unaffected. This is useful for testing data transfers to
the GCM before they are implemented, or when you need to change a variable
only at certain instances. Individual data may be write-protected or not. Typical
values for this parameter are:
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Value Action
4095 (0xFFF) All values write

protected
3071 (0xBFF) All values except

Primary Setpoint write
protected.
0000 (0x000) No values write

protected
• ScaleNet
• DF1
• Modbus RTU
• Modbus ASCII
• Modbus TCP
Data Entry screen that will allow you to enter the desired Write Protection value.
This should be done after selecting the correct protocol (see above).
Note that this parameter can also be changed via communications, using the
data map. This can be useful if only certain data needs to be written and/or only
at certain times.
For additional assistance contact the Merrick Customer Support department or
see our website www.merrick-inc.com/mct
Byte (Word) Order

The Word Order Bit, when set, reverses the order of the two words that
contains value information. To correctly transfer floating-point values to and
from some PLC’s these bits may have to be set. Typical values are 4095
(0xFFF) for Siemens S5 & S7, Allen-Bradley PLC-5 and SLC PLC's, and 0 for
the Modicon and Allen-Bradley ControlLogix family of PLC's.
• ScaleNet
• DF1
• Modbus RTU
• Modbus ASCII
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• Modbus TCP
Data Entry screen that will allow you to enter the desired Word Order value.
This should be done after selecting the correct protocol (see above). Valid
values are 0 to 4095 (0xFFF).
data map. For additional assistance contact the Merrick Customer Support
department or see our website www.merrick-inc.com/mct
Integer/Frac FP
The Integer/Fraction bits are used when the device using the data (i.e. the PLC)
does not support floating-point numbers. With the corresponding Word Order bit
cleared, the first word will carry the Integer part, and the second the fractional
part, multiplied with 10000. (4 implied decimal places). Note that for a negative
value, both the integer and fractional parts are negative.
• ScaleNet
• DF1
• Modbus RTU
• Modbus ASCII
• Modbus TCP
Data Entry screen that will allow you to enter the desired Integer/Frac FP value.
This should be done after selecting the correct protocol (see above). Valid
values are 0 to 4095 (0xFFF).
data map.
For additional assistance contact the Merrick Customer Support department or
see our website www.merrick-inc.com/mct
Register Tag 1
This is a register location (i.e. register number) in the GCM to be tagged for
reading and/or writing. Registers are memory locations containing various data;
almost any parameter in the GCM can be accessed by tagging it. Up to 5
registers can be accessed in this manner, through the small data map (CIT).
The large data map exposes more data but in a different manner.
• ScaleNet
• DF1
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• Modbus RTU
• Modbus ASCII
• Modbus TCP
Data Entry screen that will allow you to enter the desired register number to be
tagged. This should be done after selecting the correct protocol (see above).
Note: In order to select the register number corresponding to the data you want
to access, you will need a register list for your GCM application. Contact the
Merrick Customer Support department for assistance.
Register Tag 2
See Register Tag 1, above.
Register Tag 3
Register Tag 4
Register Tag 5
Use LRC
If DF-1 is the selected protocol, you have the option of using either LRC
(Longitudinal Redundancy Check) or CRC (Cyclic Redundancy Check) error
checking. CRC is the most common, and is the default. Some older PLC’s can
only accommodate LRC, however.
If you are using an Allen-Bradley DNI (DeviceNet Interface), this parameter
should be set to CRC.
Selecting this parameter from the Numeric Data menu will bring up a screen
that will allow you to select either CRC or LRC error checking. This should be
done after selecting the correct protocol (see above).
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Date & Time
(Main Menu > Advanced Setup > Date & Time)
Hour ↑
Minute
Day
Month
Year ↓
Selection of any of the above items brings up the Numeric Data Entry screen allowing
the user to set that particular parameter. All parameters are limited appropriately.
These data are normally set at the factory, according to the local time zone.
Passwords
(Main Menu > Advanced Setup > Passwords)
Calibration ↑
Basic Setup
Advanced Setup
Direct Param Edit ↓
Selection of any of the first three above items brings up the Numeric Data Entry
screen allowing the user to change that particular password. All passwords are 4 digit
numbers, settable from “0000” to “9999”. Setting all four digits of any password to
zero defeats that password (disables security) for those menus requiring that
password.
Note: If you select the “Direct Param Edit” password from the above list, you will be
asked to enter this password before being allowed to change it.
GCM Name
Each Genetix GCM is allowed to have a unique “friendly” name. This name will be
displayed in the top left corner of the User Interface, and may also be used in certain
communications modes (i.e. Bluetooth) to identify the feeder you wish to talk to.
The maximum number of characters for this name is 15 and may consist of any
alphabetic (upper or lower case) or numeric character, plus some special characters.
You may use this name to identify the feeder any way you wish, but the name should
be unique at your plant.
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To edit the GCM name, select this menu item from the “Advanced Setup” menu to be
presented with a screen that looks like this:
The current name is displayed with the cursor position highlighted. You simply scroll
to the correct character with the left/right arrow keys, and then increment/decrement
that character with the up/down arrow keys. The value shown (i.e. “Val[66]”) is the
decimal ASCII code. The characters in the name are limited to ASCII 32 (space) to
122 (“z”). Note, if you are using Bluetooth, do not embed a space within the name, as
this is not allowed by the Bluetooth protocol. All other characters are allowed. If you
wish to change an existing name and remove characters from the end, you may
erase them by entering a space.
The following may help you enter a name:
Special characters range from ASCII 32 to 47, 58 to 64, and 91 to 96
Numbers range from ASCII 48 to 57
Uppercase characters range from ASCII 65 to 90
Lowercase characters range from ASCII 97 to 122
Note that if you have an Extended Communications Card configured (see Main menu
> Advanced Setup > Configuration > Expansion Comm Bd ) and are using Bluetooth,
the GCM name you enter here becomes the Bluetooth “friendly name”. When power
is cycled on the GCM, the current name is written to the Expansion Comm Board
(“XDC”). When a Bluetooth scan is performed this is the name that will appear to the
scanning device. It is not possible to edit the Bluetooth name directly; you must edit
the GCM name, then cycle power.
Direct Param Edit

