MAGUIRE Gravimetric Gateway LineMaster Manuel du propriétaire
MAGUIRE PRODUCTS INC.
EXTRUSION & YIELD CONTROL
Gravimetric Gateway
LineMaster
Extrusion Control & Yield Control
Quick Start Tutorial Manual
Computer Communications Software
for the Maguire WSB, WST, WSD, LIW & MGF
INSTALLATION OPERATION MAINTENANCE
Revision: 1-21-2019
Copyright Maguire Products, Inc. 2019
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LineMaster
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LineMaster
Maguire LineMaster
Loss-in-Weigh System
Extrusion Control & Yield Control
Weigh Scale Blender Supplement
2019 Maguire Products Inc.
To every person concerned with use and maintenance of the Maguire LineMaster it is
recommended to read thoroughly these operating instructions. Maguire Products Inc. accepts no
responsibility or liability for damage or malfunction of the equipment arising from non-observance of
these operating instructions.
To avoid errors and to ensure trouble-free operation, it is essential that these operating instructions
are read and understood by all personnel who are to use the equipment.
Should you have problems or difficulties with the equipment, please contact Maguire Products Inc. or
your local Maguire distributor.
These operating instructions only apply to the equipment described within this manual.
Manufacturer’s Contact Information
Maguire Products Inc.
11 Crozerville Road
Aston, PA. 19014
Phone: 610.459.4300
Fax: 610.459.2700
Website: http://www.maguire.com
Email: [email protected]
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LineMaster
Table of Contents:
LineMaster Overview 5
LineMaster Kits and Components 18
Parts Identification 18
LineMaster Kits 19
LineMaster Installation 20
Safety Warnings 20
Loss-In-Weigh Hopper Installation 21
General Wiring Installation Notes 23
XC-1 – Extrusion Control Installation 25
XC-1 – Extrusion Control Wiring Diagram 26
XC-2 – Yield Control X or Yield Control T Installation 28
XC-2 – Yield Control X or Yield Control T Wiring Diagram 29
XC-3 – Yield D Installation 31
XC-3 – Yield D Wiring Diagram 33
LineMaster Operation 35
Standalone Operation 35
XC-1 Throughput Control 35
XC-2 – Yield Control X or Yield Control T 37
XC-3 – Yield D 40
Gravimetric Gateway Software (G2) 41
G2 Software Setup and Operation 43
Controller Description 61
Communications 65
Controller Keypad 66
Star Functions 69
Parameters 75
Alarms 80
Load Cell Zero Weight Calibration 81
Load Cell Full Weight Calibration 82
General Information
Updating Controller Firmware 83
LIW Model Specifications and Dimension Drawings 84
Warranty 93
Contact Information 93
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LineMaster
LineMasterTM Extrusion Control
LineMasterTM is for all continuous extrusion processes including film, sheet, pipe, coating and
lamination, wire and cable and compounding. LineMaster’s flexible design provides several
measurements and control options, and includes an integrated system for combining gain-in-
weight dosing control with loss-in-weight extrusion control. The system is an easy to use low cost
alternative to competitive loss-in-weight systems without compromising performance and control.
Benefits of LineMasterTM
Improved product quality through permanent and consistent control
Reduced material costs through improved yield
Automatic regulation of extruder output
Increased line productivity with fast start-up and reduced production scrap
Quick product changeover
Alarms and user security
WEIGHT MEASUREMENT OPTIONS
Basic Extrusion Control with Maguire® Blender
Extrusion line throughput may be determined by monitoring material consumption as recorded by
the batch weighing process of the blender divided by the time the batch takes to be consumed.
Throughput is determined by the blender controller when 5 consecutive batches have shown a
steady throughput rate. If 2 batches show consecutive errors an adjustment is made to maintain
the desired throughput rate.
Basic Extrusion Control provides a very cost effective solution for long product runs on mono-layer
lines. The blender must be throat mounted. Basic Extrusion Control is simple, has less mechanical
parts and requires low maintenance.
Basic Extrusion Control Limitations:
Frequent job and/or material changes
Blender not mounted on the extruder throat (surge hoppers / floor stands)
Co-extrusion lines running low throughputs
Lines with frequent ramp up / ramp down requirements
Restricted loading systems or poor flowing materials
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LineMaster
Enhanced Extrusion Control with Loss-in-Weight Hopper
The LineMasterTM product range has the option of monitoring material consumption by a loss-in-
weight hopper mounted on the process throat. The weight consumption data can be reported to
one of two control options: Enhanced Extrusion Control with a Maguire blender integrates the
extrusion control functions into the blender controller for a single point of control. The second
option is Enhanced LIW Extrusion Control, which utilizes LineMaster Control Operator Interface
(XCC) to be used as a stand-alone solution for throughput or yield control. Additionally, it can be
utilized in a multi-layer control application.
The weight consumption data is communicated directly to the respective controller and updates
consumption information frequently. The loss-in-weight hopper determines accurate throughput
within 5 seconds and updates thereafter every 1 second.
XC CONTROL OPTIONS
LineMaster is a comprehensive range of products that is designed to serve the vast majority of
extrusion operations that require solutions based at every level of the cost / performance
spectrum. The available control options provide throughput control for pounds or kilograms per
hour, weight per length control for lb/ft or gm/M and gauge control in microns.
