d2101639sg Marposs

SOFTWARE MANUAL
Version 1.6.39
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INDEX
1 INTRODUCTION............................................................................ Page 7

1.1 Operating limits.................................................................. Page 7
1.2 Command bar..................................................................... Page 7
1.3 User interface................................................................... Page 8
1.4 Menu................................................................................. Page 9
1.5 The virtual keyboards......................................................... Page 11
1.5.1 Japanese keyboard..................................................... Page 12
1.5.2 Chinese keyboard...................................................... Page 13
1.5.3 Korean keyboard....................................................... Page 14
1.6 Operator access................................................................ Page 15
1.7 Filtering utilities................................................................ Page 17
2 INITIAL SETTINGS......................................................................... Page 19
2.1 Multiple transducer instance............................................. Page 21
2.2 Basic devices...................................................................... Page 22
2.3 Devices with additional parameters...................................... Page 24
2.3.1 M1Wave, M2Wave, I-Wave e MultiWave..................... Page 24
2.3.2 I-Wave2..................................................................... Page 25
2.3.3 QDT MultiChannel................................................... Page 27
2.3.3.1 How to pair a QDT MultiChannel............. Page 27
2.3.3.2 How to set the command from central button. Page 28
2.3.4 Easy Box U4P........................................................... Page 29
2.3.5 Easy Box U4E.......................................................... Page 29
2.3.6 Easy Box U4H.......................................................... Page 29
2.3.7 DigiCrown 232......................................................... Page 30
2.3.8 DigiCrown USB and ETH......................................... Page 30
2.3.8.1 How to add modules to a USB network.... Page 31
2.3.8.2 How to replace the USB interface........... Page 31
2.3.8.3 How to replace LVDT probes................... Page 32
2.3.8.4 How to replace a DigiCrown module........ Page 33
2.3.8.5 How to perform the DigiCrown addressing.... Page 34
2.3.9 Serial Gauge............................................................ Page 34
2.3.9.1 Easy Box U4S.......................................... Page 34
2.3.10 Solartron Orbit3................................................... Page 35
2.3.11 U2-IO..................................................................... Page 36
2.4 Transducer settings.......................................................... Page 36
2.4.1 Parameters for Easy Box U4E.................................. Page 37
2.4.2 Parameters for Easy Box U4H................................. Page 41
2.4.3 Default measuring direction...................................... Page 42
2.5 Input reading...................................................................... Page 42
2.6 DigiCrown probe replacement function.............................. Page 43
2.7 I/O lines map................................................................... Page 44
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3 PROGRAMMING......................................................................... Page 45
3.1 Master set...................................................................... Page 45
3.1.1 Miscellaneous TAB........................................... Page 45
3.1.2 Dimensions TAB................................................. Page 46
3.1.3 Serial number TAB............................................. Page 49
3.1.4 Zero expiration.................................................. Page 50
3.2 Part program definition................................................... Page 51
3.2.2 Tracing data request TAB.................................. Page 52
3.2.3 Step definition................................................... Page 53
3.2.4 Defining the characteristic................................ Page 54
3.2.4.1 Miscellaneous TAB.............................. Page 54
3.2.4.2 Using the formula................................ Page 57
3.2.4.3 Video TAB............................................ Page 59
3.2.4.4 Zeroing parameters TAB....................... Page 60
3.2.4.5 Classification TAB............................... Page 62
3.2.4.6 Graph and fi lters TAB......................... Page 63
3.2.5 Part program structure.................................... Page 64
4 BATCHES.................................................................................... Page 65
4.1 Active batches menu......................................................... Page 65
4.2 All batches menu............................................................. Page 66
4.3 Gage Capability menu....................................................... Page 67
4.4 Batch for measuring cycle............................................... Page 68
4.4.2 Duration TAB.................................................... Page 70
4.5 Batch for Gage Capability studies.................................... Page 71
4.5.2 Operators TAB................................................. Page 72
5 MEASUREMENT PAGE.............................................................. Page 73
5.1 Zeroing .......................................................................... Page 75
5.2 Histogram....................................................................... Page 76
5.3 Control chart................................................................ Page 77
5.3.1 Control limits page ........................................... Page 79
5.4 Single value chart........................................................... Page 80
5.5 Tracing data request....................................................... Page 81
5.5.1 Control chart................................................... Page 82
5.5.2 Single value chart.............................................. Page 83
5.5.3 All other pages................................................. Page 83
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5.6 Capability tests............................................................... Page 84
5.6.1 Gage capability................................................... Page 84
5.6.2 R&R................................................................. Page 85
5.6.3 Summary............................................................ Page 86
5.6.4 Histogram.......................................................... Page 87
5.6.5 Single Value Chart............................................ Page 88
6 GLOBAL SETUP.......................................................................... Page 91
6.1 Options 1 TAB................................................................. Page 91
6.2 Transducers TAB............................................................ Page 92
6.3 Shifts TAB...................................................................... Page 93
6.4 Statistics.......................................................................... Page 94
6.4.1 Statistic TAB..................................................... Page 94
6.4.2 Alarm TAB........................................................ Page 95
6.4.3 Gauge Capability TAB......................................... Page 96
6.4.4 X/R/S limits TAB................................................ Page 97
6.5 Video TAB....................................................................... Page 98
6.6 Data export TAB............................................................. Page 99
6.7 Default batch options TAB............................................... Page 101
7 PROTOCOLS............................................................................... Page 103
7.1 Personal protocols......................................................... Page 104
7.2 Data output protocols.................................................... Page 108
7.2.1 Optional handshaking........................................ Page 108
7.3 Standard protocol N°1 (Dop-std01)............................... Page 109
8 TRACING DATA.......................................................................... Page 117
8.1 Exporting Q-DAS traceability keys.................................. Page 118
8.2 Customizing the data.......................,................................ Page 120
8.3 The user key.................................................................... Page 121
9 MERLIN DIGITAL SIGNALS MANAGEMENT............................... Page 123
9.1 Available layouts............................................................. Page 128
9.2 I/O corrispondance table................................................. Page 144
10 DATABASE TOOL....................................................................... Page 147
10.1 Backup & Restore .......................................................... Page 147
10.1.1 Backup............................................................... Page 147
10.1.2 Restore.............................................................. Page 148
10.1.2.1 Restore from external file..................... Page 148
10.1.2.2 Restore from restore point................... Page 149
10.1.2.3 Reset all.............................................. Page 149
10.2 Export Part Program...................................................... Page 150
10.3 Import Part Program....................................................... Page 151
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APPENDIX
Statistical analysis........................................................................ Page 156
X/R/S limits.................................................................................... Page 164
Changing the Merlin date/time....................................................... Page 169
Calibrating the touch-screen......................................................... Page 170
Creating a Merlin-to-PC ethernet link.......................................... Page 172
Message management following alarms.......................................... Page 176
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1 INTRODUCTION
Designed for simple measuring applications up to 16 measurements and basic
statistics analysis, Merlin stands for an innovative concept of embedded gage
computer using the same technologies created for portable electronics, for data
collection from traditional or wireless measuring devices.
The Merlin software is based on Microsoft® .Net® technology and uses the
Microsoft® Windows® CE operating system.
The simple, user-friendly touch-screen user interface can be used to program and
perform measurements without the need for additional input devices.
1.1 Operating limits

Maximum number of devices 30
Maximum number of characteristics per part program 16(*)
Maximum number of part programs 1000
Maximum number of steps per part program 16
Maximum number of batches 500
Maximum number of classes 32
(*) This number is shared between the OK/NG and the auxiliary characteristic
1.2 Command bar

A command bar containing a series of icons corresponding to the selected
menu is always displayed at the bottom of the screen, each icon includes a
brief description. Moving the mouse over any icon to display a more detailed
description of the command associated with the icon in the centre of the bar.
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1.3 User interface
The user interface is a touch-screen, so it is necessary to touch the icons and
fields in order to interact with the Merlin software, alternatively, it is also possible
to connect a USB type mouse.
Tap this icon to select the main menu from which it is possible to
access all the software functions at any moment.
This icon appears in all the programming windows when it is

necessary to confirm that the user wants to save the data.
This icon appears in all the programming windows and permits the
user to exit without saving the modified data.
Permits the user to confirm data entered via the virtual keyboard.
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1.4 Menu
The menu can be used to access all the software functions.
Change operator (see paragraph 1.6).
Access configuration phase.
Tap this icon to access the sub-menu where it is possible to

change the Language. Available languages: English, Italian,
German, French, Spanish, Portuguese, Dutch, Swedish,
Polish, Hungarian, Romanian, Czech, Turkish, Japanese,
Chinese, Korean and Russian.
Tap this icon to access the Measurement devices map page

where it is possible to insert additional devices (see chapter
2).
Tap this icon to access the I/O Lines map page that provides
a rapid overview of all the I/O signals associated with the
connected devices (see paragraph 2.7).
Tap this icon to access the List of serial input protocols
page that lists all the standard protocols handled by Merlin
and enables the user to create customised protocols (see
chapter 7).
If the menu contains more than five icons this command

can be used to scroll through the subsequent icons.
Tap this icon to access the Global setup page (see chapter
6).
Tap this icon to access the Tracing data menu (see chapter
8).
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Tap this icon to access to the software that enables the
user to manage Backup and Restore features (see Chapter
10).
Tap this icon to display Merlin version, the allocated memo-

ry and the free space remaining on the disk.
Tap this icon to update the software version.
Tap this icon to exit the measuring software.
Access programming phase (see chapter 3).
Tap this icon to access the Part program list (see para-
graph 3.2).
Tap this icon to access the Master set list (see paragraph
3.1).
Access Batch creation phase (see chapter 4).
Tap this icon to access the Active batches menu (See para-
graph 4.1).
Tap this icon to access the All Batches menu (See para-
graph 4.2).
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Tap this icon to access the Gage Capability menu (See para-
graph 4.3).
Access Measurement page (see chapter 5).
1.5 The virtual keyboards

The operator can enter data by using the virtual keyboards that vary in their format
depending on the language and type of data to be entered or modified.
Alphanumerical Enter icon to confirm the data that have been entered.
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If the keyboard refers to a filterable list, it will be possible to make a selection from
the list itself (see chapter 1.7).
NOTE: it is also possible to connect a USB keyboard to Merlin, or a

laser scanner (for reading barcodes or datamatrix) if it is configured in
wedge emulation (for example Honeywell 6300 Series DPM).
1.5.1 Japanese keyboard (Hiragana or Katakana)

NOTE: available only on Merlin for Japanese language (code
830MECCD00).
When the operator selects the language from the general menu, the software
opens the corresponding keyboard and handles all the communications with the
IME and selects the appropriate O.S. settings for the specific input language.
In the case of Japanese, it is possible to select between 3 different keyboard
types: Hiragana, Katakana, Romanji, in additional to the traditional versions.
When the operator taps a button, the corresponding character is displayed in the
text box at the top of the page.
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The EXIT key is replaced with a character selector key and the Enter key is replaced
by the OK button, which is used to confirm the character selected from the list.
Once the operator has finished entering the string, the standard buttons reappear
and it is possible to confirm the input by tapping the Enter button.
1.5.2 Chinese keyboard (Pinyin)

NOTE: available only on Merlin for Chinese language (code
830MEFCD00).
To enter text in Chinese, select the last keyboard on the list, type the desired
characters and tap Space/Ok to display the list of candidates. The green arrows
located next to the text box, can be used to scroll left and/or right through the
list. Once the desired letter has been entered, click ‘Space/Ok’ to confirm the
selection, click again to close the IME and return to the standard keyboard. Tap
the Enter button to confirm the data and return to the initial form.
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1.5.3 Korean (Hangul) keyboard
NOTE: available only on Merlin for Korean language (code
830MEECD00).
As for the default keyboard, the operator can enter data by using the virtual
keyboards that vary in their format depending on the language and type of data
to be entered or modified. Alphanumerical Enter icon to confirm the data that
have been entered.
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1.6 Operator access
The operator access function can be used to control the actions that the various
operators are permitted to carry out, in order to safeguard the programming and
configuration operations. Dedicated function keys permit the user to modify the
password and provide direct access to the operator management phase.
NOTE: to create or modify the programmed users, see the paragraph

8.3.
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As default, at the startup, Merlin has set the Admin user but there are 3 different
operators available: User, Prog and Admin. Below are pointed out the restrictions
related to any of them.
Default operators
Parameter
1 - User 2 - Prog 3 - Admin
Device list Read Read/Write Read/Write
I/O list Read Read/Write Read/Write
Setup profile options
Global setup Disable Read Read/Write

System information Yes Yes Yes
Language choice No Yes Yes
Tracing data settings No No Yes
Protocols settings No Yes Yes
Backup/Restore None None Backup/Restore
Program list Read Read/Write Read/Write
Program profile options
Master Set list Read Read/Write Read/Write

Initial zeroing No Yes Yes
XR control limits editing Yes Yes Yes
Periodic zeroing Yes Yes Yes
Measure delete Yes Yes Yes
Exit to Win No Yes Yes
All batch list Yes Yes Yes
Batch change Yes Yes Yes
Batch selection Yes Yes Yes
Batch profile options
Batch edit Yes Yes Yes

Batch creation Yes Yes Yes
Batch close Yes Yes Yes
Batch export Yes Yes Yes
Batch activation Yes Yes Yes
Batch delete Yes Yes Yes
Measure allowed on
No Yes Yes
part program
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1.7 Filtering utilities
Filtering utilities have been added in order to help the operator facing wide lists of
Part Programs or Batches.
To filter, tap on the list descriptor,
and type the filter key (i.e. 40F).
Now, only the Part Programs whose name contains the string “40F” will be shown
and the filter criterion will appear in brackets.
By clicking on the sensible line below the insert box
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the complete list of the selectable items will appear:
It is also possible to have a combined filter tapping on different columns, for

instance, selecting the string “M-“ in the “Description” column you will have.
To cancel the filtering string, tap on the relevant list descriptor.
NOTE: Part Programs list can be filtered by “Name” or “Description”;

Batches lists can be filtered by “I/O”, “Batch” or “Part Program”.
Key filter looks for the string in any position of the field and it is not case
sensitive.
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2 INITIAL SETTINGS
When a new and unprogrammed Merlin unit is switched on, the Measurement
devices map page is displayed, initially this page is empty.
The devices may be set-up either by configuring them manually (carry out the 4
steps listed below) or by tapping the Repeat P&P button so that Merlin recognises
them automatically. When the operator taps this button, Merlin detects all the
devices connected via USB.
• Select Add a device from the command bar.

• The Device Settings window appears, select the type of device connected to
Merlin from the list that appears tapping the Device Type field.
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• Enter a name in order to identify the device in the Device name field.
• Tap Ok to save the data.
As new devices are entered the Measurement devices map begins to fill up, displaying
a line for every input available on each device.
It is possible to have different statuses for the transducers.

The current status is highlighted by the color of the flag of each transducer:
Tapping on one specific transducer (in the Transducer settings column), an icon
will appear to make it possible changing the transducer status.
The available statuses are:
Normal transducer behavior.

Transducer excluded with no effect on the Part Program Status. All the
characteristics recalling this transducer will not be executed and the Part
status will be calculated excluding these characteristics.
Transducer excluded forcing scrap status for Part Program. All the characteristics
recalling this transducer will not be executed and marked as scrap and the Part
status will be calculated including these characteristics, thus it will always be scrap.
The characteristics recalling this transducer will not stop the measure cycle (i.e. with
the “Measure abnormally interrupted” message) in case it has an invalid status
and will be set to a neutral status. In that case, the Part status will be undefined
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When setting up Easy Box type devices, tap the “Repeat P&P” button to set-up
all the connected Easy Boxes. Once the program has added all the connected
devices to the configuration, it is necessary to configure all the correct transducers
manually; this completes the map, which is displayed as a tree with a line
corresponding to every available input for each device.
Key: Each transducer is identified by a three figure value, for example,

T213. The first figure identifies the device, the second the channel and the
third the instance. Hence, the transducer identified as T213 corresponds
to the third instance of the first transducer on the second device.
NOTE: If a DigiCrown network with more than 9 transducers is selected,
it may be necessary to use 4 figures to identify the transducers (e.g.
T1121). In this case, the middle two figures indicate that it is the twelfth
transducer on the network.
NOTE: if more than one device of the same type is connected we
suggest to make a note of the order in which they were connected; this is
because, if it is necessary to disconnect them they must be reconnected
in the same order otherwise Merlin will fail to recognize them.
NOTE: If it is necessary to modify a device type that has already been
configured, the system checks that the new type has the same number
of inputs, and hence that it is compatible with the previous type. This is
especially useful when replacing a faulty device.
2.1 Multiple transducer instance

Defining multiple instances for the same transducer (via the General Setup menu)
makes it possible to use different transducers in the measurement formulas,
provided the same device and input are used. In fact, the transducers connected
to a given device may have differing operating ranges, sensitivity etc. The different
instances are identified by the third character in the Transducer Name field, (e.g.
T121 and T122 are two instances of the second channel on the first device).
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If the Multiple transducer instance option is activated in the set-up, the Device map
displays an additional 3 columns that include all the different instances that may
be configured for the transducers. To every instance, it is possible to assign a
customized name on the global setup (for instance the name of the fixture where
the sensors are installed), in a way to make more readable the list.
The Del and Transducer settings commands, which are available when one of the
transducer columns is selected, can be used to delete and edit an instance.
It is possible to leave the cells empty, if the channel is not exploited for a specific
instance. It is possible to manage up to 4 instances for each transducer.
2.2 Basic devices

The following is a list of devices that can be connected to Merlin.
Whatever type of device is selected, it is necessary to enter a name in the field
• M1 Wave: Marposs Bluetooth® buffers with electrical capsules.

• M2 Wave: wireless electronic manual snap gauge.
NOTE: M2 WAVE has to be inserted as MultiWave.
• I-Wave: Marposs Bluetooth® buffers with mechanical capsules.

• I-Wave2: wireless handle with integrated 1.8” color screen for mechanical
gauge heads.
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• MultiWave: Marposs multisection buffers with Bluetooth® interface. Manages
up to 7 measurement channels, excluding the optional heat sensor (i.e. a
maximum of 6 channels if the system is also fitted with the heat sensor).
• QDT MultiChannel: up to 8 Quick Digit BT.
• Easy Box U1AIR: 1 pneumatic input.
• Easy Box U4H: for Marposs standard half-bridge/HBT transducers.
• Easy Box U4D: Mitutoyo Digimatic compatible.
• Easy Box U4T: half-bridge/HBT compatible with Tesa amplifiers.
NOTE: regarding only the Easy Box U4T, in case of Tesa HBT transducer
with the range of +/- 2,5 mm, the range exploited will be +/- 2 mm.
• Easy Box U4F: for Marposs standard full-bridge/LVDT transducers.

• Easy Box U8IO: for managing up to 8 digital Input/Output.
• Easy Box U4P: push button for remote control and data acquisition.
• Easy Box U4M: “MG” 4 HBT transducers interface.
• Easy Box U4TP_E: for type-E thermocouples.
• Easy Box U4TP_J: for type-J thermocouples.
• Easy Box U4TP_K: for type-K thermocouples.
• Easy Box U4TE: for “Trac” tranducers.
• Easy Box U4E: 3 inputs for incremental transducers.
• Easy Box U4F-HR: for Marposs standard full-bridge/LVDT transducers with
sub-micron resolution.
• DigiCrown 232, USB or ETH: Marposs network for connecting various
devices.
• Serial gauge: devices equipped with RS232 interface. Programming this
device is also possible to manage the Easy Box U4S.
• Orbit ETH, USB: for managing up to 150 Orbit3 Digital Gauging Probe
• modules (Digital Displacement, Mini probes, Lever probes, Block gauges
and Flexures) and Digital Input Output Modules (the layouts are the same as
DigiCrown).
• U1-Probe: for Marposs Red Crown 2 USB.
• U1-Encoder: 1 input for incremental transducers.
• U2-IO: for managing up to 2 digital Input/Output.
• U1-Footswitch: for managing USB Footswitch.
NOTE: if it is necessary to connect more than 5 Easy Boxes to the Merlin,

use a HUB USB with its own power supply (7 USB ports: D-Link DUB
H7, 4 USB ports: LINDY Smart Hub Pro powered - code 4701300468).
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2.3 Devices with additional parameters
On some devices it is necessary to set up additional configuration parameters, as
well as the name.
2.3.1 M1Wave, M2Wave, I-Wave e MultiWave
Tap Binding to execute pairing with a M1 Wave, M2 Wave, I-Wave

or MultiWave plug.
Programmable parameters:
• Acquisition speed: data acquisition speed (Options: Slow 10 sample/second,
Fast 40 sample/s, Medium 20 sample/s, default: Medium).
• Battery type: select the battery type of the Wave plug (Options: Alkaline, Ni-
Mh, Li-Ion, default: Alkaline).
• Battery warning level: the system provides the operator with battery level
indications (Options: 05%, 10%, 25%, 40%, 60%, 85%, default: 25%).
• Turn off time (sec): the plug switches itself off if it is inactive for a given
period (default: 1200 sec, minimum = 30, maximum 28800 = 8 hours).
Tap Info to get information on the device and to program the

maximum number of plugs you can simultaneously switch on.
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Available information:
• Plug serial number.
• Plug firmware version.
• Max number of plugs simultaneously switched on: can be set from 1 to 7.