(Main Menu > Advanced Setup > Direct Param Edit)
Note: This menu item allows you direct editing ability for all the parameters in the
Genetix controller with very few constraints. It is for the advanced user or Service
Technician only.
Selecting this menu item, you will be presented with a screen asking you for a
password. Upon successful entry of the password, you will be presented with a
screen similar to the Numeric Data Entry screen (see below)
Page 86 of 104
You may enter the register number you wish to change (upper left corner), and press
the Enter key. Once the register number is entered (299 as shown above), the cursor
will move the current value, allowing you to edit it. In order to do this properly, you will
probably need a list of registers, which can be provided by Merrick if necessary.
Note: Directly entering register values is very risky, as it is possible to enter a value
that will render your Genetix controller inoperative. Again, it is for the advanced user
or Service Technician only.
Configuration
(Main Menu > Advanced Setup > Configuration)
This section allows you to configure the Genetix controller for your specific
application. By enabling or disabling certain features, you can tailor the control to your
feeder and application. Also as you enable or disable features, the User Interface
menu system is re-configured automatically making certain items visible or invisible.
All features are enabled by setting to yes (“Y”) or disabled by setting to no (“N”).
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Feeder Control ↑
Load Cell 1
Load Cell 2
Tacho 1
Tacho 2
Zero Tracking
Belt Tracking Sws
Material on Belt Sw
Discharge Monitor
Drag Chain
Belt Index
DNA Key
Expansion IO Bd 1
Expansion IO Bd 2
Network IO
Programmable IO
Expansion Analog Card 1
Expansion Comm Bd
Use Head Load
Disable Outs in Cal
Infeed Flow Monitor
Drive Feedback
Inclinometer ↓
Each item above also shows its current setting (“Y/N”)
Page 88 of 104
Feeder Control
If this feature is not enabled (is set for “N”), the Genetix cannot function as a
feeder, but only as a weigher. An example of an application with this feature
disabled is a Belt Conveyor Scale (“Belt Scale”), or a wild flow weigher. In this type
of application, the Genetix has no control of the feedrate or speed, but can simply
measure what goes across the scale.
To function as a feeder, either to control Feedrate or Speed, you must turn this
feature on.
Load Cell 1
Turn this feature on if you have one or more load cells connected to GCM Load
Cell Channel 1. This is the lower of the two load cell connectors on the GCM
board. Note: It is possible to have more than one load cell connected in parallel to
a single load cell channel, but load cells connected like this cannot be resolved
independently. All load cells connected to a single channel are treated as one.
Load Cell 2
Turn this feature on if you have one or more load cells connected to GCM Load
Cell Channel 2. These load cells will be resolved independently of those
connected to GCM Load Cell Channel 1. This is most frequently used when the
scale or feeder has a load cell (or load cells) on both sides of the belt. Using both
channels, the two sides can be resolved independently and load cell problems can
sometimes be identified.
Also, if only one set of load cells is being used, but need to be connected to GCM
Load Cell Channel 2, then this feature must be turned on. In this case Load Cell 1
(see above) would likely be turned off.
Those features that rely on two load cells will only appear in the menus if both
Load Cell 1 and Load Cell 2 are enabled.
Tacho 1
Turn this feature on if you have a tacho (tachometer, encoder, etc.) connected to
Tac1 on the GCM board.
Tacho 2
Turn this feature on if you have a tacho (tachometer, encoder, etc.) connected to
Tac2 on the GCM board. This is frequently used in conjunction with the tacho
connected to Tac1 to detect belt slippage.
Also, if only one tacho is being used, but it must be connected to Tac 2, then this
feature must be turned on. In this case Tacho 1 (see above) would likely be turned
off.
Those features that rely on two tachos (i.e. detection of belt slippage) will only
appear in the menus if both Tacho 1 and Tacho 2 are enabled.
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Zero Tracking
Zero Tracking (also known as “Auto-Zero”) is a process by which a belt feeder or
belt conveyor can be allowed to zero itself, while running, if certain conditions are
met. Errors in Zero are the most significant source of poor accuracy and so this
can be a very powerful means to improve your performance of your belt scale (or
feeder).
Good candidates for Zero Tracking are those feeders or conveyors that
occasionally run empty for the period of time necessary to perform a Zero test, and
those belt scales that require the utmost accuracy (i.e. certified scales).
To use Zero Tracking, you must enable this feature (set to “Y”). Once enabled, the
menu for the Zero tracking parameters will appear in the Calibration menu (see
Main Menu > Calibration > Numeric Data > Zero Tracking)
Belt Tracking Sws

Some belt feeders are equipped with Belt Tracking switches (also called “run-off
switches”) that can advise the operator when the belt mis-tracks. If desired these
switches can be connected directly to Genetix digital inputs and certain operations
can be made to automatically take place when a mis-track occurs. For example, a
Warning can be displayed if the belt mis-tracks a certain amount (called “Belt
Offset”), or a Fault can occur (feeder will stop), if the belt mis-tracks a greater
amount (called “Belt Error”).
To take advantage of this functionality, this feature must be enabled.
Material on Belt Sw
Some feeders are equipped with a Material on Belt switch that can advise the
operator when there is (or is not) material on the belt. Various types of switches
are used such as paddle, tilt, capacitance, etc. If desired these switches can be
connected directly to a Genetix digital input and certain operations can be made to
automatically take place when a loss of material occurs.
Discharge Monitor
Some feeders are equipped with a Discharge Pluggage switch that can advise the
operator when material has backed up at the discharge, possibly due to a
pluggage downstream from the feeder. Various types of switches are used such as
paddle, capacitance, etc. If desired these switches can be connected directly to a
Genetix digital input and certain operations can be made to automatically take
place when a discharge pluggage occurs.
Page 90 of 104
Drag Chain
Some feeders are equipped with a Drag Chain conveyor (also called “Cleanout
Conveyor”) which sweeps the bottom of the interior of the feeder, removing any
material that has fallen off the belt. There are several settings available that control
when the Drag Chain runs, how long it runs, etc.
Belt Index
Some feeders are equipped with a Belt Index which is a switch of some type that
provides an input once per belt revolution. This can be used to detect slippage, or
for the Zero Memory feature.
DNA Key
Some Genetix controllers are provided with a DNA Key interface that allows
certain data to be transferred to a removable memory device (called a “DNA Key”).
For example, you may save all the parameters from a particular controller. These
then might be later transferred back to the controller, in case of inadvertent re-
programming, or to another controller. The “DNA Key” becomes visible in the Main
Menu when this feature is enabled.
To take advantage of DNA Key functionality, this feature must be enabled.
Expansion IO Bd 1
Expansion IO boards provide the Genetix controller with additional digital inputs
and outputs. To inform the Genetix that these additional IO points exist, and are
therefore accessible to the controller, this feature must be enabled.
Expansion IO Bd 2
See Expansion IO Bd 1 (above)
Network IO
Network I/O are “virtual” physical inputs and outputs that are accessible from an
outside source (i.e. Network) connected to a serial port on the GCM. Network
inputs are settable from the Network, and network outputs are readable from the
Network.
A Network input may have multiple Logical inputs mapped to it and takes on all
other aspects of Genetix Physical inputs. For example they may be forced and/or
inverted (see Main Menu > Advanced Setup > Digital I/O > Forces, Inverted I/O).
Multiple Network outputs may be mapped to a Genetix Logical output, and likewise
take on all other aspects of Genetix Physical outputs. For example they may be
Page 91 of 104
forced and/or inverted (see Main Menu > Advanced Setup > Digital I/O > Forces,
Inverted I/O).
The use of Network I/O is fairly sophisticated and generally done with the
assistance of Merrick. The PLC programming required to interface with Genetix
Network I/O is beyond the scope of this Manual. If you require assistance, please
To enable Network I/O you must set this Configuration parameter to “Y”. Otherwise
Network I/O will not appear in the list of Physical I/O.
Programmable IO
Programmable I/O points are Logical I/O points that can take on the characteristics
of both inputs and outputs. They have no inherent logical functionality, but are
generally used to “connect” inputs to outputs. For example one Physical input may
be mapped to multiple Programmable I/O points, each of which may in turn be
mapped to multiple Physical outputs. In this example, if the Physical input turns on,
all the Physical outputs so mapped would also turn on.
Because Programmable I/O points are Logical I/O, they can also be set for
Warning or Fault ((see Main Menu > Advanced Setup > Digital I/O >
Warnings/Faults).
The use of Programmable I/O is fairly sophisticated and generally done with the
assistance of Merrick. Many things are possible, beyond the simple example
shown above; however a complete discussion is beyond the scope of this Manual.
If you require assistance, please contact the Merrick Customer Support
department.
To enable Programmable I/O you must set this Configuration parameter to “Y”.
Otherwise Programmable I/O will not appear in the list of Logical I/O.

Some Genetix controllers are provided with an auxiliary analog card that can either
be plugged into the expansion header on the GCM as a daughtercard, or panel
mounted and connected to the GCM via a cable. Each such card card provides for
2 additional analog outputs, one additional analog input, and 4 additional digital
inputs (dry contact). There can be a maximum of two Expansion Analog cards.
If you have such a card, this feature must be turned on to enable it. Once enabled,
the additional I/O will appear in the menus.

If you have a second Expansion Analog card, this feature must be turned on to
enable it (see above).
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Expansion Comm Bd
Some Genetix controllers are provided with an auxiliary communications card (also
called a “daughter card”) that is plugged into the expansion header on the GCM.
This provides for certain special serial communications features, such as
Bluetooth.
If you have such a card, this feature must be turned on to enable it.
Use Head Load

This is a feature that allows the translation of the belt load from the suspension
(where it is actually measured) to the head pulley (where it is actually discharged).
In some applications, such as Stopped Belt Batching, this can have a very
important affect on accuracy.
Note: you must enter the distance from the suspension to the head pulley (see
Main Menu > Advanced Setup > Load Cells > Numeric Data > LC to Head Pulley)
for the Genetix to know how to make this translation. This menu item will appear if
this feature is enabled.
To take advantage of Head Load translation, this feature must be enabled.
Disable Outs in Cal

This option disables the external totalizer and the analog feedrate outputs while a
Calibration procedure is running. This prevents other process equipment from
being affected by the data that would otherwise be presented at these outputs.
To enable this feature (disable the outputs), turn this feature on.
Infeed Flow Monitor