NOTE: increase the Acquisition speed and the Turn off time can reduce
the endurance of the battery.
The battery level indication is not relevant during charging.
2.3.2 I-Wave2
Tap Binding to execute pairing with a I-Wave2 plug.
• Acquisition speed: data acquisition speed (Options: Slow 5 sample/second,
Fast 20 sample/s, Medium 10 sample/s, default: Medium).
• Mean type: selects which method to use for calculating the mean value.
Options are: Trimmed mean, Standard.
• Trimmed mean: the highest and lowest samples are rejected, and the mean
value is calculated using the remaining samples (more than 2 samples must
be acquired when using this method).
• Standard: mean of all the samples.
• Mean samples: defines how many samples are used to calculate the mean
value. Options are: None, 2, 8, 16, 32, 64, 128.
• Turn off time (sec): the plug switches itself off if it is inactive for a given
period (default: 1200 sec, minimum = 10, maximum 64800 = 18 hours).
• Display rotation: sets the display rotation on the handle

N
in the following two modes:
W
E
• Auto: automatic orientation. S

• East, West, South, North: single orientation
according to the required direction.
NOTES: the battery level indication is not relevant during charging.
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• Power on options: defines the handle activation setting. The default setting
is Inertial. Options are:
• None: No activation.
• Inertial: If selected and the handle is in standby mode, the handle
automatically turns on by a movement.
• Pickup: If selected and the handle is in standby mode positioned on the
stand, the handle automatically turns on by picking it up.
• Remote: if one handle is in standby mode and positioned on the stand,
when a measurement step associated with that handle is activated, it will be
automatically enabled. Once the step is finished, the operator must replace
the handle on its stand.
The Remote option is available only on handles having firmware versions of
1.3.0 or later.
If Remote activation is selected on a handle having an earlier version of the
firmware, it will not be possible to save the setting.
Remote activation type and other types of activation are not allowed in mix; if
a single device is programmed with Remote activation, any other device must
be programmed in the same way.
Tap Info to get information on the device and to program the

maximum number of plugs you can simultaneously switch on.
Available information:
• Plug serial number.
• Plug firmware version.
• Plug Hardware version.
• Plug Software version.
• Plug Hardware model.
• Max number of plugs simultaneously switched on: can be set from 1 to 8.
NOTES:
• The maximum number of I-Wave2 devices that can be connected to
Merlin Plus is 30, and up to 8 of these may be accessed simultaneously.
• In order to use the Start/Stop command from the I-Wave2 buttons
please use the I/O layout N° 65 or greater.
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2.3.3 QDT MultiChannel
This device can manage Marposs Quick Digit Bluetooth and Sylvac S_Dial
Bluetooth. Connection is achieved by specific USB dongle key. One dongle key
allows for simultaneous connection of max. 8 indicators, and it is possible to
manage up to two dongles (16 indicators).
Programmable parameter:
• MAC Address: by this field it is possible to select the BT Dongle MAC
address.
NOTES:
• The firmware version that must be installed on the dongle is 122 (this
information is reported, inside the brackets, in the MAC Address field).
• The dongles must be connected to the Merlin before switching it on.
2.3.3.1 How to pair a QDT MultiChannel

Soon after the new device insertion has been confirmed, 8 channels (named
following the usual Merlin convention) are created initially with no connection to
any device. Entering the Input Reading page you will see a blank page (no channel
connected). Entering the Transducer Settings page and tapping the Binding button,
you can pair a QDT Multichannel item to the required device.
A guide-operator message will appear:
From now on you will have 90 seconds to perform the following steps:
1) Detect the device you have to pair.
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2) Enable Bluetooth transmission on the device; if it is enabled, you will see a
flashing , else keep prolonged pressure (> 2s) on Mode button, then short press
several times until you see bt, push central button, you will see On, push the Set
button.
3) Reset the device configuration; keep prolonged pressure (> 2s) on Mode
button, then short press several times until you see bt, push central button twice,
you will see Reset, push the Set button.
After a few seconds, Merlin detects the device and starts the six steps automatic
configuration and connection procedure. At the end of the steps, you will see the
sensor current value so to check that the desired device has been paired.
Tapping on Ok the paired couple “Merlin transducer -> BT device” is saved in
the database; MAC address is saved too and will be shown in the MAC Address
field (not editable) and the name of the device is shown in the Serial number field
(editable). Tapping on Cancel the pairing is fully deleted. As soon as the pairing of
a device is ended, it is possible to go on with further pairings.
2.3.3.2 How to set the command from central button

In case the device central button is set as “0 data” you can push it to start and
stop measure steps. You can work in these different ways:
1) Start and Stop from the Merlin. Start and Stop commands comes from Merlin
as usual (tapping the button on the screen, pushing the footswitch or using
external inputs)
2) Start from the device and Stop after a programmed amount of time: the operator
pushes the central button (set as “0 data”) when he wants to confirm the measure
so sending a Start to Merlin. Programming the step with a short Acquisition time
(i.e. 0.1 s) the Merlin will immediately stop without further requests. This way
the measure confirmed by the operator will be the only one taken by the Merlin.
Pushing the button of a device not used in the active step, an error message will
be displayed.
3) Start and Stop from the device: the operator pushes the central button (set
as “0 data”) when he wants to begin the acquisitions and the Merlin starts the
measuring cycle. Values from the device are continuously sent to the Merlin until
the operator push the central button again, thus stopping the cycle and validating
the last acquisition. Also in this case, pushing the button of a device not used in
the active step will produce an error message.
In case the measure type set on the device is different from “Normal” (i.e. Max/
Min/Range), the device will send the value that it is displaying (that is the dynamic
operation result) instead of the last value acquired.
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2.3.4 Easy Box U4P
Box fitted with 4 push-buttons used for remote control and data acquisition. Each
input may be defined as Normal or Commutative, these two modes differ as follows:
• Normal: this button is activated by tapping it, and deactivated releasing it.
• Commutative: the button remains active even after it is released and must be
pressed again in order to deactivate it.
2.3.5 Easy Box U4E

Easy Box with 3 inputs for incremental or absolute type rotary or linear encoders,
with analogue or digital interfaces.
• External power supply: the U4E requires its external power supply unit when
the current consumption of the connected encoders is over 200 mA.
2.3.6 Easy Box U4H
NOTE: after the selection of the sensor type, the system automatically
propose the Resolution and Response values. Tapping the MODE field
it is possible to select the required compromise. Through that device,
it isn’t allowed to manage the complete range in some pencil probe
models.
- 29 -
2.3.7 DigiCrown 232
Up to one DigiCrown network (31 modules) connected to the RS232-COM port
can be managed by Merlin.
The following DigiCrown modules are compatible:
• DigiCrown BOX (1 channel only)
• DigiCrown I/O (Sink or Source)
Tap Add to execute DigiCrown network automatic recognition

(modules with firmware V1.3 or greater only).
• Net baudrate: network data transmission speed expressed in baud/s
(options: 9600, 208.3k; default: 208.3k).
• Baudrate: DigiCrown modules communication speed in baud/s (options:
4800, 9600, 19200, 38400, 57600, 115200, default: 115200).
NOTES:
• The Merlin with a DigiCrown 232 cannot accept a Red Crown probe
into that network.
• The DigiCrown 232 interfaces must be connected at the Merlin before
switching it on.
• Using the DigiCrown 232 it is not possible to configure any other
device such as Easy Box, DigiCrown USB, ecc.
2.3.8 DigiCrown USB and ETH

With this DigiCrown interface it is possible to connect up to 250 sensors (8
networks of 31 modules).
The following DigiCrown modules are compatible:
• DigiCrown BOX (1 channel and/or 2 channels)
• DigiCrown I/O (Sink, Source and Only Input versions)
• DigiCrown EI (Analog and Digital encoders)
• DigiCrown AI
• OptoCrown
Tap Ok to execute DigiCrown network automatic recognition
(modules with firmware V4.2 or greater only). If an older module is
included in a network the Merlin software will show a message at
the startup and the network will be disabled.
Tapping the Interface selection button the Merlin will propose the list of the
connected DigiCrown interface
- 30 -
• Net baudrate: network data transmission speed expressed in baud/s
(options: 9600, 208.3k, 625.0k, 2083.3k. Default: 208.3k).
• Default transducer type: it is possible to choose the default transducer that
will be applied to all the sensors of the network.
NOTES:
• The Merlin with a DigiCrown ETH and USB can accept a Red Crown
probe into that network.
• The Merlin can manage only the DigiCrown USB High Speed code
like: 767Y0105XX (not the Full Speed code like: 767Y0001XX).
• The DigiCrown ETH, USB and RS232 interfaces must be connected at
the Merlin before switching it on.
2.3.8.1 How to add modules to a USB network

You can add modules to a network also later than the device creation (up to 31
modules for each device). You simply have to connect the new modules, turn the
Merlin on, enter the Device settings and tap Ok.
Merlin will detect the new modules connected, it will advise the operator and it
will add the new channels and the new I/O lines. In this case too, it is possible
to specify the added LVDT transducer type through the “Default transducer type”
parameter; modification of this parameter will affect only the channels of the
added modules.
2.3.8.2 How to replace the USB interface

You can replace an interface module entering Device settings and tapping Ok.
Merlin will advise the operator that the discovered device is different from the
configured one and it will ask for a confirmation before substituting it.
NOTE: you have to connect only one new interface at a time, trying to
connect more than one new interface will produce random assignment.
- 31 -
2.3.8.3 How to replace LVDT probes
When substituting digital LVDT probes, Merlin can show which have changed in
the “Measure devices map” screen:
As you can see, probe 11DT5716 has been replaced with the 14DR0478.
To confirm that substitutions have been correctly performed, you can simply enter
Device settings and tap Ok.
This way it is also possible to check the connection of each probe to the correct
module, so that the operator would be able to realize possible errors.
NOTE: you have to connect the probes before turning the Merlin on.
In the “Measure device map” screen, you can detect not connected modules, if any.
Not connected modules are underlined enclosing their serial numbers in square
brackets.
- 32 -
2.3.8.4 How to replace a DigiCrown module
To replace a module it is enough to select an input and tap on Module replacement:
It will appear a window in which you can choose the new module that will substitute
the selected one. Entering “I/O lines map” you can operate in the same way with
I/O modules.
NOTE: modules have always to be replaced physically having exited

Merlin.
- 33 -
2.3.8.5 How to perform the DigiCrown addressing
This procedure allows to change the DigiCrown numbering order. Press the button
Transducer sorting and move one by one the pencil probes to define the required
order.
2.3.9 Serial gauge

In order to connect them, serial type devices require a physical port (RS232 or
USB)and a communication protocol. Programmable parameters:
• Device name: enter the unit name using the keyboard.
• Protocol name: Standard or Personal protocol type in use (see chapter 7).
• Manufacturer: manufacturer’s name of the serial gauge.
• Serial port: serial port for data exchange, the descriptions of the COM ports
that are present are displayed and the unavailable ports are indicated by an *.
2.3.9.1 Easy Box U4S

The Easy Box U4S is recognized automatically by the system, so that no set-up is
required. The programming of these inputs is handled within the parameters of
the Serial gauge.
NOTE: only one Easy Box U4S may be connected to Merlin.
- 34 -
2.3.10 Solartron Orbit3
To manage the Solartron Orbit3 modules, the “Soft-Full-Orbit3-1.3.15” driver has
to be installed. Up to 150 Digital Probes can be connected (including Digital
Displacement, Mini probes, Lever probes, Block gauges and Flexures). DIOM I/O
modules can be connected (using same layouts as per DigiCrown). Select Orbit
to manage standard speed modules:
or Orbit USB to manage high speed modules:
NOTE: every module in the net has to be a 3rd generation (Orbit3)

module.
- 35 -
2.3.11 U2-IO
• Type: to select Sink or Source.
2.4 Transducer settings
Once at least one device has been added to the Measure devices map page, it is possible
to select the commands that are used to define the parameters for each transducer.
Click on Transdusers settings to edit the transducer parameters.

The following parameters are always present, for all device types.
• Transducer: transducer name (max. 5 characters editable using the

keyboard). By default each transducer is identified by a three figure value,
for example, T213. The first figure identifies the device, the second the
channel and the third the instance. Hence, the transducer identified as T213
corresponds to the third instance of the first transducer on the second device.
If a DigiCrown network with more than 9 transducers, it may be necessary to
use 4 figures to identify the transducers (e.g. T1121). In this case, the middle
two figures indicate that it is the twelfth transducer on the network.
• Serial Number: can be edited using the keyboard.
• Description: can be edited using the keyboard.
• Gage: the gage name, can be edited using the keyboard, only in multi-instance.
• Measure Unit: the available measurement units depends on the device type.
• Precision: number decimal places displayed (options: x1, x0.1, x0.01, x0.001,
x0.0001, x0.00001, x0.000001).
- 36 -
• Ovr ±: transducer over-range settings.
• Correction: sensitivity correction; if not-standard transducers are in use, the
different behaviour can be compensated with this multiplication factor.
• Sign inversion: transducer signal sign inversion option.
• Range: transducer measurement field (expressed in µm).
• Arm ratio: sets the arm ratio.
• Resolution: real measurement accuracy.
• Offset: additional constant applied to the value measured by the transducer.
Click on Next Input to setup the transducer related to the next input.
2.4.1 Parameters for Easy Box U4E

For the EasyBox U4E there are two available tabs, the second depends on the
type of encoder selected in the Interface type field.
GLOBAL PARAMETERS TAB

• Field±: measurement range of the encoder or line.
• Interface type: Digital / Counter/ Analogue.
• Sensor type:
• Linear: to be used for linear positioning transducers (optical scales typically).
• Rotary: to be used for angular positioning transducers (rotary encoders
typically), when an information is required about both the number of
revolutions made and the position within the lap.
- 37 -
• Periodical: to be used for angular positioning transducers (rotary enco-
ders typically), when an information is required only on the position within
the lap, but not on the number of revolutions made (for example in
applications concerning spindles).
• Step: it defines the variation (in the measuring unit mentioned above) against
a Step of the sensor. For example:
- if a scale with 20 μm step is used, 20 has to be programmed.
- if an encoder featuring 7200 step/rev is used, 0.05 has to be programmed
(360°/7200=0,05 °/step).
• Max. frequency: defines the maximum frequency of the signal generated by
the sensor (expressed as Pulses/Steps per second), if the frequency exceeds
this value an error signal is generated and the counter is decalibrated. The
maximum value depends on the Type of interface:
- Digital and Counter: 2500 Ksteps per second.
- Analogue: 250 Ksteps per second.
• Real frequency: in this column the control frequency is displayed, which the
hardware is able to deploy against the programmed value of the parameter
Max Frequency.
• Calibration type:
• On current pos.: the transducer value becomes the value programmed in
the parameter Marker Position when the zeroing command is received.
• None: no calibration is foreseen.
• Test marker: it enables the input of the reference signal I or M (and the rela-
ted connection checks).
• Marker position: absolute value of the marker position.
- 38 -
ANALOGUE TAB
• Amplitude check (%): it defines the maximum percentage variation
allowed for the amplitude of the resulting of the signals A and B, i.e. (A2+
B2)1/2.
• Ampl. check enable: it enables the control described in the previous point.
• Offset A: offset value of the channel A, normally calculated by the specific
calibration utility.
• Offset B: offset value of the channel B, normally calculated by the specific
calibration utility.
• Amplitude A: amplitude of the signal of channel A, normally calculated by the
specific calibration utility.
• Amplitude B: amplitude of the signal of channel B, normally calculated by the
specific calibration utility.
• Angular Correction: phase correction of the signal of channel B, with re-
spect to the signal of channel A, normally calculated by the specific calibra-
tion utility.
DIGITAL TAB
• Division: it allows to increase the resolution of the digital sensors by splitting
the steps in 2 or 4 parts according to the logical combination of the signals.
The possible choices are:
• Step: no subdivision of the step. The resolution is set in the “Step” box in
the corresponding row of the general data table.
• Half step: subdivision of the step in two parts. The resolution is half the
value set in the “Step” box in the corresponding row of the general data
table.
- 39 -
• Quarter step: subdivision of the step in four parts. The resolution is one
quarter of the value set in the “Step” box in the corresponding row of the
general data table.
• Alarm: the control can be enabled only if the encoder has this output signal,
which normally is not present. The possible choices are Yes or No.
• Warning: it enables the reporting of a warning alert in response to linking
problems of the channels (open circuit, short circuit, exceeding of the limits
of common mode, signal below threshold, etc...). The possible choices are
Yes or No.
COUNTER TAB
• Counting edge: it allows to program on which front(s) of the input signal(s)
the count shall be made (in the case Frequency/Direction it applies only to the
fronts of the signal Frequency). The possible choices are:
• Rising Edge: the count is made on the rising edge of the signal.
• Falling Edge: the count is made on the falling edge of the signal.
• Rising & Falling Edge: the count is made on both the rising and falling
edge of the signal.
• Digital filter: enables digital filtering of the input signal to reduce the proba-
bility of incorrect counting. Filtering is only activated if in the corresponding
row of the table of general data, a max. frequency less than or equal to 712
KStep / second has been programmed. The possible choices are Yes or No.
- 40 -
2.4.2 Parameters for Easy Box U4H
For the U4H model, in addition to all the parameters normally available, it is ne-
cessary to set the working mode. This parameter has effects on range, resolution
and response time, according to the table below.
Mode Range [µm] Resolution [µm] Response [s]

1 ± 500 1,0 0,2
2 ± 500 0,5 0,3
3 ± 500 0,5 0,5
4 ± 250 0,5 0,2
5 ± 500 0,2 1,0
6 ± 250 0,2 0,3
7 ± 500 0,1 2,0
8 ± 250 0,1 0,5
9 ± 250 0,1 1,0
10 ± 250 0,1 2,0
- 41 -
2.4.3 Default measuring direction
Measurement value when Sign
Transducer type
sensor is PUSHED inversion
Pencil probe
Decreasing Yes
LVDT - HBT
Wireless bore gauge
Decreasing No
M1Wave - MiniWave LVDT
Wireless bore gauge
Increasing No
M1Wave - MiniWave HBT
Pneumatic
Decreasing Yes
(used with U1Air, U3Air, U4 Air)
2.5 Input reading
Once the transducer programming procedure has been completed,

it is possible to check the transducers by clicking on Input reading.
This opens the Input reading page where the individual transducer
readings are displayed in real time.
The Zeroing and the Zero reset functions allow to set/reset a zero value on the
transducer. This value is for setup purpose only, and does not affect the measurement
value. When the operator clicks on the Transducer identification button, the software
switches the LED, corresponding to the selected transducer, on.
- 42 -
2.6 DigiCrown probe replacement function
In order to simplify the DigiCrown probe replacement after failure, it has been
added the Replace button in the Device configuration page. Here is the sequence to
perform a single probe replacement.
From the menu click on Settings. Select Measure devices to enter the
map of the measure devices previously configured.
In the Measuring devices map the system automatically detects that a digital probe
has been replaced, showing both the serial number of the old probe and the serial
number of the new one.
Select the DigiCrown unit (DIGINET) in the list and then tap Device
settings.
- 43 -
In the Device configuration page it is now possible to Add or Replace a new probe.
Tapping the Replace button on the toolbar will change definitively the two probes,
while tapping Add the software will add the new probe from the list of the available
transducers.
2.7 I/O lines map
This page can be used to view the status of all the I/O bits associated with the
connected devices. It is possible to change the used I/O layout from the Global
Setup menu.
- 44 -
3 PROGRAMMING
3.1 Master Set
The Master sets are groups of real masters used to zero and adjust the sensitivity
on the programmed characteristics. Each set can be created using one (zeroing
only), two (min/max mastering - Sensitivity), three masters (Zeroing & sensitivity)
or dynamic (one zeroing only but calculated as result of a dynamic measure).
For each master it is possible to program a master value, a Serial number and a
Message to guide the operator during the acquisition.
From the menu, select Programs then Master set to access the
master set list page, where it is possible to use one of the following
functions:
• Add: to create a new Master set.
• Edit: to modify an existing Master set.
• Del: to delete a Master set.
• Copy: to create a new Master set by copying an existing one.
NOTE: this feature causes the loss of Zeroing/Sensitivity compatibility. It
means that in case of a Merlin software updating, the Master set fields
need too be programmed and a new Zeroing/Sensitivity acquisition must
be performed prior to restart the production.
3.1.1 Miscellaneous TAB

After creating a new Master set, access to the Miscellaneous in order to define the
basic Master set information.
• Name: name of the Master set to be programmed.