Some feeder are equipped with a device that monitors the flow in the pipe or chute
at the inlet to the feeder. Often this is an Acoustic Flow Monitor that actually listens
for this flow and sets an output when it stops, for example if the material in the silo
forms a bridge or an arch. By connecting this output directly to a Genetix digital
input certain operations can be made to automatically take place when a loss of
flow occurs. This can be very important, for example on a pressurized coal feeder
that must maintain a column of material in the infeed to form a seal. Loss of this
seal can allow hot gases into the silo and cause a fire.
Drive Feedback
In a typical belt feeder application the Genetix controller is connected to the
variable speed drive which allows it to control the belt speed. The minimum
number of signals that must be used for this connection is an analog signal that
tells the drive how fast to go (called “Belt Speed Demand”) and a digital signal that
Page 93 of 104
tells the drive to start (called “Belt Forward”). Also, in the case where the belt is
allowed to run backward, another digital output is available called “Belt Reverse”
If it is desired to provide greater integration between the Genetix controller and the
Drive, the “Drive Feedback” feature may be enabled and additional inputs and
outputs will become available.
Inclinometer
An inclinometer is a device capable of sending an analog signal representing the
angle (or “inclination”) of the conveyor or feeder relative to horizontal. Connected
to an analog input on a GCM, this will allow the Genetix controller to correctly
measure the belt load regardless of angle. This might be useful, for example if the
scale or feeder is installed such that this angle changes during operation.
To use this feature, it must be enabled, and the analog input must be mapped to
the “Inclination” logical analog input (see Main Menu > Advanced Setup > Analog
I/O > Inputs > Function ). Also, like all analog inputs it must be calibrated so that
the angle is correctly represented by the analog signal.
Reset Totals
Selecting this item from the Main Menu will bring up the following selections:
Reset Sub-Total… ↑
Reset Grand-Total…
If you select “Reset Sub-Total” from the above screen you will see a screen that shows
the respective current totalizer value and asks you to confirm the reset. Press the Enter
key to reset the totalizer or press the Menu/Esc key to cancel without resetting.
If you select “Reset Grand-Total from the above menu, you will be asked for a password
to allow the reset. This is the same password as used for Calibration (default = “1234”).
Upon successful entry of the password you will see a screen that shows the respective
current totalizer value and asks you to confirm the reset. Press the Enter key to reset the
totalizer or press the Menu/Esc key to cancel without resetting.
DNA Key
Selecting this item from the Main Menu will bring up the following selections:
Page 94 of 104
Save to Key… ↑
Restore from Key…
In addition, at the bottom of the display there will be various Help messages. For
example if no DNA Key is inserted into the receptacle, the message will read,
“Waiting for DNA Key Insertion”
Upon insertion of a properly formatted key, the message will read,
“DNA Key Inserted”, and then,
“Reading Master Page”, and then
“Ready”
If a key is inserted that has not been properly formatted, the message will read,
“Error, can’t read!”
Note: All DNA Keys must be formatted before they can be used. This is normally done at
the Merrick factory.
Once the “Ready” message is received, you may proceed to one of the options above.
Save to Key
If you select this option from the above menu, you will see a screen warning you that
all data (if any) will be overwritten on the inserted DNA Key. Press the Enter key to
confirm and continue, or the Menu/Esc key to abort, leaving the existing data on the
DNA Key intact.
If you confirm, all of the parameters, settings, and data in the internal memory of the
Genetix GCM will be saved to the key. If successful, the Help message will read,
“Writing Data”, and then,
“Successful Save”
Restore from Key

If you select this option from the above menu, you will see a screen warning you that
all data in the Genetix GCM will be overwritten by the data on the present DNA Key.
Note: Once the data is written to the GCM from the DNA Key, the GCM will
automatically be reset, making the new settings effective. This will cause the feeder
to stop (if it was running), and may cause other process related issues. It is strongly
recommended that the Restore operation only be done while the process is stopped
and peripheral devices secured.
Press the Enter key to confirm and continue, or the Menu/Esc key to abort, leaving
the data in the Genetix GCM intact.
Page 95 of 104
If you confirm, all of the data on the present DNA Key will be written to the Genetix
GCM will be overwritten, re-configuring it. If successful, the Help message will read,
“Reading data”, and then,
“Successful Restore”
Diagnostics
(Main Menu > Diagnostics)
Selection of “Diagnostics” from the Main menu presents a list of items the use can select
to see specific data for diagnostics or informational purposes. The following sections are
available,
Load Cells… ↑
Tachos…
Analog Inputs…
Analog Outputs…
Digital Inputs…
Digital Outputs…
Misc Data…
Unit Conversions…
GCM Mem/DNA Key…
Calibration…
Communication… ↓
Each of the above menu items displays additional screens with data relative to that
particular item. Many items have multiple screens, and for those you will see “← →” in
the lower right of the display. You may scroll through the available screens with the left
and right arrow keys.
Drag Chain Control

(Main Menu > Drag Chain Control)
Note: The items presented in the Drag Chain Control menu will vary depending on
current configuration. Also “Drag Chain Control” only appears in the Main Menu if “Drag
Chain” is enabled (see Main Menu > Advanced Set-up > Configuration).
The following is a list of all Feeder Control items and their functions:
Page 96 of 104
Start [Stop] Drag Chain… ↑
Jog Forward
Jog Reverse ↓
Start [Stop] Drag Chain

If the drag chain is not linked to Feeder Running (see Main Menu > Advanced Set-up
> Feeder Peripherals > Drag Chain > Settings), or if feeder is in Manual mode, this
menu item allows you to start and stop the drag chain. If the drag chain is not
running, this item will read “Start Drag Chain”. If the drag chain has already been
started, this item will read “Stop Drag Chain”.
Note: If the drag chain has been configured to run in “timed” mode, the drag chain will
actually run in accordance with the timer settings, once started (see Main Menu >
Advanced Set-up > Feeder Peripherals > Drag Chain > Numeric Data).
Jog Forward
If the feeder is in Manual mode, this command will appear and will run the drag chain
forward as long as you hold the Enter key down.
Jog Reverse
If the feeder is in Manual mode and the drag chain has been configured as reversible,
this command will appear and will run the drag chain in reverse as long as you hold
the Enter key down.
Note: If Drag Chain is linked to Auto Run, no start/stop options will be shown (see
Main Menu > Advanced Setup > Feeder Peripherals > Drag Chain > Settings).
Page 97 of 104
Appendix A
Logical Inputs
This is a list of all Logical inputs that are available in the Genetix controller.
Note: Not all inputs will be visible, depending on the Configuration settings (see Main
Menu > Advanced Setup > Configuration).
The following Logical inputs are always available, regardless of Configuration

settings.
Name Description
Belt is Running Belt is running input.
Total Enabled Enable grand total update
Subtot Enabled Enable sub total or volumetric total update
EMT Enabled Enable EMT total update
Reset Faults Reset Faults
Reset Warnings Reset warnings
Reset Subtotal Clear the active subtotal. If in “Bypassed”, will clear the
Volumetric Sub-total.
Spd Pulse Block Hold input for speed span test
Permit Calibr Calibration procedures permitted
Diverter Valve Diverter valve limit switch. ON when valve is open
Register Access Extended register access permitted
Zero Tracking Enable zero tracking
External Fault External switch that can be used for indication of fault, and trip
(stop) feeder.
Goto Volumetric Go into volumetric (inferred load) mode.
Feeder related inputs. Present when “Feeder Control” is enabled (see Main Menu >
Advanced Setup > Configuration > Feeder Control).
Run Permission Controller auto run permission
Netw. Run Perm Controller network run permission
Min Setpoint Revert to Minimum setpoint (feeder control method is Rate or
Speed)
Feeder Block Unconditional feeder block. Feeder will not run in any mode
Local Lockout Block from going out of Auto
Force Network Force Serial Setpoint at good comm’s
Belt Drv Fail Belt Drive Fault or Not Ready output from speed control
Belt Index related. Present when “Belt Index” is enabled (see Main Menu >
Advanced Setup > Configuration > Belt Index).
Belt Index Sw Belt Index Prox Switch
Drag Chain related. Present when “Drag Chain” is enabled (see Main Menu >
Advanced Setup > Configuration > Drag Chain).
Drag Chain ZSS Drag chain zero speed switch
Chn Mot Overld Chain Motor overload
Page 98 of 104
Discharge Pluggage Switch related. Present when “Discharge Monitor” is enabled
(see Main Menu > Advanced Setup > Configuration > Discharge Monitor).
Disch Monitor Discharge Pluggage detected
Material On Belt Switch related. Present when “Material on Belt Sw” is enabled
(see Main Menu > Advanced Setup > Configuration > Material on Belt Sw).
Material On Blt There is material on the belt
Flow monitor related. Present when “Infeed Flow Monitor” is enabled (see Main
Menu > Advanced Setup > Configuration > Infeed Flow Monitor).
Low Infeed Flow Low Infeed flow detected
Drive Check related. Present when “Drive Feedback” is enabled (see Main Menu >
Advanced Setup > Configuration > Drive Feedback).
Belt Drive AtSp Belt drive at desired speed
Belt Drv Overld Belt drive overload
Belt Tracking switches related. Present when “Belt Tracking Sws” is enabled (see
Main Menu > Advanced Setup > Configuration > Belt Tracking Sws).
Belt Offs Left Belt tracking Left, first stage
Belt Offs Right Belt tracking Right, first stage
Belt Err Left Belt tracking Left, second stage
Belt Err Right Belt tracking Right, second stage
Page 99 of 104
Appendix B
Logical Outputs
This is a list of all Logical outputs that are available in the Genetix controller.
Note: Its possible some outputs will not be visible, depending on the Configuration
settings (see Main Menu > Advanced Setup > Configuration).
The following Logical outputs are always available, regardless of Configuration

settings.
Name Description
Warning Warning
Fault Fault
Running Feeder belt is running
Feeding There is a feedrate
Ready Feeder is running or startable
LoadCell 1 Ovl Load Cell A/D channel 1 overload
LoadCell 1 Undl Load Cell A/D channel 1 underload
LoadCell 2 Ovl Load Cell A/D channel 2 overload
LoadCell 2 Undl Load Cell A/D channel 2 underload
LC Ch1 Failure Load cell A/D channel 1 failure
LC Ch2 Failure Load cell A/D channel 2 failure
High Belt Load High Belt Load limit
Low Belt Load Low Belt Load limit
High Belt Speed High Belt Speed limit
Low Belt Speed Low Belt Speed limit
High Feedrate High Feedrate limit
Low Feedrate Low Feedrate limit
Load Imbalance Load Cell A/D channels imbalance
Zero Track Fail Zero Tracking has stepped out of range
Belt Slippage The tacho ratio Tac2/Tac1 is outside of its limits
Inferred Load Inferred load used
Inferred Speed Inferred speed used
No Belt Motion No belt motion was detected. Note, this output always active.
Cal in Progress A Calibration procedure is active
HeartBeat Application integrity toggle output
Parameter Fail Parameter load at start-up failed or save after change failed
Port 0 Timeout Communications time out, port 0 (USB)
Port 1 Timeout Communications time out, port 1 (UART0)
Port 2 Timeout Communications time out, port 0 (UART1)
Expansion Board related. Present when one or more expansion I/O boards are
enabled (see Main Menu > Advanced Setup > Configuration ).
XIO 1 Failure Expansion board 1 is enabled and is failing
XIO 2 Failure Expansion board 2 is enabled and is failing
Analog I/O expansion board is enabled and is and is failing.
XADC Failure
(Can be either of two Expansion Analog Cards)
XDC Failure Communication board is enabled and is failing
Page 100 of 104

Feeder related outputs. Present when “Feeder Control” is enabled (see Main Menu
> Advanced Setup > Configuration > Feeder Control).
High Deviation Feedrate is higher than max deviation limit
Low Deviation Feedrate is lower than max deviation limit
High Setpoint High Setpoint limit
Low Setpoint Low Setpoint limit
High PID CV PID controller output at high limit
Low PID CV PID controller output at low limit
Good Feedrate Good feedrate maintained
Belt Motor Belt to go any direction
Belt Forward Belt to go forward direction
Belt Reverse Belt to go reverse direction
Auto State Feeder state is auto
Manual State Feeder state is manual
Rem Ana Setpnt Remote Setpoint
In Control Ready/runperm/no cal proc
Belt Drive Fail Drive fault or not ready when required
Belt Index related. Present when “Belt Index” is enabled (see Main Menu >
Advanced Setup > Configuration > Belt Index).
Missed Belt Idx Belt Position index not present when expected
Drag Chain related. Present when “Drag Chain” is enabled (see Main Menu >
Advanced Setup > Configuration > Drag Chain).
Chain Motor Drag Chain to go any direction
Chain Forward Drag Chain to go forward direction
Chain Reverse Drag Chain to go reverse direction
Drag Chain Jam Drag Chain zero speed switch time expired
Discharge Pluggage Switch related. Present when “Discharge Monitor” is enabled