- 45 -
• Description: description of the Master set.
• Type: Master set Type
• Zeroing: master used in static mode. For example where the zeroing point
is acquired as an instantaneous reading with the master in a fixed position.
• Sensitivity: minimum and maximum masters used in static mode to
calibrate a pair of, typically pneumatic, calipers.
• Zeroing & Sensitivity: as for the sensitivity, but with an additional master
used in static mode to acquire a zeroing point; the system calls up the 2
calibration masters, followed by the zeroing master, which may also be
one of the two used for the calibration.
• Precision: defines the number of places after the decimal point used for the
Master set dimensions.
• Measure unit: measure unit used for the Master set dimensions.
• Verification master (GC): name of the master used for the Gage Capability
study.
3.1.2 Dimensions TAB

Afterwards, click on the Dimensions tab where, according to the number of
dimensions of the Master set, it is possible to set the Zero limit, the Periodic limit
and the Zero master value for each dimension. If Master Set Type foresees up to
three masters for zeroing and sensitivity correction, two more master values must
be defined for each dimension. Click on the field to be changed, and then Edit the
value clicking on the relevant button.
• Zero limit: this value is the maximum allowed difference between the last
acquired zero and the first.
- 46 -
• Periodc limit: this value is the maximum allowed difference between the last
acquired zero and the zero currently acquired.
NOTE: the zeroing limits are not applied to the first zeroing.
• Zero master: this is the certified value of the master associated with the zero.
In the case of Master Set with 2 zero points, it is necessary to enter in the dimension
tab the values of each master, i.e. the minimum and maximum values, as well as
the Master Type, which may be either Generic, Ring or Plug; the latter value can
be used to include a check, verifying that the masters are used in the correct
sequence, in the calibration phase, so that the calibration is invalidated if the
sequence is incorrect (regarding only the Master Set Sensitivity and Zeroing &
Sensitivity, where there is a parameter to define the master type).
NOTE: tap edit to swap between the different choices.
• Generic: during the zeroing phase, the software doesn’t check the sequence
in which the sensitivity is acquired.
- 47 -
• Ring and Plug: during the zeroing phase, the software checks the order of the
zeroing steps depending on the differences between Ring and Plug as follows:
Max Master Min Master

Contacts less prominent. Contacts more prominent.
Ring
(OD measure)
Ring: pushing the contacts, the measure increases.
Max Master Min master

Contacts more prominent. Contacts less prominent.
Plug
(ID measure)
Plug: pushing the contacts, the measure decreases.
- 48 -
3.1.3 Serial number TAB
The Serial number of the master and, if necessary, a Message for prompting the
operator, could be inserted in the TAB below.
NOTE: Merlin asks for the Max Master first and subsequently for the
Min Master.
- 49 -
3.1.4 Zero expiration
• On batch creation, On measure batch change: if set to yes indicates that the
zero is cancelled whenever a new Batch is created or the Batch is changed
(this applies to all the master quotas associated with all the master sets used
by the program that the Batch belongs to). This obliges the operator to re-
acquire the zero before carrying out the measurement, even if he/she wants
to measure a different batch that shares the same master set as the created
batch. As always, the zero acquired for a MASTER SET on a BATCH is valid
for all the batches that share the same master set.
• On a shift beginning, On a shift ending: if set to yes indicates that the zero
expires when a shift starts/ends. Thanks to the separate expiry management
at the start/end of the shift, it is possible to program up to 8 daily expiries
(programming up to 4 non-consecutive shifts).
• Zero expires after (pieces): each time the system performs a measurement
on a piece from a batch that uses the Master set, the master set piece counter
increases by one, irrespective of how many master quotes are activated (one,
more than one, or all of them). When the counter reaches the number set up
in this field, the zero is deemed to have expired. The counter is reset when the
zero expires for any reason, or when a new zero is acquired for all the master
quotes. Set this field to zero to disable this function.
• Zero expires after (min): by setting this field to a value other than zero, it
is possible to limit the time that the zeroes remain valid. Merlin constantly
monitors the minutes that have elapsed since the oldest zero acquired on the
MASTER SET master quotes. As soon as the difference exceeds the value set-
up in this field, the zero is deemed to have expired for the entire Master set.
• On software start-up: the zero is requested each time the software is started.
- 50 -
3.2 Part program definition
To define a new Part program proceed as follows:
Select Part program from the Programs menu in order to access the
programming phase. Tap Add to create a new Part program.
NOTE: the Part program name should not contain characters that
Window does not accept as part of file names (E.g. / \ : * ? “<>| ø...). If
any of these characters is used, the system will allocate the Part program
a string containing the exportation date and time (YYYYMMDDhhmmss)
during the Batch export phase.
Click on Name to enter the Name of the part to be programmed, on Description to

enter a Description (if required) and Drawing number to enter the drawing reference.
The configuration parameters are described below.
• Name: name of the part to be programmed.
• Description: description of the part to be programmed.
• Drawing number: reference Drawing number.
• Free Running: permits the operator to enable continuous measurement mode
during the measurement phase for the current Part program. (This option is
available only if the Free running option is set to user defined in Global setup
- Miscellaneous 2).
- 51 -
• Pieces export: setting this parameter, a CSV file, with the measurement values
acquired, will be automatically exported at the end of every cycle of measure
related to a single part.
Define the number of measurement steps by clicking Step.
3.2.2 Tracing data request TAB
This programming page activates the tracing parameters and defines the way
the operator is asked to provide this information. The Tracing data are additional
runtime data that the operator can/must enter; these data are saved and associated
with the acquired measurements. It is possible to enable up to ten keys, and
define whether the operator is obliged to enter a value (Mandatory before or after
the measurement), or if it may be skipped (Optional), for each one. If a parameter
is defined as Mandatory before the measurement and has not been set when the
software is started, a data request form is displayed and the operator must assign
a value to the parameter.
- 52 -
If a parameter is defined as Mandatory after the measurement and has not been set
yet, the data request form is displayed at the end of the final step.
The state type parameters normally assume the value of the previous measurement
so that they always have an assigned value; the only exception is when the
operator starts to measure a new batch and the parameter has not been set to a
value during the batch definition phase.
The list of traceability keys may be customised in the paragraph.
NOTE: to insert the Tracing Data it is necessary that one Batch is
activated.
3.2.3 Step definition
The configuration parameters are described below.

• Description: Description of the measurement Step.
• Message: measurement Step Message; this message appears in the page
heading highlighted in yellow, and can be used to provide assistance to the
operator.
• X/R Subgroup size: this parameter defines the size of the subgroup used in
the control charts (permitted values: 2 to 15).
• Initial Delay: initial measurement delay setting (in sec.).
• Acquisition Time: data acquisition period (in sec.).
• Motor Management: enables a signal that can be used to control a motor
used to rotate the piece while the measurement is being performed. Refer to
the I/O layouts to understand which of these can manage the motor signal.
- 53 -
3.2.4 Defining the characteristic
Click on Characteristic to access the form used to define the

Characteristic.
3.2.4.1 Miscellaneous TAB

This tab is used to enter the basic Characteristic data.
• Name: to enter the Formula name.

• Char. number (K2001): to enter the extended value Characteristic number
that will be inserted in the K-Field 2001.
• Description: full description of the characteristic.
• Charact. type: to select between Normal and Attribute.
- 54 -
• Measure unit (normal characteristic only): measurement unit used for
the Characteristic; the number of places displayed after the decimal point
depends on the value set up in the Precision field.
• mm: millimeters
• in: inches
• deg: degrees and hundredths
• g: grams
• °C: degrees Celsius
• °F: degrees Fahrenheit
• °: sexagesimal degrees; when the precision is set to x0.01 the value is displayed
in degrees and minutes, e.g. 6°11’ ; when the precision is set to x0.0001 the
value is displayed in degrees, minutes and seconds, e.g. 6°11’25”.
• µm: microns
• ---: no measure unit (for special applications).
• Formula (normal characteristic only): the Formula may include Transducers,
mathematical functions or previously acquired measurements, up to a
maximum of 120 characters. Tap the T button to select the transducer list.
Tap a line to add the corresponding Transducer to the Formula. Tap the M
button to select the Characteristic list. Tap a line to Add the corresponding
Characteristic to the Formula.
• Auxiliary: several applications use intermediate Characteristics to elaborate

another Characteristic. These auxiliary characteristics aren’t involved in the
part status evaluation, not stored in the batch and it’s possible to exclude
them from the display too. It is possible to configure the measuring steps with
auxiliary characteristics only (visible or not visible); the only limitation is that a
Part Program must contain at least one not-auxiliary Characteristic.
- 55 -
• Display: enable/disable the display of the characteristic.
• X/R Type (normal characteristic only): can be used to enable or disable
the X/R control chart.
• I/O Position: in output and I/O protocols this function enables the operator to
make decision which Characteristics must be included in the protocol, and in
which order. If the field is set to None (preset value) the Class output and the
outcome of Characteristics will not be available on the digital outputs. If it is
set to a value (between 1 and 16), the Class and/or outcome will be exported
to I/O in accordance with the programming required by the active I/O layout.
The operator must make sure that the same I/O position is not programmed
multiple times for different characteristics of the same program.
• Limit types (normal characteristic only): it is possible to set-up three
different types of tolerance limits.
• Bilateral: it is possible to set-up both upper and lower limits.
• Unilateral: it is possible to set-up only one limit (upper/lower). Assuming
that a unilateral upper limit has been set-up, all the measurements between
zero and the programmed limit will be accepted, if the measurement is
less than zero it is considered invalid and highlighted in grey.
• Single limit: it is possible to set-up only one limit (upper/lower). Assuming
that a unilateral upper limit has been set-up, only the measurements
that exceed the programmed limit are rejected, all possible negative
measurement values are accepted.
• Nominal value (normal characteristic only): to enter the nominal value.
• Precision (normal characteristic only): defines the number of decimal
figures to be used for the Characteristic.
• Tolerance limits (normal characteristic only): set up the tolerance limit
type and the corresponding values based on the part technical specifications.
• Trend: using these limits it is possible to enable the prescrap (or “yellow”)
limits.
• Reject: a measure over these limits is considered as scrap.
- 56 -
3.2.4.2 Using the formula
Click on fx button to access the keyboard with the list of all functions available.
The following mathematical and trigonometric functions are available:

• Sin(): sine function.
• Cos(): cosine function.
• Tan(): tangent function.
• Asin(): arcsine function.
• Acos(): arccosine function.
• Atan(): arctangent function.
• Ctan(): cotangent function.
• Pi: high resolution pi function.
• Sqrt(): square root function.
• Abs(): absolute value function.
• Pow(x,y): power function where x is the base and y the exponent.
The following functions to determine the minimum and maximum values between
operands are available (Transducers and/or Characteristics and/or constants):
• Min: function to determine the minimum value between N operands; e.g. Min
(T1,T2,T3).
• Max: function to determine the maximum value between N operands; e.g.
Max (M1,M4).
Up to 10 comma separated values are permitted.
- 57 -
The following dynamic calculation functions are available for use on all the values
acquired during the measurement:
• Dmax: dynamic maximum function.
• Dmin: dynamic minimum function.
• Dave: dynamic mean function for all the acquired values.
• Drng: dynamic range function (maximum - minimum).
These operators may be implemented in complex mode as follows:
• it is possible to use up to 5 dynamic operators in each Formula.
• if a dynamic operator is used to process one or more characteristics, they
must be defined before they are used (otherwise the calculation could fail at
the first reading).
If the Characteristic is zeroable, the operator always returns to the instantaneous
value during the zeroing/calibration phases (the range always returns to zero for
the operator). All dynamic zeroing management functions must be implemented
by using dynamic Master Sets.
The following simulation functions are available:
• Rnd: function that generates random values.
• Nrnd: random function values with normal distribution.
• Grnd: random function values with Gamma distribution; select the (>0)
parameter to obtain exponential distributions, (=1) to closer resemble to the
classical “bell curve”.
The following manual input functions are available:
• IN: the operator can manually input a measurement value for the Characteristic.
The following logic functions are available:
• mMode(): returns a 1 during the measurement phase and a 0 during the
zeroing phase.
• zMode(): returns a 1 during the zeroing phase and a 0 during the measurement
phase.
• NV(): adds the value defined in the Nominal value field to the result.
Returns the Nominal value, previously set on the Characteristic. It is exploited
when the instrument gets back the value as absolute without zeroing. For
instance for calipers with Mitutoyo interface.
NOTE: Merlin can carry out manual dynamic acquisitions.
The performances may change according to the number of used
channels.
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3.2.4.3 Video TAB
Tap on Video TAB to set parameters for Ledbars (if enabled – see chapter 6.2).
It is possible to program the resolution of each LED in the bar and the number of
LEDs in each bar.
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3.2.4.4 Zeroing parameters TAB
Click on Zeroing parameters to assign a Master set/Zeroing parameters (previously
configured) to the Characteristic. All the characteristics assigned to a given master
set will be zeroed together during the measurement phase. The same master set
may also be used on characteristics that belong to other steps.
Associating the MasterSet and the Characteristics.

It is necessary to assign a dimension (certified quota) from a Master Set that has
been defined in the archive to each zeroable characteristic.
It is possible to associate the same dimension from a masterset to multiple
characteristics in the same program so that it is only necessary to zero a caliper
that is used during multiple measurement steps once.
Sharing the zero settings.
Provided they use the same measurement formula, the characteristics associated
with the same masterset and the same dimension will share the same zeroing
point, for example zeroing one, zeroes the other.
In practice, for each Master Set dimension, a different zero value is managed for
each different formula that uses it; this means that it is possible to use the same
master to zero the various different calipers that are compatible with it, and that
are connected to separate inputs (using different formulas).
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Automatic zeroing steps calibration.
The software creates the zeroing steps automatically when you confirm that you
wish to save a program. All the characteristics that use the same Master Set but
different dimensions, or that use the same Master Set, the same dimension and
the same formula end up in the same zeroing step.
The characteristics that use different Master Set, or characteristics that use the
same Master Set and the same dimension but with different formulas end up in
different steps.
The characteristics of the same program that use the same Master set/dimension
and have the same formula are zeroed in the same step once. In practice, only
the first characteristic of this set will be visible in the zeroing step, but the zeroing
will be valid for all of them.
Calibration.
When using a calibration Master set (2 zero points or 1+2 zero points), the
system asks for the required masters automatically; if Master Type, “ring” or
“plug” has been selected in the masterset dimensions window, the correct master
use sequence check is performed so that the calibration becomes invalid if the
sequence is incorrect.
The system can handle up to 6 characteristics.
Example of how to compile the zeroing steps:
Characteristic Formula Master Set Dimension Zero Step

M1 T111 Ms001 1 1
M2 T111 Ms001 1 1*
M3 T111 Ms001 2 1
M4 T121 Ms001 2 2**
M5 T111 Ms002 1 3***
(*) M1 and M2 are zeroed together once.
(**) This characteristic is zeroed during the second step because it uses the
same Master Set/dimension as M3 but has a different formula.
(***) This characteristic is zeroed during the third step because it uses a
different masterset.
Expire of zero settings after a certain interval or number of measured parts.
It is possible to set-up various different expiring conditions for the zero setting on
the Master Set that force the operator to carry out a new zero acquisition.
The zero settings that share the same Master Set and dimension are differentiated
according to the formula; this means that characteristics associated with the same
Master Set and dimension (but with different formulas) may have unsynchronised
zero setting expiring conditions (e.g. the system indicates that it is necessary to
zero one characteristic but not the other).
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To make it easier to keep track of the zero setting expiration, a message box is
displayed under the title bar indicating the zero state for the current step and
the outcome of the last zero acquisition command. If the zero setting fails, the
operator can access a window displaying the details by tapping on this box. By
tapping on the title bar it is possible to view the time or parts expiring condition for
each characteristic.
Verification MasterSet.
To perform R&R functions, each characteristic will have to be checked using a
specific Master; thus, for each characteristic used in the test, it is necessary to
assign a dimension (certified quote) from a Master set that has been defined in
the archive.
3.2.4.5 Classification TAB

Once enabled in Settings - Global setup - Miscellaneous 1, the Class management
function allows to create up to 32 classes for each Characteristic. In the simplest
case, the tolerance band is sub-divided into uniform parts, but it is also possible
to use zones outside the tolerance band and modify the thresholds in order to
create non-uniform amplitude classes.
• Class Definition:
• Disabled: (default).
• Uniform & fixed: the system sets the classes programmed; only the class
name is editable. All Classes are created with the same size.
• Freely editable: name and value are editable. Classes can have different
sizes.
• Classes In Tolerance: the number of classes within the tolerance band.
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• Out of Tolerances: the number of classes outside the tolerance band:
for example, if we set this value to 2, the system adds 2 classes above the
upper tolerance limit, and 2 classes below the lower tolerance limit. The Class
Calculation function recalculates the classes according to the tolerance
limits that have been entered and the nominal value; if one of these values is
modified, the user has to repeat the recalculation. The Edit function permits to
modify the name and value in the table.
NOTE: the maximum number of classes that may be exported via I/O
layout is 16, whereas the serial output protocol can be used to handle
up to 32.
3.2.4.6 Graph and filters TAB
• Dynamic graph: this parameter enable or disable the visualization of the

dynamic graph.
• Filter step 1: this parameter enable or disable the filter applied to the dynamic
graph. It is a Smoothing filter, based on mobile average of all values acquired.
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• Window[%]: this value is related to the percentage of all the samples acquired
to be considered in the calculation for the mobile average. Setting 0 is like
without filter whereas increasing the value a mobile average will be done on
wider range of values.
• Periodical: this parameter permits to connect for a dynamic graph, related to
a part in rotation, the final point of the acquisition cycle with the starting point
of next acquisition cycle.
3.2.5 Part program structure

Once the Characteristic has been defined it is possible to view the complete
structure of the Part program that has been created.
The following table includes all the information entered during the programming
phase: Part name, measurement Steps, Characteristics, Tollerance limits and
Master set. The brackets in the Characteristic “2” show that the measure has been
configured as Auxiliary.
This page enables the user to continue programming by adding new steps, new
measurements and new zeroing steps or copying an existing step or characteristic.
To add a new element, select the element to be added by highlighting it in the
display and then tap Add.
To copy an element, select the element to be copied by highlighting it in the display
and then tap Copy. The Up and Down functions allow the user to move the selected
element around the tree structure.
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4 BATCHES
Batches are the data structures used for collecting the measurements. They are
used primarily to store the data but also to arrange the measurements in layers
according to the time they were collected in order to increase the significance of the
statistical analysis and to correlate the data collection with the production batches.
There are two ways to create a new Batch:
• Tap on Active Batches menu and then on Batches creation to create a new Batch.
• Select Part program from the Programs menu, access the Part programs list page
and select the Part program the Batch is to be associated with, then tap on Batch.
4.1 Active batches menu

This menu contains the commands that are used to manage the Batches.
The following commands are available:
Tap Programming to access the current Part program programming

phase (see paragraph 3.2.6).
Batch creation: enables the operator to create a new Batch for

measuring or Gage Capability purpose (see paragraph 4.3).
Edit Batch: modifies the parameters of the selected Batch.
Close batch: enables the operator to close and active Batch, for
example set it to a state where it is not possible to add measurements
and in which it can be deleted.
Batch change: fast change of the selected Batch; enables the

operator to close the Batch quickly, while simultaneously opening a
new one having the same parameters.
All batches: enables the operator to view all active and closed
Batches.
Measure: enables the operator to activate the measurement phase

for the selected Batch (see chapter 5).
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4.2 All batches menu
The All batches function can be used to view all active and closed batches and
generate an alternative command list that enables the operator to work on closed
Batches, exporting and deleting them.
File transfer: enables the operator to transfer the exported Batches

to a specific destination defined in the General setup.
Export: exports the selected Batch to a file; the operator may

decide to export only the measurements, only the statistics, or the
measurements and the statistics.
Activate batch: activates the selected Batch.
Edit batch: modifies the parameters of the selected Batch.
Delete: deletes the selected Batch, functions only if it is already

closed.
Active batches: enables the operator to view the active Batches only.
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4.3 Gage Capability menu
The Gage Capability menu contains the commands that are used to manage the
Batches used for the Gage Capability tests.
Tap Programming to access the current Part program programming

phase (see paragraph 3.2.6).
Batch creation: enables the operator to create a new Batch for

measuring or Gage Capability purpose (see paragraph 4.4).
Edit Batch: modifies the parameters of the selected Gage Capability

Batch.
Delete: deletes the selected Gage Capability Batch.
Export: exports the selected Gage Capability BATCH to a file; the

operator may decide to export only the measurements, only the
statistics, or the measurements and the statistics.
Summary page: shows the list of the available summary pages of the
completed tests (if any).
Measure: enables the operator to activate the gage capability test for
the selected Batch (see chapter 5).
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4.4 Batch for measuring cycle
• Name: field to define a production Batch name.

NOTE: the Batch name should not contain characters that Window
does not accept as part of file names (E.g. / \ : * ? “<>| ø...). If any of
these characters is used, the system will rename the Part program using
a string containing the exportation date and time (YYYYMMDDhhmmss)
during the Batch export phase.
• I/O Index (Dec/Hex): the I/O index function allows to automatically switch
Batch, and relevant part program associated, through a digital input sent by
an external logic (PLC) or manually by a push button/rotary switch. The I/O
reference number of each batch can be entered either in decimal (Dec), or in
an hexadecimal form (Hex).
• Statistical study: indicates if a statistical study on the data is required and
select the type.
• None: only the part counters are saved in the batch.
• Process: each individual acquisition is stored.
• Serial number behaviour:
• Standard: the operator may enter the serial number normally via keyboard.
• Autoincremental: the serial number corresponds to the measurement
number, it is formed by 5 characters (e.g. 00001, 00002, etc.) and it is
incremented automatically each time a measurement is carried out.
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• Serial number prefix: if the previous field is set to “autoincrement” it is possible
to define an alphanumerical prefix; for example, if the letter “A” is inserted in
this field, the serial number becomes A-00001, A-00002 etc.
NOTE: the Serial number behaviour and Serial number prefix parameters
may be viewed in the Tab only if at least one traceability key has been
set up.
• Export mode: the export mode could be:
• Batch close: at Batch closing.
• End of sample: at the end of the programmed sample (5 parts default). The
data will be exported at the start of subsequent sample to allow the user
to delete the last measured part, if it is necessary.
• Automatic data export: the function allows choosing which data must be
exported. To set the export path see paragraph 6.6. The options are:
• Cycle: the software creates and exports a CSV file at the end of each
Measure Cycle.
• End of Sample: the software creates and exports a CSV file at the end of
each Measure Sample.
• No: no automatic export.
• Only measures Batch close: on batch closing the software generates a
file containing all the batch measurement values and export it to the
preselected path.
• Only statistics Batch close: on batch closing the system creates and
exports a file (.csv Microsoft Excel® compatible format) containing the
statistical data from the most significant.
• Measures and statistics Batch close: on batch closing the software creates
and exports both types of file: measurements in the programmed format
and statistics in the Excel® compatible text format.
In the “Actions on batch closing” panel it is possible to select the operation to be
performed when closing a batch, as described below (these variables may be
preset using the Actions on batch closing menu, see paragraph 6.7).
• Automatic deletion: if this parameter is set to Yes, the system deletes the
Batch after closing.
• Automatic change: when enabled the software creates a new Batch
automatically after closing the current one. The new file will inherit the current
settings, but with a different name. The system creates the name as follows:
YYYYMMDDhhmmss. The Automatic change parameter works only when
the batch is closed inside the measure environment, with some automatic
mechanism, like the Batch duration, it does not work closing the batch
manualy from the menu.
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The user can select the batch manually from the list or through I/O signal, in the
latter case the selection numbering system in the I/O Index parameter is used.
The software is also able to select the Batch automatically by exploiting a
transducer generated event. The following parameters must be programmed in
order to define the automatic batch change event:
• Selection Channel: use this parameter to select the Transducer that triggers
the change. Each transducer may only be used to select a single Batch; a
message appears next to the Transducer name, indicating whether it is free or
already used for another selection.
• Threshold ±: Transducer measurement field thresholds that are used to
enable the selection.
• Selection condition: this parameter defines the condition for which the
selection is enabled: either as the value moves into (From out to in), or out of
(From in to out) the range defined by the thresholds.
4.4.2 Duration TAB

In the Batch duration window it is possible to choose between various conditions
under which the Batch closes automatically.
• Max. number of parts: the Batch is automatically closed at the completion of

the number of parts.
• Max duration (Hours / Minutes): in this case the Batch is closed when a
span of hours/minutes is elapsed.
• Action on Changing Shift(None/enable): this function can be used to close
the batch automatically at the end of each shift defined in the Global setup
--> Shifts menu (see par. 6.3). This function works for all active batches and
not just the current one.
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In the Tracing data request window the user has to insert the initial value only for
K-field parameters having Behaviour set on State (input data valid until the next
modification).
4.5 Batch for Gage Capability studies

• Name: field to define a Gage Capability Batch name.

NOTE: the Batch name should not contain characters that Window
does not accept as part of file names (E.g. / : ? “<...). If any of these
characters is used, the system will rename the Batch using a string
containing the exportation date and time (YYYYMMDDhhmmss) during
the Batch export phase.
• Statistical study: Study 1 (AR) for measuring equipment repeatability study.
Study 2 (RR) for Gauge Repeatability and Reproducibility study.
• Trials: Number of trials.
• Parts: Number of Parts (RR only).
• Operators: Number of operators (2 or 3, RR only).
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• Sequence: Study actions sequence (Parts or Operators, RR only).
• TV calculation: Type of calculation for the Total Variation (From tolerance or
From the study data, RR only).
4.5.2 Operators TAB
• Operator 1-2-3: identifies the operators (Admin, Prog, User, None).
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5 MEASUREMENT PAGE
Tap Measure to access the Main measure page. This page allows the
user to view the measurements acquired by the device connected
to the Merlin in real time.
All the measurements can be displayed simultaneously, if there are more than 8
measurements they are arranged in columns.
Tap Start button to start a measurement sequence. If more than

one measurement step was set up during the programming phase,
tap the same button to proceed step-by-step.
Tap Histogram button to modify the display by activating the histo-

gram.
Tap Control chart button to modify the display by activating the X/R
Chart.
NOTE: this graph should be enabled from the Characteristic
definition page.
Tap Single value chart button to modify the display by activating the
Single value Chart.
NOTE: this graph should be enabled from the Global Setup.
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Tap LED Bars button to modify the display by activating the LED Bars.
NOTE: this mode should be enabled from the Video Tab in the Global
Setup Form selecting All Pages in the Measure page mode parameter.
Tap the Dynamic page button to modify the display by activating the
Dynamic chart.
NOTE: this graph should be enabled from the Global Setup - Miscellaneous
1 and in the Graph and Filters tab in the Characteristic definition page.
Tap Main page button to modify the display by activating the Stan-
dard Measure page.
The Delete function enables the user to delete the last acquisition.
If this button is tapped during a stepped acquisition, the operator
can decide whether to delete the last step only or all the preceding
ones, (limited to the steps associated with the last part).
Tap Tracing button to insert the Tracing data.
Click on Zeroing to carry out the device electrical zeroing procedure.
Tap on Reset counters button to set the counters to zero

NOTE: available only when no batch is selected.
Click Programming to access the current part program programming

phase (see paragraph 3.2.5). Click on the Characteristic identification
number (yellow or grey) to access the programming phase for the
corresponding Characteristic directly. The modifications have an
immediate effect on the measurement process.
1 2 3 4
5 6 7 8
1. Name of activate Batch.
2. Part program name.
3. Step name (Step 1 of 2).
4. Last Serial Number inserted if programmed in the Tracing data page.
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5. Good: Number of Good parts / percentage of Good parts.
6. Scrapt: Number of Scrapt parts / percentage of Scrapt parts.
7. Trend: Number of Trend parts / percentage of Trend parts.
8. Total number of measured parts.
The icon below shows the measured part counter related to the active current
sample.
If the saving at the end of the sample is configured, this field becomes green when
the sample is ready to be saved.
5.1 Zeroing
During the zeroing phase, several help messages are shown to clarify better the
outcome of this procedure.
NOTE: zeroing steps are proposed exactly as they have been defined
in the corresponding part program.
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5.2 Histogram
The Histogram page allows the user to view the Histogram as well as executing
acquisition cycles in the same way as on the Main measure page.
In addition to the measurement bar and the Histogram graph, this page also
includes summary table containing statistical parameters for the data stored in
the current Batch.
The execute measurement Step, delete and modify programming functions are
the same as on the Main measure page.
• Control chart: tap this button to display the page containing the Control
chart for the Batch in use.
• Tracing: tap Tracing button to insert the Tracing data.
• Display mode: tap this button to display one or more Characteristics, complete
with measurement bar and Histogram, on the same page. When using the dual
characteristic configuration, the table containing the statistical evaluations is
automatically hidden in order to simplify the display.
• Next charact.: enables the Operator to navigate among the various
programmed Characteristics.
• Programming: click Programs to view the Part program definition page and
access the programming phase (see paragraph 3.2.5).
NOTE:
Green: measurement within tolerance.
Red: measurement outside tolerance.
Pink: measurement at tolerance limits.
Grey: invalid measurement.
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5.3 Control chart
Use the Control chart page to view the graph and carry out acquisition cycles.
The adjacent table contains the numerical statistical results corresponding to the
Control chart. The execute measurement Step, delete and modify Programming
functions are the same as on the Main measure page.
• Subgroup: clicking on any point of the chart it’s possible to get more
informations on the subgroup that represents. Information like samples value
and alarms are shown on the table available on the right side of the screen.
• Single value chart: tap this button to display the page containing the Single
value chart for the Batch in use.
• Tracing: tap Tracing button to insert the Tracing data.
• Display mode: tap this button to change the displayed charts from X/R to X/S.
• Control limits: tap this button in order to modify the chart control limits.
• Zeroing: click on Zeroing to carry out the device electrical zeroing procedure.
By means of the statistic alarms management the system notifies if there are
- 77 -
unusual patterns or trends in Control charts, which could be evidence of erratic
behaviour during the production.
The alarms refer to:
• exceeding of Control limits.
• Running alarm on XR/S chart (i.e. seven points in a row on one side of the
middle line between Control limits).
• Trend alarm on XR/S chart (i.e. seven points in a row that are consistently
increasing or decreasing).
• Middle third alarm on XR/S chart (i.e. normal distributions have generally about
2/3 of the points within the middle third of the region between the Control
limits and about 1/3 will be in the outer two/thirds of that region, if this does not
happen there could be problems on Control limits values).
As soon as a subgroup causes an alarm condition, the Control chart is updated
with red dots in correspondence of the subgroup in alarm condition.
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5.3.1 Control limits page
The control limits page may only be accessed when working with a batch and if
the X/R control chart has been enabled.
This table displays the pre-set control limits (these limits are calculated
automatically by the software depending on the programming that has been
carried out, the tolerance limits, etc.), the calculated limits (the software updates
these limits at regular intervals, depending on the measurement results) and the
current limits (the limits that are currently in use). The latter limits can be set-up
manually by clicking on the corresponding field. To select the calculated limits as
the current limits, simply click on the field in the desired calculated limits column.
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5.4 Single value chart
The Single value chart page displays information for each single acquisition. This
can be easily done by pointing and clicking directly on the chart; the data are
reported on a grid located underneath the chart itself. This chart must be enabled
using the Global setup form, defining the number of measurements to be displayed
(minimum 25, maximum 100).
If a Batch has been defined for data collection, the informations displayed under
the chart include the first three Tracing data defined for the Part program in use.
The values of these data are entered via the Tracing data request window (see
paragraph 3.2.2).
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5.5 Tracing data request
In order to trace production, the operator may append additional

information to the completed measurements by using the Tracing
button; this button opens a request form that is divided into two
tabs: Tracing and Events.
The first TAB contains all the data required for the current part-program, with the
exception of the N.9 Event datum.
The data defined with Behaviour = Event are highlighted in blue.
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The Events tab contains the list of possible values for the N.9 Event datum.
For both tabs, select the desired values and confirm by tapping on the Ok key.
The following paragraphs provide a detailed description of the Tracing key
functions for the various measurement pages.
5.5.1 Control chart

Since it is necessary to select a sample on the control chart by clicking on it, the
Tracing button behaves in two different ways when it is tapped:
• no sample has been selected: in this case, when the operator taps the button,
it is possible to set up new tracing data and insert new events associated with
the measurement in progress. A message appears under the title of the Tracing
data request form indicating whether the information that has been inserted is
associated with a new sample, or with the last sample to be completed.
• A sample has been selected : in this case, when the operator taps the button, it
is possible to view the selected tracing data and modify the events that have been
appended to the sample in the past. The number and date of the selected sample
are indicated under the title of the Tracing data request form.
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5.5.2 Single value chart
Since it is necessary to select a measurement on the single values chart by
clicking on it, the Tracing button behaves in two different ways when it is tapped:
• No measurement has been selected on the chart: in this case, when the operator
taps the button, it is possible to set up new tracing data and insert new events
associated with the measurement in progress. A message appears under the title
of the Tracing data request form indicating whether the information that has been
inserted is associated with a new measurement, or with the last measurement to
be completed.
• A measurement has been selected: in this case, when the operator taps the
button, it is possible to view the tracing data for the selected measurement and
modify the events that have been appended to the measurement in the past (see
picture below). The date of the selected measurement is indicated under the title
of the Tracing data request form.
5.5.3 All other pages

The Tracing button enables the operator to set up new tracing data and insert
new events associated with the measurement in progress. A message also
appears under the title of the Tracing data request form indicating whether the
information that has been inserted is associated with a new measurement, or the
last measurement to be completed.
NOTE: the Events TAB is displayed only if the Event tracing datum has
been enabled with at least two programmed parameters.
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5.6 Capability tests
5.6.1 Gage capability
Having selected a Gage Capability Batch, entering the Main Measure Page it will
appear:
1 2 3
4
1. Name of Gage Capability Batch.
4. ID Part and Sample (Samples 1 of 5).
Now it is possible to perform all the measuring cycles to complete the test.
At the end the cycle stops advising that operation has completed successfully:
or unsuccessfully:
It is possible to check the general results in the Summary page:
It is also possible to check the details for each characteristic in the Histogram
page.
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5.6.2 R&R
Having selected an R&R Batch, entering the Main Measure Page it will appear:
1 2 3
4 5 6
1. Name of Gage Capability Batch.
4. ID Part.
5. ID Trial.
6. ID Operator.
Now it is possible to perform all the measuring cycles to complete the test.
At the end the cycle stops advising that operation has completed successfully:
or unsuccessfully:
It is possible to check the results for each characteristic looking in the Histogram
page or in the Single Value Chart page.
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5.6.3 Summary
The summary page will help you to have a global sight on the Gage Capability
or R&R results, showing in a single page the main parameters resulting from this
test.
After a Gage Capability test you will have the Cg and Cgk values and statuses
(the latter in case you have inserted a Verification Master value in the Zeroing
Parameters of the specific characteristic).
After an R&R test you will have the %RR values and statuses.
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5.6.4 Histogram
The histogram page will help you to have detailed information on the Gage
Capability for each characteristic.
The following picture shows an example of the result of a successful Gage
Capability test for a characteristic.
Please note Cg value and status (Good in this case).

In case of a bad result you will see something like this:
You can see the value of Cg and the status (Scrap in this case).
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5.6.5 Single Value Chart
The following picture shows an example of the result of a successful Gage
Capability test on a characteristic.
Please note Cg value and status (Good in this case).

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The following picture shows an example of the result of a successful R&R test on
a characteristic.
Please note %RR value and status (Good in this case).
- 89 -
- 90 -
6 GLOBAL SETUP
6.1 Options 1 TAB
• Class management: enables the measurement classification (default:

Disabled).
• Allow attribute characteristic: enables the insertion of attribute
characteristics into a Part program.
NOTE: attribute characteristics are manually inserted and can have
only the “good” or “scrap” values.
• Free running: this operation mode may be set to Yes, so that it is enabled for
any part program or “User defined” order to enable it for the individual part
program. The measurement is acquired continuously and registered in
correspondence with the “Dato OK” command. In Free running it is possible
to change the active page, insert traceability keys and cancel the current step.
All the other functions are available after activating the Pause command.
• Debug enable: reserved to Marposs service.
• I/O Configuration: set the layout according to the I/O signal behaviour.
NOTE: the default port used for the TCP/IP and UDP protocols is the
2000. To modify the port edit the “<NetPort>2000</NetPort>” tag in the
DOP.RSP file (after having selected the protocol in General setup), or in
the DOP-STD03.RSP file (before performing the same setup procedure).
The two files reside in the “Merlin\Database” folder.
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6.2 Transducers TAB
• OVR sensor diagnostic: this function, if enabled in the Global Setup,

implements the check of all the Part Program inputs, verifying both sensors
electronic or mechanical faults or operator errors (i.e. trying to double measure
the same part without disengaging the measuring equipment).
The check is implemented before the first measuring start step and tests
whether all the working transducers (for each with over-range limits set) can
detect, at least for a while, an over-range situation. If check fails, measure
can be forbidden or not (depending on the control type activated in the
Global Setup), but a message always advises the operator specifying all the
transducers that didn’t pass the test.
• Disabled: diagnostics disabled.
• By Piece Blocking: diagnostics enabled and blocking, the measurement
cannot proceed until all the sensors currently in the error state return to the
over-range zone. The system checks this requirement at the end of each
measured part.
• By Piece Information: diagnostics enabled but not blocking, the system
displays a message indicating which sensors are currently in the error state;
the measurement may proceed even if the sensors currently in the error state
do not return to the over-range zone. The system checks this requirement at
the end of each measured part.
• Controlled by I/O: diagnostics enabled by digital I/O, it is necessary to
prepare an I/O layout that implements the corresponding logic; it is possible
to obtain either a blocking or a purely informative operating mode.
- 92 -
• By Step Blocking: diagnostics enabled and blocking, the measurement
cannot proceed until all the sensors currently in the error state return to the
over-range zone. The system checks this requirement at the end of each
measuring step.
• By Step Information: diagnostics enabled but not blocking, the system
displays a message indicating which sensors are currently in the error state;
the measurement may proceed even if the sensors currently in the error state
do not return to the over-range zone. The system checks this requirement at
the end of each measuring step.
• Multiple transducer instance: enables the system to handle multiple
instances of the same device, so that it is possible to work with several
instruments connected to the same interface. If this parameter is Enabled, the
following parameters will appear:
• Transducer instance 1÷4: to enter the Transducer instance name.
6.3 Shifts TAB
This page can be used to setup a maximum of four working shifts so that the
system can perform the following functions when they expire:
• Zeroing (see chapter 5.1).
• Automatic batch closing (see chapter 6.7).
- 93 -
6.4 Statistics
6.4.1 Statistic TAB
The statistics tab contains all the options that can be used to set-up the
measurement statistics calculation and handle the alarms. These parameters are
ignored unless the measurements are acquired within a batch.
• Measures on histogram: maximum number of measurements to be used

when calculating the histogram; maximum value allowed: 1000. This value
will be ignored if the control chart is enabled, and the maximum number of
measurements is the same as required to compile the X/R chart (number of
chart subgroups x subgroup dimension).
• Measures on single value chart: number of measurements used to compile
the single values chart. Possible values: None (chart disabled), 25, 50, 75,
100.
• Subgroups On X/R Chart: number of samples used to compile the X/R
chart; possible values : 25, 30, 50.
• Save mode: Every Measure, End of sample.
- 94 -
6.4.2 Alarm TAB
• Consecutive rejects alarm: enables the alarm that analyses consecutive

scrap parts, you can specify the number of scrap parts that activates the
alarm.
• Middle third alarm on xr/s chart: enables the alarm that analyses the
“middle third” of the samples; when this function is enabled two additional
fields are displayed that permit the operator to define the minimum and
maximum values used when calculating this alarm. When this function is
enabled, in the column labeled “Configuration” you can specify the Max and
Min number of subgroups that are expected to fall in the middle third interval.
• Running alarm on XR/S chart: enables the alarm that analyses the samples
“running”; when this function is enabled an additional field is displayed that
permits the operator to define the number of samples used to calculate this
alarm. When this function is enabled, in the column labeled “Configuration”
you can specify the number of subgroups for this alarm.
• Trend alarm on xr/s chart: enables the alarm that analyses the samples
“trend”; when this function is enabled an additional field is displayed that
permits the operator to define the number of samples used to calculate this
alarm. When this function is enabled, in the column labeled “Configuration”
you can specify the number of subgroups for this alarm.
- 95 -
• Out of control alarm on XR/S chart: enables the alarm that indicates when
a sample is outside the chart control limits; when this function is enabled
an additional option (“Sample Correction”) permits the operator to open a
window that displays the correction calculations; these values represent the
difference between the mean value of the sample and the mid-point of the
tolerance range for all of the characteristics that have generated an alarm
condition. When this function is enabled, in the column labeled “Configuration”
you can specify whether to show only the alarmed channels, all the channels
or nothing.
NOTE: For each alarm it is possible to specify the program behavior at

measure end. Options available:
None: no action.
Show message: shows a message with a summary of every alarm, in
case it is possible to insert events.
Mandatory events: shows a message with a summary of every alarm
and force the operator to insert an event.
When an alarm is present, the “Tracing” icon changes showing an
exclamation mark; in this case, tapping the button, the “Tracing” form
will show in addition a card containing the summary of active alarms.
6.4.3 Gauge Capability TAB
• Enabled: set Yes to show the Gauge Capability features.
- 96 -
• Tolerance % (Cg): percentage of the tolerance for calculation of Gage
Capability index.
• Acceptance Threshold (Cg): threshold for the Gage Capability index.
• RR sigma coverage: multiplication factor to define the confidence level.
• RR% Validity limit: suitable thresold for the R&R study.
• RR% Derogation limit: limited suitable thresold for the R&R study.
6.4.4 X/R/S limits TAB
• X/R limits calculation mode: type of performed calculation, it can be Cpo

target (Cpo stands for “optimum capacity index”), i.e. the default choice (see
APPENDIX - Statistical analysis, Quality control chart) or Tolerance %, i.e. the
limits are calculated as a percentage of the programmed tolerance.
Selecting Cpo target it is possible to program the value for the Target Cpo for
bilateral or unilateral tolerances.
Selecting Tolerance % it is possible to program the tolerances percentages for X
chart, R chart, S chart.
- 97 -
6.5 Video TAB
• Bargraph background: Black, Coloured.