(see Main Menu > Advanced Setup > Configuration > Discharge Monitor).
Disch Plugged On when a discharge plugged condition has existed longer then
the delay setting (see Main Menu > Advanced Setup > Feeder
Peripherals > Discharge Monitor > Numeric Data ). Feeder must
be in Auto and must be running.
Material on Belt Switch related. Present when “Material on Belt SW” is enabled
(see Main Menu > Advanced Setup > Configuration > Material on Belt SW).
No Material On when a no material on belt condition has existed longer then
the delay setting (see Main Menu > Advanced Setup > Feeder
Peripherals > Material on Belt SW > Numeric Data ). Feeder
must be in Auto and must be running.
Infeed Flow Monitor related. Present when “Infeed Flow Monitor” is enabled (see
Main Menu > Advanced Setup > Configuration > Infeed Flow Monitor).
On when a loss of flow condition has existed longer then the
delay setting (see Main Menu > Advanced Setup > Feeder
Peripherals > Infeed Flow Monitor > Numeric Data ). Feeder
No Flow must be in Auto and must be running.
On when a calculated loss of material is greater than the
Empty Pipe allowable loss (see Main Menu > Advanced Setup > Feeder
Page 101 of 104

Peripherals > Infeed Flow Monitor > Numeric Data ). Feeder
must be in Auto and must be running.
When a loss of flow is detected (logical input “Low Infeed Flow”
turns on, an internal totalizer is started. If this totalizer exceeds
the set amount, the logical output “Empty Pipe” is set.
Drive Check related. Present when “Drive Feedback” is enabled (see Main Menu >
Advanced Setup > Configuration > Drive Feedback).
Belt Drive Ovld Drive Overload. Time delayed version of “Belt Drv Overld” input.
Time set by “Overld On Delay” parameter in Feeder Peripherals
menu.
Belt Drive NAS Drive not at speed when required. Time allowed for drive to
come up to speed set by “Not at Spd On Delay” parameter in
Feeder Peripherals menu.
Page 102 of 104

Appendix C
GCM Connections
Consult your Merrick wiring diagram for additional connection information, or contact the
Merrick Customer Support department for assistance.
Page 103 of 104

Appendix D
GCM Specifications
Environmental
Maximum ambient temperature: 50°C (122°F)
Minimum ambient temperature: -10°C (14°F)
Power
Supply voltage: 24 VDC +/- 1V
Power consumption: 8W nominal, 12W maximum
Power dissipation: 5W nominal, 10W maximum
Loadcell Inputs (2)

Excitation voltage: 5 VDC
Excitation current: 300mA (max)
Tachos (2)
Supply voltage: 5 VDC
Supply current: 400mA, maximum (total)
Analog Inputs
Input impedance (Current input): 200 ohms
Input impedance (Voltage input): 100Kohms
Analog Outputs (2)

4-20mA, 1000 ohm maximum
Digital Inputs (4)

Note: Standard GCM digital inputs require external voltage sourcing, jumper selectable for
24VDC, 120 VAC, or 240 VAC.
Input impedance at 24 VDC: 7.5 KΩ

Input impedance at 120 VAC: 64 KΩ
Input impedance at 240 VAC: 120 KΩ
Digital Outputs (4)

Note : Standard GCM digital outputs are relays with form “C” contacts (1 NO, 1 NC).
Contact ratings: 5A, 250 VAC; 5A, 30 VDC
EMT (external mechanical totalizer)

Contact ratings: 120mA, 240 VAC; 120mA, 24 VDC
Page 104 of 104

PROGRAMMING DATA SHEETS
GENETIX PROGRAMMING PARAMETERS
Machine S/N 475EZ-GNX-32045 Propar by Ed B

Sales Order No. M13500-000 Date 4/1/2012
User name SIGSIG LTDA
Buyer Name SIGISG LTDA
Feeder Designation 475EZ-200#
Software Version GCM 1.6.10 (Belt) GCM Rev/Batch/Code

LUI 1.6.8 LUI Rev/Batch/Code
Entered by Revised by
Date Date
Display Settings
Final
Upper Feedrate
Lower Sub-Total
Damping
Feedrate 2
Speed 2
Load 2
Basic Settings
Speed Load Tot Len Rate Weight
Units m/s kg/m t m t/h kg
Decimal Points Final Design Capacities Final

Weight/Load 2 Design Load 32.81 kg/m
Total 1 Design Feedrate 300.0 t/h
Length 3 Design Speed 2.540 m/s
Feedrate 1
Speed 3
Advanced Settings
Feeder Control Settings Final

Control Belt Reversible
Source AutoStart
Method RP Start/Stop in Local
Jog OK
Lock Source
Lock Method
Clamp SetP to Limits
Clamp Drv Dem (CV) to Limits
Fast Start
Auto/Man w/o Pword
Numeric Data Belt Reverse Delay s
Genetix Belt Propar

Template Rev 5 Page 1 of 9
Limits
Feedrate Final Setpoint Final
High Feedrate 330.0 t/h Max Rate Setpoint t/h
Low Feedrate 30.0 t/h Min Rate Setpoint t/h
High Feedrate Delay 10 s Max Rate SP Delay s
Low Feedrate Delay 10 s Min Rate SP Delay s
High Abs Deviation t/h Max Speed Setpoint m/s
Low Abs Deviation t/h Min Speed Setpoint m/s
High Rel deviation % Max Speed SP Delay s
Low Rel Deviation % Min Speed SP Delay s
High Deviation Delay s
Low Deviation Delay s Belt Speed Demand Final
Max Spd Demand %
Belt Load Final Min Spd Demand %
High Belt Load 36.09 kg/m Max Spd Dem Delay s
Low Belt Load 9.84 kg/m Min Spd Dem Delay s
High Belt Load Delay 10 s
Low Belt Load Delay 10 s
Belt Speed Final