• Bargraph indicator: Bar, Cursor.
• Bargraph mode: Horizontal, Vertical
• Measurement display mode: Absolute, Displacement. The measurement is
displayed as an absolute value or displacement with respect to the centre of
the tolerance range.
• Measurement page mode: Only standard pages, All pages. If the all pages option
is selected the system also displays the “led bars” page in vertical bars format.
• Summary page: setting Yes, soon after a stop measure command, a summary
page will be displayed showing each step result. Tap Ok to exit from this page.
• View active step only: if enabled, only the current step is displayed during
the measurement phase, this means that, at each Start, the previous Step
characteristics are replaced by the current ones; in this mode it is possible
to have up to 32 characteristics for each step, with a maximum of 48 normal
characteristics for each program.
- 98 -
• Graphic and filters: enables the dynamic analysis (options: Enabled,
Disabled).
NOTE: For each alarm it is possible to specify the program behavior at
measure end. Options available:
None: no action.
Show message: shows a message with a summary of every alarm, in
case it is possible to insert events.
Mandatory events: shows a message with a summary of every alarm
and force the operator to insert an event.
When an alarm is present, the “Tracing” icon changes showing an
exclamation mark; in this case, tapping the button, the “Tracing” form
will show in addition a card containing the summary of active alarms.
• Enable Ledbar settings: set “Yes” to enable specific programming for the
Ledbars in the Part Program definition.
6.6 Data Export TAB
• Data export format: Q-Das (file.dfq), Text (file.csv), SESAME (file.txt). The
text file format is totally compatible with Microsoft® EXCEL.
• Data export timeout [s]: if this value is zero, the files are exported at the
beginning of the next cycle or exiting from the measuring page, else it
represent the maximum amount of time to wait before exporting the data.
Please, note that after the data are sent, it will no more be possible to delete
the last measure cycle; thus, the “Delete” icon will disappear.
- 99 -
• Export default path: enter the data saving path. Both local (Compact Flash
or USB memory) and remote (preconfigured Ethernet connection) paths may
be used. For example: C:\FolderName\ when saving to the internal Compact
Flash, or \USB HDD\FolderName when saving to the USB memory, or \\
PCName\SharedFolder\ for the network connection.
• Gauge capability export path: enter the Gauge Capability data saving path.
NOTE: both local (Compact Flash or USB memory) and remote
(preconfi gured Ethernet connection) paths may be used. For example:
C:\FolderName\ when saving to the internal Compact Flash, or \USB
HDD\FolderName when saving to the USB memory, or \\PCName\
SharedFolder\ for the network connection.
• Batch export filename: defines the possible rules to compose the batch export
file name; see below for the available tags. Pieces export filename: defines the
rules to compose the piece export file name; see below for the available tags.
• Pieces export filename: defines the rules to compose the piece export file
name; see below for the available tags.
• Limits combination: define whether to use specification limits (K2110-K2111)
or allowance limits (K2112-K2113).
• Additional K-fields: select Yes during the Part Program definition phase to
enable a TAB where it is possible to program a series of additional traceability
keys (see paragraph 3.2.3).
• Output protocol: permits the operator to enable a communication protocol;
upon completion of each measurement, the system transmits the acquired
data via a serial, TCP or UDP port using the selected ASCII protocol. In case
of serial protocols, the output may use the Merlin Plus serial port or any port
on an Easy Box U4S.
• Protocol name: name of the protocol in use.
• Gauge: to insert a name for the current gage so to better identify it in case of
multiple export in the same directory.
Tap Info to check the available tags used for creating export file
names:
<G> Gauge
<P> Part program
<B> Batch
<D> Date
<C> Counter
NOTE:
• You can also export data in SESAME format, please contact Marposs
personnel directly for more information.
• To export data and statistics to a network, use the Ethernet port located
on the rear panel or a Wi-Fi dongle.
- 100 -
6.7 Default batch options TAB
From these TAB it is possible to define wich are the default options proposed
during a new batch definition.
• Automatic deletion: setting Yes, the batch will be automatically deleted when
closed. Obviously you should work with export enabled when you select this
option.
• Automatic change: setting Yes, a new batch will be automatically created
when the previous batch is closed; the new batch will be named using current
date and time.
• Autorun after batch autoselection: if enabled, this option commands the
measurement cycle to start after the Batch is selected automatically by the
transducer (options: Yes, No).
• Automatic data export: programming this field you can select whether and
what you can export. Available options are: No, Measurement only, Statistic
only. Measurement and statistics.
- 101 -
- 102 -
7 PROTOCOLS
The “Serial Inputs” column displays the number of parameters handled by the
protocol and hence the number of inputs that will be made available by creating
a device that uses that protocol. The system is now capable of acquiring
measurement information from the following external devices:
MARPOSS
• Quick Digit Simplex.
• Quick Digit Duplex.
• E4N single column (configurations with daisy-chained columns are not allowed).
• Quick Read (up to four daisy-chained units).
MARPOSS - MG
• CS2-Linear.
TESA
• Micro-Hite.
• Tesa Bi-directional.
MAHR
• M1 Perthometer.
• MILLITAST 1083/1085.
• Marcator Duplex.
BOWERS
• Holematic.
TAYLOR HOBSON
• Surtronic 25 (manual).
• Surtronic 25 (automatic).
- 103 -
MITUTOYO
• SJ-201P roughness gage.
• SJ-210 roughness gage.
SYLVAC
• S_CalPRO (with continuous updating).
FISHER
• Deltascope (single-reading).
BOBE
• HF-MS-M/1 (4ch) or (8ch) - systems on devices for 4 and 8 channels.
NOTE: in order to access the information about the inputs handled by

a given protocol, select it from the list, click “Copy” and view the inputs
in the “Serial Inputs” tab”. Tap “Exit” to quit.
7.1 Personal Protocols

The Copy function enables the user to create a new Personal protocol starting
from an existing one.
• Manufacturer: manufacturer’s name.

• Name: name allocated to the protocol.
• Baudrate: communication speed expressed in bits per second (options:
B300, B600, B1200, B2400, B4800, B9600, B14400, B19200, B38400,
B57600, B115200).
• Parity: protocol parity (options: None, Odd, Even, Mark, Space).
• Stop bits: None, One, One Point Five, Two.
• Data bits: 5,6,7,8.
- 104 -
• Handshake: None, Xon/Xoff, RTS, RTS Xon/Xoff.
• Port behaviour: normally closed, always open. Using normally closed the
system will open the COM port only when it has to comunicate with the serial
device, using always open the serial device is meant to be powered from the
COM port and needs that this port is open to have the power supply.
• Power supply on RTS/DTR: if the box is ticked, the Merlin provides power
supply between RTS (-) and DTR (+) pins. A typical device that requires this
feature is the Mahr Millitast 1085.
The Request form defines the external device data request parameters.
• Init. string: enter the initialising string required to activate communications
with the device. Merlin sends the string only the first time it communicates
with the device (each time the device is switched on); the virtual keyboard
includes a list of all ASCII characters, complete with control characters. Tap
“fx” to access.
• Single measure: option Yes, No. This feature optimizes the management of
serial devices with long acquisition time, avoiding to repeat the request more
than once.
• Inter request time: delay time between 2 measure requests to a serial gauge.
• By string: specify the prefix, the suffix and, whether or not the ID input should
be sent.
- 105 -
• By signal (DTR): protocol requests via DTR signal; specify the duration in
second.
• None: no request; in this case the device sends the measurement data
autonomously.
• RJ-201 and RJ-210: as some instruments are really complex, a specific
item to select has been developed (the software will automatically manage all
required details in a transparent way for the operator).
The End of message TAB defines the external device end of answer message
recognition parameters.
• Timeout: select the closing message maximum waiting time, expressed in

seconds.
• End of answer message on lenght: end of message option based on length;
specify the number of characters in the answer message.
• End of answer message with a termination string: specify the character
sequence used to end an answer.
- 106 -
The Serial inputs TAB allow to define how to identify each measurement signal
within the context of the answer message from the external device.
By tapping the test button, Merlin sends a measure request to an

external serial unit and reads the feedback from the device. This
feature is particularly useful for debugging the protocol, in fact it is
immediately clear if the request is sent in the proper way (if not, no
answer from the serial device).
- 107 -
7.2 Data output protocols
The software allows the operator to select which of the released protocols to use
during the setting up phase, using the same method as used for the digital input/
outputs management cycles.
If a data output protocol has been setup, upon completion of each measurement
the Merlin software creates the message corresponding to the piece that has just
been measured and sends it automatically (without the need for confirmation on
the part of the operator).
The protocols are managed on one of the available serial ports. On Merlin, the
protocols have been expanded so that they are compatible with TCP-IP sockets.
The default port for the TCP/IP protocols is the 2000.
In general, a message is made up of the following sections:
• Start: contains the start communication characters.
• Global data: contains the general information about the piece that has just
been measured.
• Characteristics data: contains the information regarding the n characteristics
that transmission has been enabled for. This section consists of n sub-
sections, one for each characteristic.
• Closing: contains the checksum and the closing character.
7.2.1 Optional handshaking

It is possible to enable a simple handshaking mechanism for a protocol that can
be used to monitor the connection to the remote partner and check whether it
remains open.
• If the message is received correctly, the remote unit returns the confirmation
message: <STX><ACK><ETX> (ASCII characters 2-6-3).
• If the message is not received correctly, the remote unit either returns an error
message: <STX><NACK><ETX> (ASCII characters 2-21-3) or does not
respond at all.
• After sending the message, Merlin software awaits the response; there are
three possible outcomes:
1. positive response (ACK) -> message sent correctly
2. no response within the time limit (TimeOut) -> connection interrupted
3. negative response -> Merlin sends the message again (until it reaches
the preset maximum number of attempts) and awaits the response. No reply
or persistent negative response -> connection interrupted
When the connection interrupted status is diagnosed, a video message is
displayed indicating the type of error that has been detected.
• After sending the message, the Merlin software proceeds with its activities,
regardless of the outcome.
- 108 -
7.3 Standard protocol N°1 (DOP-STD01)
The following is a description of the standard data output protocol on a serial port
for the Merlin software, denominated DOP-STD01.
OUTPUT MESSAGE FORMAT
START
Name Characters Meaning
Start 1 Start message character: <STX>
2 <CR><LF>
GLOBAL DATA
Date 8 Date test was performed in “DD/MM/YY” format
Hour 8 Time test was performed in “HH:MM:SS” format
Program 20 Name of part program used
Serial number or progressive number of piece
Serial number 20
within the active batch
Code that indicates the result of the measure-
Piece result 2 ment performed on the piece: G (good), T(trend),
R(reject), NV(not valid)
Number of Number of characteristics sent (only non auxiliary
2
characteristics characters are sent)
2 <CR><LF>
CHARACTERISTIC DATA
The following information is sent for each characteristic
Name 3 Name of the characteristics.
Absolute or relative measurement value, as di-
splayed. The value is formatted according to the
Value 12 precision setup for the characteristic. The decimal
separator is always represented by a point. The
sign is always indicated.
Measurement Measurement unit symbol, as displayed (μm,
4
unit mm, °C…)
Code that indicates the result of the measurement
Result 3 performed on the single characteristic: G,T+,T-
,R+,R-,NV+,NV-
2 <CR><LF>
- 109 -
CLOSING
Message checksum, defined as the low byte of the
sum of the ASCII codes of all the characters in the
Checksum 3
message (apart from the stop message ETX cha-
racter and the final <CR> <LF>)
Stop 1 Stop message character: <ETX>
2 <CR><LF>
EXAMPLE OF DATA OUTPUT

In the following example, the values of two measurements (OG1 and OG2) perfor-
med on good piece number 11 using the Biella program are transferred:
<STX><CR><LF>
10/01/0815:10:01Biella______________11__________________G_2_<CR><
LF>
OG1+24.1234____µm__G__<CR><LF>
OG2-12.123_____µm__G__<CR><LF>
xxx<ETX><CR><LF>
Legend:
<STX>: character ASCII 2
<ETX>: character ASCII 3
<LF>: character ASCII 10
<CR>: character ASCII 13
_ : ASCII space character 32
xxx: indicates the value calculated for the checksum.
NOTE: the default parameters used by the standard protocols on Merlin

are:
Baudrate: 9600 Bit: 8
Parity: None StopBit: 1
- 110 -
START
2 <CR><LF>
GLOBAL DATA
Serial number 20
Piece result 2 ment performed on the piece: G (good), T(trend),
R(reject), NV(not valid)
Number of Number of characteristics sent (only non auxilia-
2
characteristics ry characteristics are sent)
2 <CR><LF>
CHARACTERISTIC DATA
Value 12 precision setup for the characteristic. The deci-
mal separator is always represented by a point.
The sign is always indicated.
4
unit mm, °C…)
Result 3 ment performed on the single characteristic:
G,T+,T-,R+,R-,NV+,NV-
- 111 -
Characteristic classification code, calculated
on the basis of the measurement value, in ac-
cordance with the table selected during the pro-
Class 5
gramming phase. If the classification code is not
required for the characteristic a series of space
characters is sent instead.
2 <CR><LF>
CLOSING
Message checksum, defined as the low byte of
the sum of the ASCII codes of all the characters
Checksum 3
in the message (apart from the stop message
ETX character and the final <CR> <LF>)
2 <CR><LF>

In the following example, the values of two measurements (OG1 and OG2) per-
formed on good piece number 11 using the Biella program are transferred. The
classification for the first measurement value is 02 for the second it is 05:
<STX><CR><LF>
10/01/0815:10:01Biella______________11_________________G_2_<CR><LF>
OG1+24.1234____µm__G__02___<CR><LF>
OP1-12.123_____µm__G__05___<CR><LF>
xxx<ETX><CR><LF>
Legend
<STX> : character ASCII 2
<ETX> : character ASCII 3
<LF> : character ASCII 10
<CR> : character ASCII 13
xxx: indicates the value calculated for the checksum
NOTES:
• The only difference between protocol DOP-STD01 and protocol DOP-
STD02 is that the latter also includes the characteristic class code.
• The default parameters used by the standard protocols on Merlin are:
- 112 -
START
GLOBAL DATA
Serial number 20
Code that indicates the result of the measu-
Piece result 2 rement performed on the piece: G (good),
T(trend), R(reject), NV(not valid)
Number of Number of characteristics sent (only non auxi-
2
characteristics liary characters are sent)
2 <CR><LF>
CHARACTERISTIC DATA
Characteristic exportation index (number betwe-
en 01 and 16) that determines the order in which
Index 2 it is exported. This value is setup by the admini-
strator level user in the characteristic program-
ming window.
4
unit mm, °C…)
- 113 -
Characteristic classification code, calculated on
the basis of the measurement value, in accor-
dance with the table selected during the pro-
Class 5
gramming phase. If the classification code is not
required for the characteristic a series of space
characters is sent instead.
2 <CR><LF>

In the following example, the values of two measurements (OG1 with exportation
index 01 and OP1 with exportation index 02) performed on good piece number 11
using the Biella program are transferred. The classification for the first measure-
ment value is 02 for the second it is 05:
<STX>
10/01/0815:10:01Biella______________11__________________G_2_<CR><
LF>
OG101+24.1234____µm__G__02___<CR><LF>
OP102-12.123_____µm__G__05___<CR><LF>
<ETX>
Legend
NOTES:
• The only differences between the DOP-STD02 protocol and the DOP-
STD03 protocol are that latter includes the characteristic exportation
index, contains variations in the start and closing sections and does not
include the checksum.
• The default parameters used by the standard protocols on Merlin are:
- 114 -
START
2 <CR><LF>
GLOBAL DATA
Batch 21 Name of batch used
Serial number 20
Code that indicates the result of the measu-
Piece result 2 rement performed on the piece: G (good),
T(trend), R(reject), NV(not valid)
Number of Number of characteristics sent (only non auxi-
2
characteristics liary characters are sent)
2 <CR><LF>
CHARACTERISTIC DATA
4
unit mm, °C…)
- 115 -
2 <CR><LF>
CLOSING
Message checksum, defined as the low byte of
the sum of the ASCII codes of all the characters
Checksum 3
in the message (apart from the stop message
ETX character and the final <CR> <LF>)
2 <CR><LF>

In the following example, the values of two measurements (OG1 and OP1) perfor-
med on good piece number 11 using the Biella program are transferred.
<STX><CR><LF>
10/01/0815:10:01biella______________Prod. April
2013_____11__________________G_2_<CR><LF>
OG1+24.1234G______µm__<CR><LF>
OP1-12.123G_______µm__ <CR><LF>
xxx<ETX><CR><LF>
Legend
xxx: indicates the value calculated for the checksum
NOTE: the default parameters used by the standard protocols on Merlin

are:
- 116 -
8 TRACING DATA
This menu contains the default traceability keys managed by Merlin.
The list of data can be expanded by using the Add command. It is possible to
import files from the Catalog using the Import command. The file import must be
done through a USB memory stick, the Merlin software will look for the “Kataloge.
dfd” file in the USB memory root.
• Import: to import files from the Catalog. The file import must be done through
an USB memory stick, the Merlin software will search the “Kataloge.dfd” file
in the root of a plugged USB memory stick.
• Add: to insert a new Tracing Data.
• Edit: to modify the selected Tracing Data.
• Cancel: to delete the selected Tracing Data.
The following table contains a list of the pre-defined data, in text form if their value
is free or Catalog form if their value has to be selected from a pre-defined list (the
Catalog corresponding to the specific datum). Catalog type data must contain at
least one value before they can be used.
N° Tracing Parameter Q-DAS Default settings

Data corresponding K-field Type Behaviour
1 Serial number K 0006 Integer number Event
2 Cavity K 0007 Catalog* State
3 Gage K 0012 Catalog* State
- 117 -
4 Machine K 0010 Catalog* State
5 Operator K 0008 Catalog* State
6 Part Ident. K 0009 Text Event
7 Reason of test K 0015 Catalog* State
8 Order K 0053 Text State
9 Event K 0005 Catalog* Event
10 Custom text K 0009 Text Event
11 Production number K 0016 Text State
12 Work piece fixture K 0017 Text State
(*) The Q-DAS catalogue may only contain the keys that are listed in the above table, if it is necessary to use Q-Das
keys that are not included in the table, contact Marposs.
During the measurement phase, the tracing information request is sub-divided

into 2 tabs: the N.9 Event datum is used automatically for the events tab, whereas
all the other data are used for the tracing tab.
8.1 Exporting Q-DAS traceability keys

K-field Parameter
K00005 Events
K00006 Serial number
K00007 Cavity
K00008 Operator
K00009 Custom text
K00010 Machine
K00011 Process parameter
K00012 Gage
K00014 Part ident
K00015 Reason for test
K00016 Production number
K00017 Work piece fixture number
K00053 Order
- 118 -
K00100 Total number of characteristics in file
K01001 Part number
K01002 Part description
K01041 Drawing number text
K01053 Contract
Exporting general Part Program/Batch data
K02001 Characteristic number (required)

K02002 Characteristic description (required)
K02004 Characteristic type
K02022 Decimal places
K02101 Nominal valuee
K02110 Lower limit value
K02111 Upper limit value
K02120 Lower limit type
K02121 Upper limit type
K02141 Unit
K02142 Unit description
K02404 Gage resolution
K01103 Cost center
K02003 Characteristic abbreviation
K02005 Class of the characteristic
K08501 Subgroup type
K04060 Machine catalog

Catalog type keys
K04070 Gage catalog

K04090 Operator catalog
K04220 Event catalog
K04240 Process parameter catalog
K04250 Cavity catalog
K08010 Chart Type and additional attributes (location)

Characteristics
with a control
associated
K08110 Chart Type and additional attributes (variation)

chart
Subgroup size (total). The dimension is stored in the

K08500
group that this characteristic belongs to.
NOTE: descriptions in accordance with the document: “Q-DAS ASCII

Transfer Format”, version dated 6/8/10. The additional K fields present
on Merlin are supported only in Q-DAS exportation, and not CSV.
- 119 -
8.2 Customizing the data
Add a new datum or modify an existing one (using the Edit command) to access
the following form.
• Parameter: original name of the parameter, the K Q-DAS value for this
parameter appears in square brackets.
• Description: description that identifies the datum.
• Type: the data may be in Text form if their value is free or Catalog form if their
value has to be selected from a pre-defined list (the Catalog corresponding
to the specific datum). It’s possible to input a list of values among which the
operator has to choose, using the table on the right side of the form and
commands Add, Del end Edit.
• Default: default value for a catalog parameter while creating a new batch. This
field for Operator parameter (K0008) identifies also the operator that performs
the auto-login at program start up; if a default value is not programmed, at
start up, the program will show the login form.
• Behaviour: defines how the key marks the measurements:
• State: if a certain key value is inserted, all the measurements will assume
that value until it is modified again.
• Event: if a certain key value is inserted, it will be valid for the current
measurement only.
NOTE: a batch must be active in order to insert the traceability keys.

Modifying the parameters after collecting data may corrupt these data,
therefore it is important to be careful, especially when cancelling values.
- 120 -
8.3 The user key
Among pre-defined keys the user key is very important: on Merlin, it allows to
manage different user levels to access software functions in a controlled way,
through the login procedure from the menu.
The password may be modified during the login procedure. Only Advanced level
users may modify the operator type keys data. When using Merlin for the first time,
a predefined, Advanced level operator key value is available (“0001Admin”).
If the operators are imported from a Qdas catalogue, the first operator is assigned
the Advanced level, whereas all the others are assigned the “Base” level.
The user profile options are divided into three different files, as indicated in the
table. The fields may contain values such as yes/no, which correspond to whether
the function is enabled or disabled, or Read/Write, which correspond to whether
the function may be used in read-only mode or may also be modified.
When creating a new user-key, the profile options have predefined values that
depend on the user level, in addition, some options may be locked for lower level
users.
- 121 -
- 122 -
9 MERLIN DIGITAL SIGNALS MANAGEMENT
In order to minimize the programming performed by the user, the Merlin software
manages digital signals (Input and Output) using precompiled lists of signals. The
operator has only to choose the I/O layout according to his needs.
For more detailed information on the I/O Layout management, please contact the
nearest Marposs office.
SIGNAL LIST
Line Meaning and management

Start/Stop type1: the same line is used to give both commands. On
rising edge the Start, on falling edge the stop. This configuration is
In
available (and cannot be changed) in all the footswitch connected to
Easy Box.
Start/Stop type2: the same line is used to give both commands.
Start and Stop commands are active on rising edge, it means that two
In pushes on the button are necessary to complete an acquisition. This
configuration is available (and cannot be changed) for all the Wave
family pushbuttons.
In Start type3: Start command active on rising edge.
In Stop type3: Stop command active on rising edge.
Zero mode: when the input is high and it’s programmed at least one
zeroing step, Merlin Plus software shows the zeroing page. When the
In
signal is low the system shows the standard measuring page. This
configuration is available for: Easy Box U8IO, DigiCrown, GageBox.
Next zero step: active on rising edge. Merlin Plus software skips to
next zeroing step. The system must be in Zeroing mode and more than
In
one zeroing step has to be available. This configuration is available for:
Easy Box U8IO, DigiCrown, Gage Box.
Batch selection: active on high level. When activated the software
changes Batch (and as consequence could change Part program too)
In according to the binary code set on “Batch Code” signals (see next
point). If the addressed batch is not valid, the system remains on the
current one and “Error status” output signal is enabled.
- 123 -
Batch code: binary code which identifies the active Batch to use to
store acquired measures. The addressed Batch is activated once Batch
selection signal is high, or if Batch selection is not available, as soon as
a bit changes in the code.It’s up to 4 bit binary code with a shift of one
In
unit, this means that addressed Batches are:
0000 → Batch with I/O index 1
Disable statistic: Disable temporarily the internal data storage and counters.
In The status of this signal is checked just after the end of measurement during
the first step and the status is frozen till the end of last Step.
Redo step: Active on rising edge. The signal deletes the measure
In acquired in last performed step allowing to repeat it. The function can
be used several times until the complete deletion of current part.
Batch n: Direct Batch selection, for each signal which goes high a
batch is activated. If the addressed Batch is not valid (i.e. two signals
In
for direct selection active at the same time), the system remains on the
current one and “Error status” output signal is enabled.
Get Zero: when the zero mode is active, the raising edge of this signal
In causes the acquisition of the “Zero Value” for all the characteristics
within the active zero step.
Get Zero (single shot): the rising edge of this signal causes acquisition
In of zero for all the resettable characteristics without the need to access
the zeroing step.
Batch code A, B, .. , K: batch code bits are continuously controlled.
When all the “Batch code bits” are OFF, the manual batch selection is
In free. When the Free Running Mode is On and the selected batch is
changed, first the measure is set in pause, then the batch is changed,
then the Free Running is restarted.
Batch code bits (MSB, LSB): the batch code is passed in BCD format,
using up to 2 digits from “01” to “99”. When the selector position is
changed, a short delay time (0.5 sec) is waited before to really command
In the batch selection; this procedure allow to the user to terminate the
selector movement before to start the batch selection. Batch code bits
are continuously controlled, so it is not possible to manually select a lot
with a code different from the one specified via I/O.
- 124 -
Emergency (active low): manages the emergency signal (active when
low). At the occurrence of the emergency (physical status of the signal:
In low) it interrupts the active step, resets all the output signals and forces the
software to display a message for the operator. This message disappears
as soon as the signal is no longer active (physical status of the signal: high).
Data Ok: validate data/OK: the same line is used to give both
In commands. Data valid is the confirmation of the measure in free running
mode, OK serves to acknowledge viewing of the summary page.
Data valid/Ok summary page: this input is used to perform a double
function. During the “Free Running Mode”, it is used to confirm the
In actual measure collection. During the “Summary Page Presentation”, it
is used to confirm that the measure is valid and it has to be saved into
the database and into the statistics.
Reset zero: when in zero mode, the raising edge of this signal becomes
In
performs a reset of the zeroing status.
In Next zero step: it is used to enter the next zeroing group (if present).
Position request: enables the sensor diagnostic procedure (obtained
by passing through the over range position of all the sensors between
In
one measure and another). It works if sensor diagnostic is enabled in
configuration with command via I/O.
Go: when an attributive measure is in progress, the Merlin opens a
window to ask to the operator if the measure is OK (Go) or NOT OK
In
(NoGo). When this window is on the screen, it is possible to mark the
measure as OK setting the “Go” input to ON.
NOGO: when an attributive measure is in progress, the Merlin opens
a window to ask to the operator if the measure is OK (Go) or NOT OK
In
(NoGo). When this window is on the screen, it is possible to mark the
measure as OK setting the “NoGo” input to ON.
Sensitivity mode: these inputs are used in “OR”: if almost one is ON,
the sensitivity mode is selected; if both are OFF, the control mode or the
In
zeroing mode is selected. If the active batch has no Sensitivity master,
this signal is ignored.
Message Ok: it allows the user to confirm an error message when
In
asked.
Redo Part/Cancel Summary Page: this input is used to perform a
double function, during the “Free Running Mode”, it is used to delete
In all the measured steps, restarting the control from the first step; during
the “Summary Page Presentation”, it is used to communicate to the
software that the measure is not valid and it has to deleted.
- 125 -
Ready to start: The signal indicates that Merlin Plus is available to receive
Out
measuring or zeroing commands.
Out Piece good: the signal indicates that last gauged part is Good.
Out Piece reject: signal indicates that last gauged part is Scrap.
Out Piece trend: signal indicates that last gauged part is in Trend range.
Error status: signal indicates an error during batch selection (the
addressed Batch is not available) or measure interrupted by error
Out during the sensor acquisition (sensor broken, disconnected, …). The
measurement is interrupted abnormally if one of the inputs is in over-range
(programmed at sensor level) upon completion of the measurement.
Acquisition running: signal indicates that system is gauging. The
signal goes high following the Start signal (beginning of measuring
Out
step) and goes down on the end of measuring step. In zeroing mode
the signal is always high.
Out End of cycle: gauging sequence completed.
Motor: it is enabled at every step of measurement for which the
Motor Management field is set to YES. It is active at the beginning of
the step and remains active for the entire duration. It is possible to
Out
use the Initial Delay setting to delay the start of acquisition to ensure
constant rotation speed of the part during acquisition. It can be used
to enable the motor that controls part rotation.
Measure n Good: indicates that on the last part gauged the result of
Out
measure n was Good (n can be 1 or 2).
Measure n Reject +: indicates that on the last part gauged the
Out
result of measure n was Reject + (n can be 1 or 2).
Measure n Reject -: indicates that on the last part gauged the result
Out
of measure n was Reject - (n can be 1 or 2).
Measure n Trend +: indicates that on the last part gauged the result
Out
of measure n was Trend + (n can be 1 or 2).
Measure n Trend -: indicates that on the last part gauged the result
Out
of measure n was Trend - (n can be 1 or 2).
Class code: class calculated for the characteristics that associate
the I/O position equal to 1. The class value is coded on 4 bit in binary
format, where zero indicates an invalid class (that is, measurement
Out was outside, above or below the entire range programmed for the
different classes), 1 indicates that the first programmed class has
been selected (starting from the top of the specific entry list), and so
on.
- 126 -
Measure n Good/Trend +/Trend -: indicates that on the last part
Out
gauged the result of measure n was Good or Trend +/-.
Measure n Scrap +/Scrap -, (Zero Not Ok): indicates that on
the last part gauged the result of measure n was Reject +/-. During
Out
zeroing the meaning of this signal becomes “reset unsuccessful
because outside of limits”.
Position Ok: indicates that sensor diagnostic has had a positive
Out
result. It is managed when the input “Request position” is high.
Position Not Ok: indicates that the sensor diagnostic has not yet
reached the OK condition (that is, at least one reading in OVR on all
sensors used). If a start measuring command is issued with this input
Out
high, measuring starts normally but the title bar displays the list of
sensors that have not passed the diagnostic test. It is only managed
when the input “Request position” is high.
Out Zero Ok: during zeroing this signal means “zero successful”.
Zero Not Ok: during zeroing this signal means “zero unsuccessful
Out
because outside of limits”.
Active Batch Code (MSB/LSB): Indicates the most/least significant
Out bit of the I/O code programmed on the batch selected for measuring.
0 indicates that measurement is not running.
- 127 -
9.1 Available layouts
LAYOUT 1 and LAYOUT 31 LAYOUT 2 and LAYOUT 32 LAYOUT 3 and LAYOUT 33
IN Out IN Out IN Out
1 Start (T3) Start/Stop (T2) Batch code Bit4 (MSB)
2 Stop (T3) Batch code bit2 (Most Significant Bit) Batch code Bit3
3 Zeroing mode Batch code bit1 (Less Significant Bit) Batch code Bit2
4 Next Zero Step Ready Batch code Bit1 (LSB)

Easy BOX U8IO
N°1
5 Ready Part Good Zeroing mode
6 Part Good Part Trend Next Zero Step
7 Part Reject Part Reject Disable Stat
8 Error Cycle End Redo Step
1 Batch Selection - -
2 Batch code bit3 (MSB) - -
3 Batch code bit2 - Ready
4 Batch code bit1 (LSB) - Part Good

Easy BOX U8IO
N°2
5 Disable Stat - Part Reject
6 Redo Step - Error
7 Part Trend - Part Trend
8 Running - Running
Easy Box (NON

1 Start/Stop (T1) Start/Stop (T1) Start/Stop (T1)
U8IO) N.1,2,3,4
Easy Box U4S 1 Start/Stop (T1) Start/Stop (T1) Start/Stop (T1)
1 Start (T3) Start (T3) Start (T3)
2 Stop (T3) Stop (T3) Stop (T3)

Easy Box U4P
3 Zeroing mode Zeroing mode Zeroing mode
4 Next Zero Step Next Zero Step Next Zero Step
Wave N. 1,2,3,..48 1 Start/Stop (T2) Start/Stop (T2) Start/Stop (T2)
1 Start (T3) Start/Stop (T2) Batch code Bit4 (MSB)
2 Stop (T3) Batch code bit2 (MSB) Batch code Bit3
3 Zeroing mode Batch code bit1 (LSB) Batch code Bit2
4 Next Zero Step Ready Batch code Bit1 (LSB)

DigiCrown I/O N°1
5 Ready Part Good Zeroing mode
6 Part Good Part Trend Next Zero Step
7 Part Reject Part Reject Disable Stat
8 Error Cycle End Redo Step
1 Batch Selection - -
3 Batch code bit2 - Ready
4 Batch code bit1 (LSB) - Part Good

DigiCrown I/O N°2
5 Disable Stat - Part Reject
6 Redo Step - Error
7 Part Trend - Part Trend
8 Running - Running
- 128 -
1 Start/Stop (T2) Start (T3) Start/Stop (T2)
2 Redo Step Stop (T3) Redo Step
3 Zeroing mode Zeroing mode Zero mode (on/off on rising edge)
4 Next Zero Step Ready Next Zero Step

Easy BOX U8IO
N°1
5 Disable Stat Part Good Batch D
6 Batch code Bit3 (MSB) Part Reject Batch C
7 Batch code Bit2 Part Trend Batch B
8 Batch code Bit1 (LSB) Error Batch A
1 - - -
2 Ready - -
3 Part Good - -
4 Part Reject - -
Easy BOX U8IO
N°2
5 Error - -
6 Part Trend - -
7 Running - -
8 - - -
Easy Box (NON

U8IO) N.1,2,3,4

Easy Box U4P
1 Start/Stop (T2) Start (T3) Start/Stop (T2)
2 Redo Step Stop (T3) Redo Step
3 Zeroing mode Zeroing mode Zero mode (on/off on rising edge)
4 Next Zero Step Ready Next Zero Step

DigiCrown I/O N°1
5 Disable Stat Part Good Batch D
6 Batch code Bit3 (MSB) Part Reject Batch C
7 Batch code Bit2 Part Trend Batch B
8 Batch code Bit1 (LSB) Error Batch A
1 - - -
2 Ready - -
3 Part Good - -
4 Part Reject - -
DigiCrown I/O N°2
5 Error - -
6 Part Trend - -
7 Running - -
8 - - -
- 129 -
1 Start (T3) Start/Stop (T2) Redo Step
2 Stop (T3) Zeroing mode Zeroing mode
3 Redo Step Next Zero Step Next Zero Step
4 Zeroing mode Ready Disable Stat

Easy BOX U8IO
N°1
5 Next Zero Step Running Running
6 Ready Part Good Part Good
7 Part Good Part Reject Part Trend
8 Part Reject Error Part Reject
1 - Batch code bit3 (MSB) Batch code bit2 (MSB)
2 - Batch code bit2 Batch code bit1 (LSB)
3 - Batch code bit1 (LSB) -
4 - Disable Stat -
Easy BOX U8IO
N°2
5 - Redo Step -
6 - Part Trend -
7 - - -
8 - - -
Easy Box (NON

U8IO) N.1,2,3,4

Easy Box U4P
1 Start (T3) Start/Stop (T2) Redo Step
2 Stop (T3) Zeroing mode Zeroing mode
3 Redo Step Next Zero Step Next Zero Step
4 Zeroing mode Ready Disable Stat

DigiCrown I/O N°1
5 Next Zero Step Running Running
6 Ready Part Good Part Good
7 Part Good Part Reject Part Trend
8 Part Reject Error Part Reject
1 - Batch code bit3 (MSB) Batch code bit2 (MSB)
2 - Batch code bit2 Batch code bit1 (LSB)
3 - Batch code bit1 (LSB) -
4 - Disable Stat -
DigiCrown I/O N°2
5 - Redo Step -
6 - Part Trend -
7 - - -
8 - - -
- 130 -
LAYOUT 10 and LAYOUT 40 LAYOUT 11 [io-std11.iom] LAYOUT 12 and LAYOUT 42
1 Redo Step - Zeroing mode
2 Zeroing mode - Measuring mode
3 Emergency (active low) - Next zero step
4 Motor out - -
Easy BOX U8IO
N°1
5 Running - -
6 Part Good - -
7 Part Trend - -
8 Part Reject - -
1 Batch code bit2 (MSB) - Batch code-Part Type bit1 (LSB)
2 Batch code bit1 (LSB) - Batch code - Part Type bit2
3 Next Zero Step - Batch code - Part Type bit3
4 Disable Statistics - Batch code - Part Type bit4 (MSB)

Easy BOX U8IO
N°2
5 - - Batch code - Spindle Type bit 1 (LSB)
6 - - Batch code - Spindle Type bit 2
7 - - Batch code - Spindle Type bit 3
8 - - Batch code-Spindle Type bit 4 (MSB)
Easy Box (NON

1 Start/Stop (T1) - Start/Stop/Get Zero (T1)
U8IO) N.1,2,3,4
Easy Box U4S 1 Start/Stop (T1) - Start/Stop/Get Zero (T2)
1 Start (T3) Start /Data OK (Type 2) -
2 Stop (T3) Get zero (one shot) -

Easy Box U4P
3 Zeroing mode Redo Step / Redo Part -
4 Next Zero Step Next Page -
Wave N. 1,2,3,..48 1 Start/Stop (T2) - Start/Stop/Get Zero (T2)
1 Redo Step - -
2 Zeroing mode - -
3 Next Zero Step - -
4 Disable Stat - -
DigiCrown I/O N°1
5 Running - -
6 Part Good - -
7 Part Trend - -
8 Part Reject - -
2 Batch code bit1 (LSB) - -
3 - - -
4 - - -
DigiCrown I/O N°2
5 - - -
6 - - -
7 - - -
8 - - -
- 131 -
LAYOUT 13 and LAYOUT 43 LAYOUT 14 [io-std14.iom] LAYOUT 15 and LAYOUT 45
1 Batch code bit 7 (MSB) Data OK Batch code bit 7 (MSB)
2 Batch code bit 6 Get Zero (one shot) Batch code bit 6
3 Batch code bit 5 Next Page Batch code bit 5
4 Batch code bit 4 Message OK Batch code bit 4

Easy BOX U8IO
N°1
5 Batch code bit 3 Batch D Batch code bit 3
6 Batch code bit 2 Batch C Batch code bit 2
7 Batch code bit 1 (LSB) Batch B Batch code bit 1 (LSB)
8 Start /Stop/Get Zero (T2) Batch A Start /Stop/Get Zero (T2)
1 Redo Step - -
2 Zeroing mode - -
3 Emergency (active “low”) - -
4 Motor out - -
Easy BOX U8IO
N°2 5 Running - -
6 Part Good - -
7 Part Trend - -
8 Part Reject -
Easy Box (NON

1 Start/Stop/Get Zero (T1) - Start/Stop/Get Zero (T1)
U8IO) N.1,2,3,4
Easy Box U4S 1 Start/Stop/Get Zero (T2) - Start/Stop/Get Zero (T2)
1 - Data OK -
2 - Get Zero (one shot) -

Easy Box U4P
3 - Next Page -
4 - Message OK -
Wave N. 1,2,3,..48 1 Start/Stop/Get Zero (T2) - Start/Stop/Get Zero (T2)
- 132 -
1 Start /Stop/Get Zero (T2) Start /Stop/Get Zero (T2) Start /Stop/Get Zero (T2)
3 Piece Good Ready Batch code bit 1 (LSB)*
4 Reject M1 + (see Note***) Part Good Batch code bit 2

Easy BOX U8IO
N°1
5 Reject M1 - (see Note***) Class bit 0 (LSB)* Batch code bit 3
6 Trend M1 + (see Note***) Class bit 1 Batch code bit 4 (MSB)
7 Trend M1 - (see Note***) Class bit 2 -
8 End Cycle Class bit 3 (MSB) -
1 Reject M2 + (see Note***) - -
2 Reject M2 - (see Note***) - -
3 Trend M2 + (see Note***) - -
4 Trend M2 - (see Note***) - -

Easy BOX U8IO
N°2 5 - - -
6 - - -
7 - -
8 - -
Easy Box (NON

1 Start/Stop/Get Zero (T2) Start/Stop (T1) Start/Stop (T1)
U8IO) N.1,2,3,4
Easy Box U4S 1 Start/Stop/Get Zero (T2) Start/Stop (T1) -
1 Start (T3) - -
2 Stop (T3) - -
Easy Box U4P
3 Zeroing mode - -
4 Next Zero Step - -
Wave N. 1,2,3,..48 1 Start/Stop/Get Zero (T2) Start/Stop (T1) -
* Binary value (0=Invalid class, 1= first class, ..) * Binary value (0=Batch 1, 15= Batch 16)
Note ***: to enable this signal it is necessary to set the I/O position parameter - see Software manual chapter Part Program Definition - Defining the characteristic
- Miscellaneous TAB
- 133 -
1 Start /Stop (T2) Start (T3) + Get zero Start/Stop (T2)
2 Batch code bit 2 (MSB) Stop (T3) + Reset zero Zeroing mode
3 Batch code bit 1 (LSB) Zeroing mode Next Zero Step
4 Zeroing mode Next Zero step Batch code bit1 (LSB)*

Easy BOX U8IO
N°1
5 Ready Good M1 + Zero OK (see Note***) Batch code bit2
6 Part good Scrapt M1 + Zero not OK (see Note***) Batch code bit3
7 Part reject Good M2 (see Note***) Batch code bit4 (MSB)
8 Cycle end Scrapt M2 (see Note***) Batch Selection
1 - Good M3 (see Note***) Position control req.**
2 - Scrapt M3 (see Note***) Ready
3 - Good M4 (see Note***) Error
4 - Scrapt M4 (see Note***) Part Good

Easy BOX U8IO
N°2
5 - Good M5 (see Note***) Part Reject
6 - Scrapt M5 (see Note***) Part Trend
7 - Good M6 (see Note***) Position OK
8 - Scrapt M6 (see Note***) Position NOK
Easy Box (NON

U8IO) N.1,2,3,4

Easy Box U4P
1 - Start (T3) + Get zero -
2 - Stop (T3) + Reset zero -
3 - Zeroing mode -
4 - Next Zero step -

DigiCrown I/O N°1
5 - Good M1 + Zero OK -
6 - Scrapt M1 + Zero not OK -
7 - Good M2 -
8 - Scrapt M2 -
1 - Good M3 -
2 - Scrapt M3 -
3 - Good M4 -
4 - Scrapt M4 -
DigiCrown I/O N°2
5 - Good M5 -
6 - Scrapt M5 -
7 - Good M6 -
8 - Scrapt M6 -
* Binary value (0=Batch 1, 3= Batch 4) Note ***: to enable this signal it is necessary * Binary value (0=Batch 1, 15= Batch 16)
to set the I/O position parameter - see Software ** It is necessary to enable “Ovr sensor dia-
manual chapter Part Program Definition - Defi- gnostic on Controlled by I/O”. The control is not
ning the characteristic - Miscellaneous TAB. blocking.
- 134 -
1 - Start/Stop (T2) Start (T3)
2 - Redo step Stop (T3)
3 - Batch F Zeroing mode
Easy BOX U8IO 4 - Batch E Next zero step

N°1
5 - Batch D Ready
6 - Batch C Part good
7 - Batch B Part reject
8 - Batch A Error
1 - Zeroing mode Batch selection
2 - Next Zero step Batch code bit3 (MSB)
3 - - Batch code bit2
4 - - Batch code bit1 (LSB)

Easy BOX U8IO
N°2
5 - - Disable stat
6 - - Redo Step
7 - - Part trend
8 - - Running
Easy Box (NON

U8IO) N.1,2,3,4

Easy Box U4P
3 Batch A Zeroing mode Zeroing mode
4 Batch B Next Zero Step Next zero step
1 - Start/Stop (T2) Start (T3)
2 - Redo step Stop (T3)
3 - Batch F Zeroing mode
4 - Batch E Next zero step

DigiCrown I/O N°1
5 - Batch D Ready
6 - Batch C Part good
7 - Batch B Part reject
8 - Batch A Error
1 - Zeroing mode Batch selection
2 - Next Zero step Batch code bit3 (MSB)

DigiCrown I/O N°2
5 - - Disable stat
6 - - Redo Step
7 - - Part trend
8 - - Running
* Binary value (Batch A=Batch 1, Batch
B=Batch 2)
- 135 -
LAYOUT 25 and LAYOUT 55 LAYOUT 26 and LAYOUT 56 LAYOUT 28
1 Start/Stop (T2) Batch code Bit4 (MSB) Data valid/OK summary page
2 Active batch code bit 2 (MSB) Batch code Bit3 Get zero (single shot)
3 Active batch code bit 1 (MSB) Batch code Bit2 Next page
Easy BOX U8IO 4 Ready Batch code Bit1 (LSB) Message OK

N°1
5 Part good Zeroing mode Redo Step/Cancel summary page
6 Part trend Next Zero Step -
7 Part reject Disable Stat -
8 Cycle end Redo Step -
1 - - Batch code B
2 - - Batch code C
3 - Ready Batch code D
4 - Part Good Batch code E

Easy BOX U8IO
N°2
5 - Part Reject Batch code F
6 - Error Batch code G
7 - Part Trend Batch code H
8 - Running -
Easy Box (NON

1 Start/Stop (T1) Start/Stop (T1) -
U8IO) N.1,2,3,4
Easy Box U4S 1 Start/Stop (T1) Start/Stop (T1) -
1 Start (T3) Start (T3) Data valid/OK summary page
2 Stop (T3) Stop (T3) Get zero (single shot)

Easy Box U4P
3 Zeroing mode Zeroing mode Next page
4 Next zero step Next Zero Step Message OK
Wave N. 1,2,3,..48 1 Start/Stop (T2) Start/Stop (T2) -
1 Start/Stop (T2) - -
3 Batch code bit1 (LSB) - -
4 Ready - -
DigiCrown I/O N°1
5 Part good - -
6 Part trend - -
7 Part reject - -
8 Cycle end - -
In the layout Nr.26 the batch changing is on

the level, in the layout Nr.3 the batch chan-
ging is on the edge
- 136 -
LAYOUT 57 LAYOUT 58 LAYOUT 59
1 Batch code Bit4 (MSB) Batch code Bit 8 (LSB) Redo Step
2 Batch code Bit3 Batch code Bit 7 Zeroing Mode
3 Batch code Bit2 Batch code Bit 6 Next Zero Step
4 Batch code Bit1 (LSB) Batch code Bit 5 Go