High Belt Speed 2.794 m/s
Low Belt Speed 0.000 m/s
High Belt Speed Delay 10 s
Low Belt Speed Delay 10 s
Load Cells Final Tachos Final

Function First Only Function First Only
Settings Tacho 1
Inf Load AutoUpdate N Type F-25/Mag
Numeric Data Direction None
Inferred Load 32.81 kg/m Tacho 2
LC to Headpulley m Type
Difference Time 5 s Direction
Max Difference 10 %
Scale Factor 1 28861 Numeric Data
Zero Load 1 25.67 kg/m Zero Timeout 5 s
Scale Factor 2 Inferred Speed 2.540 m/s
Zero Load 2 kg/m Speed Factor %
Max Allowed Ratio Diff %
ZSpd Distance m
Genetix Belt Propar

Process Control Analog Input 1 Final
PID Final Function
Proportional Gain %
Integral 1/s Numeric Data
Derivative s High mA
Full Scale t/h
Accel/Decel Low mA
Max Accel %/s Zero t/h
Max Decel %/s
Analog Input Network Final
Filters Final Function
Speed 2
Load 3 Numeric Data
Setpoint High mA
PID Rate Full Scale
Low mA
Zero
Analog Output 1 Final Analog Input 2 Final

Function Feedrate Function
Numeric Data Numeric Data

High mA 20 High mA
Full Scale 300.0001 t/h Full Scale
Low mA 4 Low mA
Zero 0 t/h Zero
Analog Output 2 Final

Function Feedrate
Totalizer Final
Numeric Data Totalizer Cutoff -0.2 kg/m
High mA 20 Weight per EMT Pulse 100 kg
Full Scale 300.0001 t/h EMT Pulse Length 0.05 s
Low mA 4
Zero 0 t/h
Analog Output 3 Final See Last sheet for Communications settings

Function
Numeric Data
High mA
Full Scale
Low mA
Zero
Analog Output 4 Final

Function
Numeric Data
High mA
Full Scale
Low mA
Zero
Genetix Belt Propar

Digital I/O
Logical Inputs Physical Input Wrn/Flt

Belt is Running
Total Enabled
Subtot Enabled
EMT Enabled
Reset Faults
Reset Warnings
Reset Subtotal
Spd Pulse Block
Permit Calibr
Diverter Valve
Register Access
Zero Tracking
External Fault
Goto Volumetric
Run Permission
Netw. Run Perm
Min Feedrate
Feeder Block
Local Lockout n/a
Force Network
Belt Drv Fail
Belt Index Sw
Drag Chain ZSS
Chn Mot Overld
Disch Monitor
Material On Blt
Low Infeed Flow
IsoVlv Not Open n/a
IsoVlv Not Clsd n/a
Belt Drive AtSp
Belt Drv Overld
Belt Offs Left
Belt Offs Right
Belt Err Left
Belt Err Right
InfVlv Not Open n/a
InfVlv Not Clsd n/a
Genetix Belt Propar

Physical Inputs Force Invert
Always Off
Always On
Token Inserted
XDC Present
GCM Input 1
GCM Input 2
GCM Input 3
GCM Input 4
Note: The following Physical IO only appear if the Exp IO Bd 1 is configured

Exp 1 Input 1
Exp 1 Input 2
Exp 1 Input 3
Exp 1 Input 4
Exp 1 Input 5
Exp 1 Input 6
Exp 1 Input 7
Exp 1 Input 8
Exp 1 Input 9
Exp 1 Input 10
Exp 1 Input 11
Exp 1 Input 12
Exp 1 Input 13
Exp 1 Input 14
Exp 1 Input 15
Exp 1 Input 16
Genetix Belt Propar

Digital I/O (cont'd)
Physical Outputs Logical Output Force Invert

Green LED Heartbeat
Orange LED Warning
Red LED Fault
GCM Output 1
GCM Output 2
GCM Output 3
GCM Output 4
Note: The following Physical IO only appear if the Exp IO Bd 1 is configured

Exp 1 Output 1
Exp 1 Output 2
Exp 1 Output 3
Exp 1 Output 4
Exp 1 Output 5
Exp 1 Output 6
Exp 1 Output 7
Exp 1 Output 8
Exp 1 Output 9
Exp 1 Output 10
Exp 1 Output 11
Exp 1 Output 12
Exp 1 Output 13
Exp 1 Output 14
Exp 1 Output 15
Exp 1 Output 16
Logical Output Warn/Flt

Warning
Fault
Running
Feeding
Ready
LoadCell 1 Ovl Warning
LoadCell 1 Undl Warning
LoadCell 2 Ovl
LoadCell 2 Undl
LC Ch1 Failure Warning
LC Ch2 Failure
High Belt Load Warning
Low Belt Load Warning
High Belt Speed Warning
Low Belt Speed Warning
High Feedrate Warning
Low Feedrate Warning
Load Imbalance
Zero Track Fail
Belt Slippage
Inferred Load
Inferred Speed
No Belt Motion
Cal in Progress
Genetix Belt Propar

HeartBeat
Parameter Fail Warning
Port 0 Timeout
Port 1 Timeout
Port 2 Timeout
XIO 1 Failure
XIO 2 Failure
XADC Failure
XDC Failure
High Deviation
Low Deviation
High Setpoint
Low Setpoint
High PID CV
Low PID CV
Good Feedrate
Belt Motor
Belt Forward
Belt Reverse
Auto State
Manual State
Rem Ana Setpnt
In Control
Belt Drive Fail
Missed Belt Idx
Chain Motor
Chain Forward
Chain Reverse
Drag Chain Jam
Disch Plugged
No Material
No Flow
Empty Pipe
Close Iso Valve n/a
Open Iso Valve n/a
Iso Valve Fail n/a
Belt Drive Ovld
Belt Drive NAS
Genetix Belt Propar