Easy BOX U8IO
N°1
5 Batch code Bit4 (MSB) Batch code Bit 4 NoGo
6 Batch code Bit3 Batch code Bit 3 Part Good/Zero OK
7 Batch code Bit2 Batch code Bit 2 Running
8 Batch code Bit1 (LSB) Batch code Bit 1 (MSB) Part Reject/Zero Not OK
1 Zeroing mode Start (T3) Batch code Bit2 (MSB)
2 Next Zero Step Stop (T3) Batch code Bit1 (LSB)
3 Ready Zeroing mode -
4 Part Good Next Zero Step -

Easy BOX U8IO
N°2
5 Part Reject Ready -
6 Error Running -
7 Part Trend End Cycle -
8 Running Error -
Easy Box (NOT

1 Start/Stop (T1) + Get zero Start/Stop (T1) + Get zero Start/Stop (T1) + Get Zero
U8IO) N.1,2,3,4
1 Start (T3) + Get zero Start (T3) + Get zero Start (T3) + Get Zero + Sensitivity Step
2 Stop (T3) + Reset zero Stop (T3) + Reset zero Stop (T3) + Reset Zero
Easy Box U4P
3 Zeroing mode* Zeroing mode* Sensitivity mode*
4 Next zero step Next zero step Zeroing mode*
*This button must be configured as “Auto *This button must be configured as “Auto *This button must be configured as “Auto
retentive mode” retentive mode” retentive mode”
- 137 -
1 - Redo Step Start (T3) + Get Zero
2 - Sensitivity Mode Stop (T3) + Reset Zero
3 - Zero Mode Zero Mode
4 - Disable Stat. Next Zero Step

Easy BOX U8IO
N°1
5 - Running M1 Good/Trend+/Trend-,Zero ok (see Note***)
6 - Part Good M1 Scrap+/Scrap-, Zero Not ok (see Note***)
7 - Part Trend M2 Good/Trend+/Trend- (see Note***)
8 - Part Reject M2 Scrap+/Scrap- (see Note***)
1 - Batch code Bit2 (MSB) Batch Selection
2 - Batch code Bit1 (LSB) Batch code bit3 (MSB)

Easy BOX U8IO
N°2
5 - - M3 Good/Trend+/Trend- (see Note***)
6 - - M3 Scrap+/Scrap- (see Note***)
7 - - M4 Good/Trend+/Trend- (see Note***)
8 - - M4 Scrap+/Scrap- (see Note***)
Easy Box (NOT

1 Start/Stop (T1) Start/Stop (T1) + Get Zero Start/Stop (T1) + Get Zero
U8IO) N.1,2,3,4
1 - Start (T3) + Get Zero + Sensitivity Step Start (T3) + Get Zero
2 - Stop (T3) + Reset Zero Stop (T3) + Reset Zero

Easy Box U4P
3 - Sensitivity mode* Zero Mode
4 - Zeroing mode* Next Zero Step
*This button must be configured as “Auto Note ***: to enable this signal it is necessary
retentive mode” to set the I/O position parameter - see Software
manual chapter Part Program Definition - Defi-
ning the characteristic - Miscellaneous TAB.
- 138 -
1 Batch code Bit8 (MSB) Start (T3) + Get Zero -
2 Batch code Bit7 Stop (T3) + Reset Zero -
3 Batch code Bit6 Zero Mode -
4 Batch code Bit5 Next Zero Step -

Easy BOX U8IO
N°1
5 Batch code Bit4 M1 Good, Zero Ok -
6 Batch code Bit3 M1 Trend+ -
7 Batch code Bit2 M1 Trend- -
8 Batch code Bit1 (LSB) M1 Scrap+, Zero not Ok -
1 Start/Stop (T2) M1 Scrap- -
2 Zeroing mode M2 Good -
3 Ready M2 Trend+ -
4 Part Good M2 Trend - -

Easy BOX U8IO
N°2
5 Part Reject M2 Scrap+ -
6 Error M2 Scrap- -
7 Part trend Free -
8 Free Free -
Easy Box (NOT

1 Start/Stop (T1) + Get Zero Start/Stop (T1) + Get Zero Start/Stop (T1)
U8IO) N.1,2,3,4
1 Start (T3) + Get Zero Start (T3) + Get Zero -
2 Stop (T3) + Reset Zero Stop (T3) + Reset Zero -

Easy Box U4P
3 Zeroing mode* Zero mode -
4 Next Zero Step Next Zero Step -
1 - - Start/Stop (T2)
Wave2
N. 1,2,3...30
*This button must be configured as “Auto *This button must be configured as “Auto
retentive mode” retentive mode”
- 139 -
1 - - Batch code bit4 (MSB)

Easy BOX U8IO
N°1
5 - - Zeroing Mode
6 - - Next Zero Step
7 - - Disable Stat
8 - - Redo Stat
1 - - Free
2 - - Free
3 - - Ready
4 - - Part Good
Easy BOX U8IO
N°2
5 - - Part Scrap
6 - - Error
7 - - Part Trend
8 - - Running
Easy Box (NOT

1 Start/Stop (T1) Start/Stop (T1) Start/Stop (T1) + Get Zero
U8IO) N.1,2,3,4
1 - - Start (T3) + Get Zero
2 - - Stop (T3) + Reset Zero

Easy Box U4P
3 - - Zero Mode
4 - - Next Zero Step

Wave2
N. 1,2,3...30
1 Start/Stop (T1) Part Good -

U2IO N°1
2 Part Good Part Scrap -
1 Part Trend Ready -

U2IO N°2
2 Part Scrap Running -
U1FS 1 Start/Stop (Type 1) + Get Zero Start/Stop (Type 1) + Get Zero -
Note ***: to enable this signal it is necessary

to set the I/O position parameter - see Software
manual chapter Part Program Definition - Defi-
ning the characteristic - Miscellaneous TAB.
- 140 -
1 - Data Valid/OK Summary Page Start/Stop/Get Zero (Type 2)
2 - Get Zero (single shot) Zeroing mode selection
3 - Redo Step/Cancel Summary Page (IN) Piece Good
4 - Message OK Reject + M1
Easy BOX U8IO
N°1
5 - Batch code D Reject - M1
6 - Batch code C Trend + M1
7 - Batch code B Trend – M1
8 - Batch code A End Cycle
1 - Batch code L Batch code Bit 8 (MSB)
2 - Batch code K Batch code Bit7
3 - Batch code J Batch code Bit6
4 - Batch code I Batch code Bit5

Easy BOX U8IO
N°2
5 - Batch code H Batch code Bit4
6 - Batch code G Batch code Bit3
7 - Batch code F Batch code Bit2
8 - Batch code E Batch code Bit1 (LSB)
Easy Box (NOT

1 Start/Stop (T1) - Start/Stop (T1)
U8IO) N.1,2,3,4
1 - Data Valid/OK Summary Page -
2 - Get Zero (single shot) -

Easy Box U4P
3 - Redo Step/Cancel Summary Page (IN) -
4 - Message OK -
Wave N. 1,2,3,..48 1 Start/Stop (T2) - Start/Stop (T2)

Wave2
N. 1,2,3...30
1 Start/Stop (T2) - -
U2IO N°1
2 Running - -
1 Part Good - -
U2IO N°2
2 Part Scrap - -
U1FS 1 Start/Stop (Type 1) + Get Zero - -
- 141 -
1 Data Valid/OK Summary Page Start/Stop (T3) Start/Stop (T2)
2 Get Zero (single shot) Stop (T3) Class bit 0 LSB
3 Redo Step Batch Selection Class bit 1
4 Message OK Batch Code bit 0 (MSB/LSB) Class bit 2

Easy BOX U8IO
N°1
5 Redo Part/Cancel Summary Page (IN) Position Request Class bit 3
6 Batch code C Position OK Class bit 4
7 Batch code B Position NOK Class bit 5
8 Batch code A Ready Class bit 6 MSB
1 Batch code K Part Reject Zeroing Mode
2 Batch code J Measure 1 Trend - Next Zero Step
3 Batch code I Measure 1 Trend + Ready
4 Batch code H Part Good Running

Easy BOX U8IO
N°2
5 Batch code G Free (Off) Part Good + Zero OK
6 Batch code F End Cycle Part Reject + Zero Not OK
7 Batch code E Running Part Trend
8 Batch code D Error Error
Easy Box (NOT

U8IO) N.1,2,3,4
1 Data Valid/OK Summary Page - -
2 Get Zero (single shot) - -

Easy Box U4P
3 Redo Part/Cancel Summary Page (IN) - -
4 Message OK - -
Wave N. 1,2,3,..48 1 - - Start/Stop (T2)
Wave2
N. 1,2,3...30
1 - - -
U2IO N°1
2 - - -
1 - - -
U2IO N°2
2 - - -
U1FS 1 - - -
- 142 -
1 Start (T3) - Batch code Bit4 (MSB)
2 Stop (T3) - Batch code Bit3
3 Get Zero (One Shot) - Batch code Bit2
4 Keys Confirm - Batch code Bit1 (LSB)

Easy BOX U8IO
N°1
5 Ready - Zeroing mode
6 Running - Next Zero Step
7 Part Good - Disable Stat
8 Part Reject - Redo Step
1 - - Free
2 - - Free
3 - - Ready
4 - - Part Good
Easy BOX U8IO
N°2
5 - - Part Scrap
6 - - Error
7 - - Part Trend
8 - - Running
Easy Box (NOT

1 - Start/Stop (T1) Start/Stop (Type 1) + Get Zero
U8IO) N.1,2,3,4
1 Start (T3) Batch A Start (Type 3) + Get Zero
2 Stop (T3) Batch B Stop (Type 3) + Reset Zero

Easy Box U4P
3 Get Zero (One Shot) Batch C Zero Mode
4 Keys Confirm Batch D Next Zero Step
Wave N. 1,2,3,..48 1 - Start/Stop (T2) Start/Stop (Type 2)
1 - Start/Stop (T2) -
Wave2
N. 1,2,3...30
U2IO N°1
2 - Running -
1 - Part Good -
U2IO N°2
2 - Part Scrap -
U1FS 1 - Start/Stop (Type 1) + Get Zero Start/Stop (Type 1) + Get Zero
- 143 -
9.2 I/O corrispondance table
Layout 01 [io-Std01.iom] Layout 31 [io-Std31.iom]
Layout 11 [io-Std11.iom] -
- Layout 57 [io-Std57.iom]
- 144 -
NOTE: layouts from 31 can manage I/O for 64 Easy Box with footswitch
input (all but U8IO and U4S) and 48 Wave devices.
- 145 -
- 146 -
10 DATABASE TOOL
10.1 Backup & Restore
The ‘Backup and Restore’ included in Merlin enables the user to save a complete
copy of all programming, configuration and measurement data in a ZIP format file.
If necessary it is possible to restore the system using these data.
It is possible to run the Backup & Restore software either as a tool from the Merlin
software by clicking on an icon in the menu, or in stand-alone mode by running
the executable file in the Merlin installation path. Running the tool in stand-alone
mode should only be done as a precaution if Merlin fails to open properly. In such
cases, it is possible to create a backup of the archives and send it to customer
service in order to check the integrity.
The option may be accessed from the “Settings” menu and only if the user is
authorised to do so. In fact, it is possible to select between the following alternatives
during the user configuration phase:
• do not authorise the user to access the tool.
• Authorise Backup only.
• Authorise Backup and Restore.
10.1.1 Backup
When the tool is started, the following window appears, where the Backup is
normally selected:
The default name of the file where the data backup will be saved appears,
consisting of the name of the computer and the current date and time, however
the user may modify it as desired.
- 147 -
The Notes can be used to provide additional information about the contents of the
backup and are added to the comments in the file.
The devices table on the right of the screen contains a list of the removable units
connected to the USB ports, which are updated in real time. If no Devices are
present, the backup may be saved to a local folder (path: ‘\MMCMemory\Merlin\
Restore’), thereby creating a “restore point”. To create the backup, click on Start.
Once the backup is complete, if an external device is connected it will be disabled
automatically so that it can be removed safely.
10.1.2 Restore
Click on the restore option in the menu described above in order to select one of
the following alternatives:
NOTE: it is possible to restore applications saved with Merlin CE5 and
Merlin CE7. The Merlin checks that the software used to perform the
backup has not an higher version than the expected one to carry out
the restore. It is possible to make an application restore also without the
hardware connected.
10.1.2.1 Restore from external file
To restore the system from a “ZIP” file on a device connected to a USB port, select
the path by clicking on the “…” button and choose the ZIP file containing the
desired backup. Click on the Start button to restore all the archives.
NOTE: writing in the specific field the network path, it is possible to

perform the restore from the network too.
- 148 -
10.1.2.2 Restore from restore point
This option permits the user to restore the system from a restore point that has
been saved at some earlier date in the local folder.
Select a Backup from the list and the entire path will be displayed in the text box
above the grid, at this point, click ‘Start’ to restore all the archives.
10.1.2.3 Reset all

The third option - ‘Reset all’ - deletes all the archives and restores the Merlin to its
initial state. After carrying out this procedure it is necessary to reconfigure all the
devices and re-enter all the programs.
- 149 -
10.2 Export Part Program
The ‘Export Part Program’ function included in Merlin enables the user to save a
set of the programmed Part programs, including configuration and measurement
data, in a dedicated file.
Tap on “Select Code” on the highlighted line to select/deselect a single Part

Program, tap on “Select/Deselect all” to select / deselect the whole list. If some
Part Programs have been selected, tap on “Export” to save the selected items.
Tapping on “Home”, “Select” and “Up” it is possible to navigate on your disks.

Typing a file name and tapping on “Ok” it is possible to save the Export file.
- 150 -
10.3 Import Part Program
The ‘Import Part Program’ function included in Merlin enables the user to add a
set of saved Part programs, including configuration and measurement data,
extracting them from a dedicated file.
Tap on “Select File” to start the identification of the location of the file containing
the Part programs to import.
Tapping on “Home”, “Select” and “Up” it is possible to navigate on your disks.

Tap on “Ok” to open the highlighted file containing the Part programs.
- 151 -
After selecting the backup file, it will be possible to choose the Part programs to
import:
Tap on “Select Code” on the highlighted line to select/deselect a single Part

Program, tap on “Select/Deselect all” to select/deselect the whole list. If some Part
Programs have been selected, tap on “Import” to load the selected items.
For each selected Part, a summary of the transducers involved is shown:
- 152 -
In the upper area of the window, under the columns “Original channels”, you will
find the list of the transducers that formulas refer to, in the lower side of the window,
it is possible to see the formulas in the Part program that contains the highlighted
“channel”.
Tap on “Edit” and then on the highlighted cell in the Channels Replacement column,
to scroll on the list of the available channels and select the correct one; repeat the
settings for each “Original channel”.
Tap on “Cancel” to abort the Import procedure, tap on “Skip code” to abort the
modifications for this Part Program and make the settings for the next Part program
(if any), tap on “Ok” to save the settings for this Part program.
You will be advised in case of overwrite of an existing Part Program or Master set.
- 153 -
- 154 -
APPENDIX
- 155 -
APPENDIX - Statistical analysis
General definition
BATCH
A set of similar measurements that are to be subjected to statistical analysis.
CHARACTERISTIC TYPE
Bilateral characteristic: this type of characteristic has no natural limits, therefore
it is necessary to indicate specification limits; e.g. a diameter that may have a
dimension greater or less than the design.
Single limit characteristic: this type of characteristic has a single limit indicating
an acceptability threshold, so only one specification limit need to be indicated;
e.g. a breaking strain control, where the part is considered acceptable if the force
required to break exceeds a certain level. This differs from a characteristic with a
single, upper limit if the acceptable threshold represents the maximum value that
the characteristic may assume.
Unilateral characteristic: this type of characteristic has a natural, “Insuperable”
limit; e.g. a parallelism that may not fall below 0. In this case, the specific limit is
indicated, as well as the physical limit, if other than zero.
TOLERANCE LIMITS
Two tolerance limits can be defined for a characteristic:
UTL - Upper Tolerance Limit: represents the upper specification limit.
LTL - Lower Tolerance Limit: represents the lower specification limit.
TOLERANCE INTERVAL
Also known simply as tolerance, it represents the acceptable range of
measurement values for a given characteristic. It is determined using different
methods, depending on the characteristic type:
Bilateral characteristic: UTL - LTL.
Unilateral characteristic: calculated as |TL - PL|, where TL is the tolerance limit
and PL is the physical limit (usually 0).
Single limit characteristic: cannot be calculated.
TOLERANCE MID-POINT
The mid-point of the tolerance interval.
It is determined using different methods, depending on the characteristic type:
Bilateral characteristic: (UTL – LTL) / 2.
Unilateral characteristic: calculated as |TL - PL| / 2.
Single limit characteristic: cannot be calculated.
- 156 -
Position indices
Mean - The sum of all the measurements carried out, divided by the number of
measurements.
Where:
xi is the ith measurement.
N is the number of measurements.
Dispersion indices
Range - The difference between the largest and the smallest value in a set of N
measurements
Xmax - Xmin
Where:
Xmax is the maximum value.
Xmin is the minimum value.
Standard deviation - Indicates the dispersion of the measurements. Given a set

of measurements:
Where:
xi is the ith measurement.
X is the mean measurement value.
N is the number of measurements.
NOTE: standard deviation is also identified as SIGMA and represented
by the corresponding letter in the Greek alphabet (s).
Natural tolerance
Indicates the variability inherent in the measurements. It is determined using
different methods, depending on the characteristic type:
Bilateral or single limit characteristic
Natural Tolerance = 6*s
where s is the standard deviation of the measurements.
- 157 -
Unilateral characteristic
with upper limit: Natural Tolerance = Minimum between (6*s) and (3*s + X).
With lower limit: Natural Tolerance = Minimum between (6*s) and (3*s - X).
Where:
s is the standard deviation of the measurements.
X is the mean value of the measurements.
In the case of the unilateral characteristics formula it is assumed that the natural
limit is 0. If the mean value X is closer to this 3*s limit, it means that, for this part
of the measurement, 3*s cannot be considered as dispersion, because, as the
limit is insuperable, the maximum dispersion value will be equivalent to the mean
value.
Estimated process sigma (Sigma Hat)

When sample measurements are used to evaluate a process, instead of using
the standard deviation to find its inherent variability, we use a formula and a series
of tables to estimate the process dispersion, taking into account the fact that the
measurements were obtained through a sampling method.
The index calculated in this way is known as Sigma Hat (s). This dispersion index
is based exclusively on the variability within the samples, and does not take into
account any variability between different samples that may have been taken at
significantly different periods.
There are two formulas that can be used for estimating this dispersion
• the first one is based on the Range of each sample,
where Ri represents the range of the ith sample, Nc is the number of samples
taken, and d2 refers to the values in column of the same name in the tables found
in the appendix, in the row corresponding to number of measurements in the
sample used.
• The second one is based on the Standard Deviation of each sample,
where si represents the standard deviation of the ith sample, Nc is the number of
samples taken, and c4 refers to the values in column of the same name in the ta-
bles found in the appendix, in the row corresponding to number of measurements
in the sample used.
- 158 -
Process natural tollerance
Natural Tolerance is an attempt to express the variability inherent in a given process.
The formula depends on how the measurements are distributed. As the aim is to
represent the variability of the process, we use the Sigma Hat, estimated using the
samples, rather than the Standard Deviation s used in the case of Natural Tolerance.
Bilateral or single limit characteristic
Process Natural Tolerance = 6 * ^ s
where ^s is the estimated process sigma.
Unilateral characteristic
With upper limit: Process Natural Tolerance=Minimum between (6*s) ^ and (3*s^+X).
With lower limit: Process Natural Tolerance=Minimum between (6*s) ^ and (3*s-X).
^
Where:
^
s is the standard deviation of the measurements.
X is the mean value of the measurements.
Capability indices (Cp)

The process capacity is used as the reference index when Process is selected
as the statistical scope of the batch. It is only calculated in the case of bilateral
characteristics, using the following formula:
where:
UTL – LTL = Tolerance interval.
^= Process natural tolerance.
6*s
NOTE: the Cp index is calculated only if control charts are provided for
the characteristic.
CpK
This represents the process critical capacity. It is the reference index when the
statistical aim of the batch has been indicated as Process. It is calculated using
different methods, depending on the characteristic type:
Bilateral characteristic:
Cpk = Minimum value between:
^
(2 * (UTL – X)) / (6*s)
^
(2 * (X – LTL)) / (6*s)
where:
UTL = Upper Tolerance Limit.
LTL = Lower Tolerance Limit.
X = mean measurement value.
^
s = estimated deviation of the measurements.
- 159 -
Unilateral or single limit characteristic:
^
upper limit only; Cpk = (2*(TL – X)) / (6*s)
^
lower limit only Cpk =(2*(X – TL)) / (6*s)
where:
TL = Tolerance limit <> 0.
X = mean measurement value.
^
s= estimated deviation of the measurements.
Quality control chart

Standard XR and XS chart for bilateral or unilateral characteristics. The following
table lists the possible chart types. Consult the relevant paragraph for the formulas
used to calculate the control limits.
Forming the samples

Chart name Dispersion index
and notes
A consecutive number of
Standard XR chart
Range measurements between
(Shewhart XR chart)
2 and 15
A consecutive number of
Standard XS chart
Sigma measurements between
(Shewhart XS chart)
2 and 15
The XR and XS charts are based on a series of values known as Control Limits that
are used to control the process trend; these limits can be calculated beforehand,
based on the characteristic specification limits. The following formulas are used
to calculate them: the values A, D1, D2, E7, E6, B5 and B6 indicate the values
in the columns of the same name in the tables found in the appendix, in the row
corresponding to number of measurements in the sample used.
Vn is the bilateral characteristic tolerance mid-point; whereas, if the variable is
unilateral, it is assumed that Vn=0 and one of the two limits is null.
Cpo is the optimum capacity index to be achieved for the process. At the moment
this is equivalent to 1 in the case of bilateral characteristics, and 1.33 for unilateral
characteristics.
Pre-set control limits for the X chart
LCL = Vn – (A x (UTL-LTL))/ (6*Cpo))
UCL = Vn + (A x (UTL-LTL))/ (6*Cpo))
Pre-set control limits for the R chart
LCL = D1 x (UTL-LTL)/ (6*Cpo)
UCL = D2 x (UTL-LTL)/ (6*Cpo)
Pre-set control limits for the R chart
LCL = B5 x (UTL-LTL)/(6*Cpo)
UCL = B6 x (UTL-LTL)/(6*Cpo)
- 160 -
Calculated control limits
The XR and XS charts are based on a series of values known as Control Limits that
are used to control the process trend; these limits can be calculated by using the
appropriate sample measurement formulas (if possible, after having completed a
chart consisting of 25 samples, with no out of control alarms).
In the following formulas, the values A, D1, D2, E7, E6, B5 and B6 indicate the
values in the columns of the same name in the tables found in the appendix, in
the row corresponding to number of measurements in the sample used. The value
Xm indicates the mean sample value, and Sm indicates the mean sigma value of
the samples.
Chart name X CHART R CHART S CHART
Standard XR chart LCL: Xm – Rm*A2 LCL:Rm*D3

-
(Shewhart XR chart) UCL: Xm+Rm*A2 UCL:Rm*D4
Standard XS chart LCL: Xm – Sm*A3 LCL:Sm*B3

-
(Shewhart XS chart) UCL:Xm+ Sm*A3 UCL:Sm*B4
- 161 -
Table of coefficients
Sample
size
A D2 D1 B6 B5 E7 E6 d2 C4
2 2.121 3.686 0.000 2.606 0.000 4.494 0.305 1.128 .7979
3 1.732 4.358 0.000 2.276 0.000 3.979 0.498 1.693 .8862
4 1.500 4.698 0.000 2.088 0.000 3.686 0.638 2.059 .9213
5 1.342 4.918 0.000 1.964 0.000 3.491 0.749 2.326 .9400
6 1.225 5.078 0.000 1.874 0.029 3.491 0.749 2.534 .9515
7 1.134 5.203 0.205 1.806 0.113 3.491 0.749 2.704 .9594
8 1.061 5.307 0.387 1.751 0.179 3.491 0.749 2.847 .9650
9 1.000 5.394 0.546 1.707 0.232 3.491 0.749 2.970 .9693
10 0.949 5.469 0.687 1.669 0.276 3.491 0.749 3.078 .9727
11 0.905 5.534 0.812 1.637 0.313 3.491 0.749 3.173 .9754
12 0.866 5.592 0.924 1.610 0.346 3.491 0.749 3.258 .9776
13 0.832 5.646 1.026 1.585 0.374 3.491 0.749 3.336 .9794
14 0.802 5.693 1.121 1.563 0.399 3.491 0.749 3.407 .9810
15 0.775 5.737 1.207 1.544 0.421 3.491 0.749 3.472 .9823
16 0.750 5.779 1.285 1.526 0.440 3.491 0.749 3.532 .9835
17 0.728 5.817 1.359 1.511 0.458 3.491 0.749 3.588 .9845
18 0.707 5.854 1.426 1.496 0.475 3.491 0.749 3.640 .9854
19 0.688 5.888 1.490 1.483 0.490 3.491 0.749 3.689 .9862
20 0.671 5.922 1.548 1.470 0.504 3.491 0.749 3.735 .9869
21 0.655 5.950 1.606 1.459 0.516 3.491 0.749 3.778 .9876
22 0.640 5.979 1.659 1.448 0.528 3.491 0.749 3.819 .9882
23 0.626 6.006 1.710 1.438 0.539 3.491 0.749 3.858 .9887
24 0.612 6.031 1.759 1.429 0.549 3.491 0.749 3.895 .9892
25 0.600 6.058 1.804 1.420 0.559 3.491 0.749 3.931 .9896
- 162 -
Sample
size
A2 D4 D3 A3 B4 B3 E2 E3
2 1.880 3.267 .000 2.659 3.267 .000 2.660 3.760
3 1.023 2.575 .000 1.954 2.568 .000 1.772 3.385
4 0.729 2.282 .000 1.628 2.266 .000 1.457 3.256
5 0.577 2.115 .000 1.427 2.089 .000 1.290 3.191
6 0.483 2.004 .000 1.287 1.970 .030 1.184 3.153
7 0.419 1.924 .076 1.182 1.882 .118 1.109 3.129
8 0.373 1.864 .136 1.099 1.815 .185 1.054 3.109
9 0.337 1.816 .184 1.032 1.761 .239 1.010 3.095
10 0.308 1.777 .223 0.975 1.716 .284 0.975 3.084
11 0.285 1.744 .256 0.927 1.679 .321 0.946 3.076
12 0.266 1.716 .284 0.886 1.646 .354 0.921 3.069
13 0.249 1.692 .308 0.850 1.618 .382 0.899 .063
14 0.235 1.671 .329 0.817 1.594 .406 0.881 3.058
15 0.223 1.652 .348 0.789 1.572 .428 0.864 3.054
16 0.212 1.636 .364 0.763 1.552 .448 0.849 3.050
17 0.203 1.621 .379 0.739 1.534 .466 0.836 3.047
18 0.194 1.608 .392 0.718 1.518 .482 0.824 3.044
19 0.187 1.596 .404 0.698 1.503 .497 0.813 3.042
20 0.180 1.586 .414 0.680 1.490 .510 0.803 3.040
21 0.173 1.575 .425 0.663 1.477 .523 0.794 3.038
22 0.167 1.566 .434 0.647 1.466 .534 0.785 3.036
23 0.162 1.557 .443 0.633 1.455 .545 0.778 3.034
24 0.157 1.548 .452 0.619 1.445 .555 0.770 3.033
25 0.153 1.541 .459 0.606 1.435 .565 0.763 3.032
- 163 -
APPENDIX - X/R/S limits
Cpo target calculation mode
Using this calculation mode, Cpo targets are defined for bilateral and unilateral
limits (see chapter 6.4.4).
Every time a new batch is created, initial control limits are calculated for each
characteristic requiring an X/R/S chart using the following formulas:
• Bilateral characteristics
Center = (UpLimit+LwLimit)/2
SigmaTarget = (UpLimit-LwLimit)/(6*Cpo)
UCLx = Center + (CoeffXA*SigmaTarget)
LCLx = Center - (CoeffXA*SigmaTarget)
UCLr = CoeffRD2 *SigmaTarget
LCLr = CoeffRD1 *SigmaTarget
UCLs = CoeffSB6 *SigmaTarget
LCLs = CoeffSB5 *SigmaTarget
• Unilateral characteristics
SigmaTarget = UnLimit/(6*Cpo)
UCLx = CoeffXE7*SigmaTarget
LCLx = CoeffXE6*SigmaTarget
UCLr = CoeffRD2 *SigmaTarget
LCLr = CoeffRD1 *SigmaTarget
• One limit (upper)
Ux = UnLimit
(usually) Lx = NV – Abs(UnLimit – NV)
(case NV = 0, Ux = 0) Lx = -10000
Center = Lx + ((Ux – Lx) / 2)
SigmaTarget = (Ux – Lx)/(6*Cpo)
UCLx = Center + (3*SigmaTarget)
LCLx = Center - (3*SigmaTarget)
UCLr = SigmaTarget
LCLr = 0
UCLs = SigmaTarget
UCLs = 0
- 164 -
• One limit (lower)
Lx = UnLimit
(usually) Ux = NV + Abs(UnLimit – NV)
(case NV = 0, Lx = 0) Ux = 10000
Center = Lx + ((Ux – Lx) / 2)
SigmaTarget = (Ux – Lx)/(6*Cpo)
UCLx = Center + (3*SigmaTarget)
LCLx = Center - (3*SigmaTarget)
UCLr = 0
LCLr = SigmaTarget
UCLs = 0
UCLs = SigmaTarget
where:
NV is the Nominal Value.
UpLimit is the Upper Limit (absolute value, i.e. including the nominal value).
LwLimit is the Lower Limit (absolute value, i.e. including the nominal value).
UnLimit is the unilateral / one limit upper or lower limit (absolute value, i.e. including
the nominal value).
Cpo is the target for Cp (see chapter 6.4.4).
NC (see below) is the X/R Subgroup size (see chapter 3.2.3).
CoeffXA is the value from the coefficients table in the A column at the row
corresponding to NC.
CoeffXE7 is the value from the coefficients table in the E7 column at the row
CoeffXE6 is the value from the coefficients table in the E6 column at the row
CoeffRD2 is the value from the coefficients table in the D2 column at the row
CoeffRD1 is the value from the coefficients table in the D1 column at the row
CoeffSB6 is the value from the coefficients table in the B6 column at the row
CoeffSB5 is the value from the coefficients table in the B5 column at the row
UCLx is the Upper control limit for the X chart.
LCLx is the Lower control limit for the X chart.
UCLr is the Upper control limit for the R chart.
LCLr is the Lower control limit for the R chart.
UCLs is the Upper control limit for the S chart.
LCLs is the Lower control limit for the S chart.
- 165 -
Bilateral limits example
Nominal value = 10.000

UpLimit = 10.100
LwLimit = 9.900
Cpo = 1.00
NC = 5
Calculation:
Center = (UpLimit+LwLimit)/2 = (10.100+9.900)/2=10.000
SigmaTarget = (UpLimit-LwLimit)/(6*Cpo) = (10.100-9.900)/(6*1.00)=0.033
UCLx = Center + (CoeffXA*SigmaTarget) = 10.000 + (1.342*0.033)=10.0447
LCLx = Center - (CoeffXA*SigmaTarget) = 10.000 - (1.342*0.033)=9.9553
UCLr = CoeffRD2 *SigmaTarget=4.918*0.033=0.1639
LCLr = CoeffRD1 *SigmaTarget=0.000*0.033=0.0000
UCLs = CoeffSB6 *SigmaTarget=1.964*0.033=0.0655
LCLs = CoeffSB5 *SigmaTarget=0.000*0.033=0.0000
Unilateral limits example

UnLimit = 0.100
Cpo = 1.33
NC = 5
Calculation:
SigmaTarget = UnLimit/(6*Cpo)=0.100/(6*1.33)=0.0125
UCLx = CoeffXE7*SigmaTarget=3.491*0.0125=0.0437
LCLx = CoeffXE6*SigmaTarget=0.749*0.0125=0.0094
UCLr = CoeffRD2 *SigmaTarget=4.918*0.0125=0.0616
LCLr = CoeffRD1 *SigmaTarget=0.000*0.0125=0.0000
- 166 -
One limit (upper)

ULimit = 10.100
Cpo = 1.33
NC = 5
Calculation:
Ux=UnLimit=10.100
Lx = NV – Abs(UnLimit – NV)=10.000 – Abs(10.100 – 10.000) = 9.900
Center = Lx + ((Ux – Lx) / 2) = 9.900 + ((10.100 – 9.900) / 2) = 10.000
SigmaTarget = (Ux – Lx)/(6*Cpo) = (10.100 – 9.900) / (6*1.33) = 0.0251
UCLx = Center + (3*SigmaTarget) = 10.000 + (3 * 0.0251) = 10.0752
LCLx = Center - (3*SigmaTarget) = 10.000 - (3 * 0.0251) = 9.9248
UCLr = SigmaTarget = 0.0251
LCLr = 0
UCLs = SigmaTarget = 0.0251
UCLs = 0
One limit (lower)

ULimit = 9.900
Cpo = 1.33
NC = 5
Calculation:
Lx=UnLimit=9.900
Ux = NV – Abs(UnLimit – NV)=10.000 + Abs(9.900 – 10.000) = 10.100
Center = Lx + ((Ux – Lx) / 2) = 9.900 + ((10.100 – 9.900) / 2) = 10.000
SigmaTarget = (Ux – Lx)/(6*Cpo) = (10.100 – 9.900) / (6*1.33) = 0.0251
UCLx = Center + (3*SigmaTarget) = 10.000 + (3 * 0.0251) = 10.0752
LCLx = Center - (3*SigmaTarget) = 10.000 - (3 * 0.0251) = 9.9248
UCLr = 0
LCLr = SigmaTarget = 0.0251
UCLs = 0
UCLs = SigmaTarget = 0.0251
NOTE: if the automatic batch change is activated (see chapter 4.1), the
control limits are automatically copied from the closed batch, thus no
initial calculation will be performed.
- 167 -
Tolerance percentage calculation mode
Using this calculation mode, a percentage of the tolerance to initialize the control
limits can be set for each chart. A value between 0.01% and 100% activates this
mode. Setting 0% the Cpo target calculation mode will be used for the related
chart.
Default percentages can be set in the Global Setup(see chapter 6.4.4). These
values will be used for each new programmed characteristic using X/R/S charts.
- 168 -
APPENDIX - Changing the Merlin date/time
From the menu click on the Exit button to exit the measurement
software. Merlin enters the Windows® Operating System.
Double click on the digital clock displayed in the bottom right hand corner of the
screen.
The date/time setting Windows® is displayed.
Select the desired time then tap on Apply.
After this, go to Start Settings Control Panel and double-tap on Registry

Saver then tap Save.
- 169 -
APPENDIX - Calibrating the touch-screen
Follow the directions below to calibrate the touch-screen:
Click on Start Settings Control Panel
Double click on “Stylus”.
- 170 -
Select “Calibration” tab, then click on “Recalibrate”.
Now the program will ask to you to touch the parts of the screen with the cross.
After these operations, the touch-screen is calibrated.
Now go to Start Settings Control Panel and double-tap on Registry Saver

then press Save.
NOTE: this operation is required every time you update the Operating
System.
- 171 -
APPENDIX - Creating a Merlin-to-PC Ethernet Link
The following procedure defines the steps necessary to link the Merlin to a PC.
Specifically, we are creating a network with the PC as the “host” and Merlin as its
“guest.” The purpose of the connection is for simple file sharing of statistical and
measurement data. Interactivity other than basic file sharing is limited at this time.
Hardware Requirements
The hardware required to link Merlin to a PC is various depending on the type
of network being set up. Wireless Cards, Routers, Bluetooth Adaptors, Internet
Connectivity and similar technologies offer a multitude of networking options. The
configuration used in this example details a basic ‘wired’ LAN/Ethernet connection.
The minimum hardware requirements to create such a connection should be a
HUB, two (2) LAN/Cross ethernet cables and a USB keyboard.
Software
The perpetual software upgrades and releases of both Windows and Marposs
Merlin Gage Computer inherently create a ‘gap’ in uniformly defining a Network
creation procedure. Examples will show connection between Windows XP/
Windows 7 and Merlin.
Hardware Set-up
1. Plug one end of the LAN/Ethernet cable into the back of the PC and the other
end into the HUB.
2. Plug one end of the second LAN/Ethernet cable into the HUB and the other
end into Merlin LAN jack.
3. Power up both systems.
Windows XP/7 set-up

1. Create and Name a folder on the PC main storage drive (C:/stats_meas).
2. Right-Click on the folder and select “sharing and security” options.
3. Place a check mark in the “Share this folder on the Network”.
4. Place a check mark in the “Allow network users to change my files”.
5. A file sharing folder icon now appears on the folder.
- 172 -
Example of connection between Merlin and a PC to
Windows 7
This chapter shows how to connect in a network a PC desktop (operating system
Windows7) with a Merlin.
Shows the settings of the network board inside the PC, selected the internet protocol
version 4 (TCP/IPv4) and press the propreties button to set the parameters shows
in the picture below (IP address, Subnet mask, Default gateway and Prefered DNS
server).
Entering on the “Control Panel” —> ”Network Connection Center …” then select
“Change advanced sharing settings” as in the picture below.
- 173 -
Tick the option of sharing files then allow the users any operation on reading/
writing and then save the changes. See the picture below.
Create the folder for sharing, open the “Properties” by clicking on the right button
of the mouse. Enter on the Tab “File Sharing”, then tap on the button “Share” and
select “Everyone” from the combo and then tap on “Add”. Modify the “Authorization
level”, from “Reading” to “Reading/Writing”. Tap on “Share”.
- 174 -
The configuration of the PC is ended.
From the Merlin side, select the path “\\NamePCW7\NameSharedFolder” and in-
sert the User Name and Password to access at the Network domain.
From now, the shared folder could be connected and accessible and it is possible
to create, modify and delete files.
Now go to Start Settings Control Panel and double-tap on Registry Saver

then press Save.
NOTE: this operation is required every time you update the Operating
System.
NOTE: before accessing from Merlin to the shared folder on the PC, it
is essential to use a user profile with administrator rights. If it does not
exist it is necessary to create it.
- 175 -
APPENDIX - Message management following alarms
When an alarm is present, the “Tracing” icon changes showing an exclamation
mark; in this case, tapping the button, the “Tracing” form will show in addition a
card containing the summary of active alarms.
Consecutive scraps alarm example:
- 176 -
This alarm has distinct behavior whether measurements are saved as sample or not.
Measures saved after each part: in this case, all the consecutive scraps are
counted and the alarm stays active until a good part is measured. In case batch
changes or the program restarts, the state of the last consecutive scrapes from
the measures archive is loaded.
Measure saved as sample: in this case, only the consecutive scrapes inside a
sample are counted and the alarm is zeroed every new sample.
Alarm on Control Charts example:
If the program is configured to show corrections, two more columns appear that,
in case of out of control alarm on X chart, show the tolerance mid-point and the
correction for the NC.
- 177 -
- 178 -
NOTES:
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NOTES:
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- 180 -
NOTES:
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- 181 -
INFORMATION FOR USERS
concerning the terms of the National Legislation enforcing the Directives
2014/35/EU, 2014/30/EU on the restriction of the use of certain hazardous substances in
electrical and electronic equipment, and the disposal of waste materials
The wheelie bin symbol with a cross through it on the equipment or its packaging indicates that the
product must be disposed of separately from other waste materials at the end of its working life.
If the user wishes to dispose of this equipment, he/she must do so in accordance with the applicable Na-
tional regulations governing the separation of the unit into its waste materials at the end of its working life.
Separating waste materials correctly before submitting the equipment for recycling, treatment and envi-
ronmentally compatible disposal can help to prevent potentially negative effects on health and the
2014/35/EU environment, as well as making it easier to reuse and/or recycle its constituent materials.
2014/30/EU Failure to dispose of this product in accordance with these indications is punishable in accordance with
the applicable laws.
Consult the official site Marposs: www.marposs.com for a full and updated address list
D2101639SG – Issued 02/2018 – These specifications may be subject to modifications.

© Copyright 2018 MARPOSS S.p.A. (Italy) – All rights reserved.
MARPOSS S.p.A. Via Saliceto, 13 - 40010 Bentivoglio (Bo) Italy

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SOFTWARE MANUAL

1.1 Operating limits

1.2 Command bar

This icon appears in all the programming windows when it is

Change operator (see paragraph 1.6).

Access configuration phase.

Tap this icon to access the sub-menu where it is possible to

Tap this icon to access the Measurement devices map page

If the menu contains more than five icons this command

Tap this icon to display Merlin version, the allocated memo-

Tap this icon to update the software version.

Tap this icon to exit the measuring software.

Access programming phase (see chapter 3).

Access Batch creation phase (see chapter 4).

Access Measurement page (see chapter 5).

1.5 The virtual keyboards

NOTE: it is also possible to connect a USB keyboard to Merlin, or a

1.5.1 Japanese keyboard (Hiragana or Katakana)

1.5.2 Chinese keyboard (Pinyin)

NOTE: to create or modify the programmed users, see the paragraph

Global setup Disable Read Read/Write

Master Set list Read Read/Write Read/Write

Batch edit Yes Yes Yes

and type the filter key (i.e. 40F).

By clicking on the sensible line below the insert box

It is also possible to have a combined filter tapping on different columns, for

To cancel the filtering string, tap on the relevant list descriptor.

NOTE: Part Programs list can be filtered by “Name” or “Description”;

• Select Add a device from the command bar.

It is possible to have different statuses for the transducers.

Normal transducer behavior.

Key: Each transducer is identified by a three figure value, for example,

2.1 Multiple transducer instance

2.2 Basic devices

• M1 Wave: Marposs Bluetooth® buffers with electrical capsules.

• I-Wave: Marposs Bluetooth® buffers with mechanical capsules.

• Easy Box U4F: for Marposs standard full-bridge/LVDT transducers.

NOTE: if it is necessary to connect more than 5 Easy Boxes to the Merlin,

Tap Binding to execute pairing with a M1 Wave, M2 Wave, I-Wave

Tap Info to get information on the device and to program the

• Max number of plugs simultaneously switched on: can be set from 1 to 7.

Tap Binding to execute pairing with a I-Wave2 plug.

• Display rotation: sets the display rotation on the handle

• Auto: automatic orientation. S

NOTES: the battery level indication is not relevant during charging.

Tap Info to get information on the device and to program the

• Max number of plugs simultaneously switched on: can be set from 1 to 8.

2.3.3.1 How to pair a QDT MultiChannel

2.3.3.2 How to set the command from central button

2.3.5 Easy Box U4E

2.3.6 Easy Box U4H

Tap Add to execute DigiCrown network automatic recognition

2.3.8 DigiCrown USB and ETH

2.3.8.1 How to add modules to a USB network

2.3.8.2 How to replace the USB interface

NOTE: modules have always to be replaced physically having exited

2.3.9 Serial gauge

2.3.9.1 Easy Box U4S

NOTE: only one Easy Box U4S may be connected to Merlin.

or Orbit USB to manage high speed modules:

NOTE: every module in the net has to be a 3rd generation (Orbit3)

Click on Transdusers settings to edit the transducer parameters.

• Transducer: transducer name (max. 5 characters editable using the