Calibration Numeric Data Feeder Peripherals
Final Note: Settings below will not appear unless the specific
Belt Length 610.877 m peripheral is configured
Pulses/Belt Rev 1 11962 Drive Feedback
Pulses/Belt Rev 2 Settings Final
Test Revs 2 Overld Connected
Weigh Span 1.219 m AtSpd Connected
Test Weight 27.22 kg Numeric Data
Test Chain kg/m Overld On Delay s
Zero Slots Not at Spd On Delay s
Ecal LC 1 Value 0.8818 mV/V
Ecal LC 2 Value mV/V
Material On Belt Sw
Settings Final
Configuration Switches Blocking
Jog OK While Blocking
Feeder Control N Numeric Data
Load Cell 1 Y MOB Off Delay s
Load Cell 2 N
Tacho 1 Y
Tacho 2 N Discharge Monitor
Zero Tracking N Settings Final
Belt Tracking Sws N Blocking
Material on Belt Sw N Numeric Data
Discharge Monitor N Disch On Delay s
Drag Chain N
Belt Index N Drag Chain
Zero Memory N Settings Final
DNA Key N Link with Feeder Run
Expansion IO Bd 1 N Timed (N = Cont)
Expansion IO Bd 2 N Reversible
Network IO N Has Zero Spd Sw
Programmable IO N Numeric Data
Expansion Ana Card 1 N On Time s
Expansion Ana Card 2 N Off Time s
Expansion Comm Bd N Reverse Delay s
Use Head Load N ZSS Off Delay s
Disable Outs in Cal N
Infeed Flow Monitor N Infeed Flow Monitor
Drive Feedback N Numeric Data
Inclinometer N Loss of Flow Delay s
Old XIO N Loss of Flow Weight kg
Integrity Check N
Hard Lockout N
Genetix Belt Propar

Communications
GCM Port 0 (USB) Final
Protocol Monitor
GCM Port 1 Final Numeric Data Final

Protocol UI Unit Address 1
Baudrate 115200 Start Code
Parity N End Code
Data bits 8 Comm Timeout 20.0
Stop bits 1 Comm Data Mapping
Exp Comm Bd Routing N Write Protection
Byte(Word) Order
Int/Frac FP
Register Tag 1
Register Tag 2
Register Tag 3
Register Tag 4
Register Tag 5
Use LRC
GCM Port 2 Final Numeric Data Final

Protocol ScaleNet Unit Address 1
Baudrate 115200 Start Code
Parity N End Code
Data bits 8 Comm Timeout
Stop bits 1 Comm Data Mapping
Write Protection
Byte(Word) Order
Int/Frac FP
Register Tag 1
Register Tag 2
Register Tag 3
Register Tag 4
Register Tag 5
Use LRC
Genetix Belt Propar


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Operation & Maintenance Manual

Model 475EZ Belt Scale

SigSig LTDA (Tecnagent Chile)

Customer Purchase Order Number: 12-MERR-01

Merrick Industries, Inc.

SECTION 1 CONTACT AND SPARE PARTS INFORMATION

SECTION 2 BELT SCALE

SECTION 4 REFERENCE INFORMATION

In House Customer Technical Support – Willie Allen

Field Service Technicians

Ken Allen Marvin Allen

Willie Allen Ron Deleon

Chuck Hall Larry Helsene

John Ingalls Walter Kukyciak

John Roberts Randy Schoolcraft

Daryl Strickland Tom Gongloff

Spare Parts Sales Department

Customer Support Assistance

Customer: SIGSIG LTDA (Tecnagent Chile)

PART DESCRIPTION PART NUMBER QUANTITY LEADTIME

Genetix GCM Module M22633-1 1 6 Weeks

MODEL 475EZ BELT SCALE

MERRICK INDUSTRIES, INC.

1. OBSERVE ALL STANDARD PRECAUTIONS, WHICH PERTAIN TO MOVING MACHINERY.

2. OBSERVE ALL STANDARD PRECAUTIONS, WHICH PERTAIN TO ELECTRIC DRIVES AND

3. PAY PARTICULAR ATTENTION TO THE SPECIAL "CAUTIONS" AND "NOTES" WHICH

1. When working on Merrick equipment (whether for installation, cleaning, maintenance or

4. Never impair the function of a fuse.

5. Never undertake electrical work when the floor is wet or flooded.

IF PERSONNEL ARE IN DOUBT ABOUT A PROCEDURE, CALL THE MERRICK SERVICE

(NOTE SEPARATE INSTRUCTIONS FOR MECHANICAL AND ELECTRICAL)

MECHANICAL EQUIPMENT - STORED ON RECEIPT FROM FACTORY:

1. Grease-lubricated Gear Boxes: No special requirements.

5. Slacken the Belt fully.

6. Install adequate amounts of desiccant in Feeders. A minimum of ten pounds is

7. Remove all pressure from belt Scraper Blades (If furnished).

8. Locate the Suspension in the raised (shipping) position.

1. Change oil in Gear Boxes yearly.

MECHANICAL EQUIPMENT - STORAGE FOLLOWING USE:

A. Empty the machine completely of conveyed material.

B. Oil-lubricated Gear Boxes:

1. Drain the rust-preventative or operating oil completely.

C. Reinstall and re-tension the Conveyor Belt.

D. Re-grease all bearings.

F. Reposition belt scrapers.

ELECTRICAL EQUIPMENT - STORED ON RECEIPT FROM FACTORY:

B. Storage Longer Than Six Months:

1. In a heated warehouse with temperatures ABOVE FREEZING.

a. All equipment must be kept dry. Vaporizing Corrosion-Inhibitors MUST be used

2. In a warehouse with temperatures BELOW FREEZING.

3. Outside Storage IS NOT RECOMMENDED. If it is unavoidable, then damage from

A. Clean all equipment and enclosures thoroughly inside and out.

D. Keep panels dry with anti-condensation heaters if possible.

ELECTRICAL EQUIPMENT - OPERATION AFTER STORAGE:

B. Remove all packing and protective materials.

BELT LOAD MEASUREMENT

Belt Scale with Single Weigh Unit

Belt Scale with Multiple Weigh Units

Scale Frame Conveyor Idler Scale Frame