XC-1 Throughput Control
Control is maintained by monitoring the throughput of the process and regulating the extruder
speed. The XCC controller utilizing the consumption data from the LIW hopper communicates with
the XCD-X Extruder Drive Speed Control to adjust the extruder speed via a 0-10 volt signal to
maintain the throughput target.
XC-2 Yield Control
XC-2 offers the ability to maintain a product’s weight per length (lb/ft or gm/M) by monitoring the
process throughput against the line speed. An XCE Digital Encoder mounted on a take-off device
monitors the line speed. Control is accomplished by adjusting either the extruder speed with a
XCD-X Drive Speed Control Module by referencing the manually controlled line speed or
controlling the take-off speed with a XCD-T Line Speed Control Module from a manually controlled
extruder.
XC-3 Multi-Layer Yield Control via Computer and G2 Software
XC-3 provides complete weight per length control (lb/ft or gm/M), via simultaneous control of the
extruder and take-off. Controllers are connected via a high speed serial or Ethernet network using
the XC Software. Gauge or thickness control can be initiated in set-up utilizing data of the
materials or blend specific gravity.
Advanced Weigh Control Benefits:
Lines requiring constant feedback
Frequent job / material / production changes
Blenders not mounted on the extruder throat
Co-extrusion lines
Lines requiring frequent ramp up / ramp down control
Lines using only one material
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LineMaster
Computer Control and Data Options
With the LineMasterTM product range, the Gravimetric Gateway TM (G2) software program is
available for centralized control and data reporting. The software program is an integral part of the
XC-3 Extrusion Multi-layer Control and as an option for mono- layer applications of throughput or
yield control.
A brief overview of G2
A Gravimetric GatewayTM Server (G2 Server) provides communication with all Maguire controllers
for data collection and control. The G2 software enables communication directly from the server
with one or more blender or loss-in-weight controllers to connect remotely from anywhere over a
TCP/IP network using the Gravimetric GatewayTM Client software. The server provides two-way
communication with the network of blenders and loss-in-weight controllers for constant retrieval of
information such as:
Precise weight of all materials
Settings (sending and retrieval)
Recipe numbers
Work order numbers
Operators information
The G2 server organizes and tracks material usage and allows the user to gather accurate
information according to a number of factors including: time period (day, shift, etc), process
machine, work order, operator, recipe, blender and line recipe.
Throughout and Yield Control
LineMaster can monitor and control up to 7 layers; each layer is graphically depicted. All lines
visually merge where the Total Throughput is displayed. Take-off and downstream controls are
displayed at the right showing line speed, weight per length and/or gauge.
A more detailed examination of each blender’s settings and output can be accessed through the
Line Blender Screen by clicking on the individual extruder.
Throughput Reporting
The software also allows reporting on average throughput, total throughput, and the percentage of
total uptime of an individual blender or all blenders in the line. Reports are based on start/stop
date and time, weight units and percentage of run time.
Event Monitoring
The computer software also incorporates an event monitoring service allowing users to access a
history of alarms, actions and changes.
Materials and Blend Management
The software can also store a complete dataset of materials and recipes used in production. This
data is easy to edit and maintain, and allows for full tracking of material consumption and
inventory management – a valuable tool for data regarding quality, certification, costs and
productivity.
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LineMaster
REDUCE RESIN CONSUMPTION WITH
ENHANCED GRAVIMETRIC EXTRUSION YIELD CONTROL
The diagram on the following page illustrates a 3-layer film line utilizing LineMasterTM Extrusion
Control. Loss-in-weight hoppers are mounted on 3 extruders that are feeding the die producing the
film bubble. The loss-in-weight hoppers provide precise throughput data and an encoder (mounted
on nip rolls or any rotating shaft) provides line speed data. Any change in throughput due to
screen pack, back pressure, melt temperature or other variables is detected and adjusted for.
Typical process variations are reduced with LineMaster gravimetric control to within ± 0.5%,
significantly reducing resin consumption. Typically, 3 to 4% resin savings is realized resulting in
payback in as little as 6 months. LineMaster simplifies line start-up, enables rapid job changes and
reduces scrap during string-up.
LineMasterTM Encoder – Model XCE
Extruder Drive Speed Control – Model XCD-X
Take-off / Line Speed Control – Model XCD-T
LineMasterTM Speed Control modules communicate directly with the XCC or blender controllers.
The controller receives process throughput updates from the loss-in-weight hopper and
commands the speed control modules to increase or decrease screw rpm.
The speed control modules provide a 0 – 10 Vdc analog signal to the extruder or take-off drive
being controlled. The XCD Speed Control Modules include a digital potentiometer, which replaces
the existing manual pot or can communicate with an existing digital speed control. A toggle switch
is included to provide selection of either Manual or Automatic control.
APPLICATIONS
Wood Composite
Corrugated
Pipe & Tubing
Wire & Cable
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LineMaster
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LineMaster
Overview - XC-1 LineMaster® Throughput Control (lb/hr or kg/hr)
Monitors throughput - Adjusts extruder drive speed to maintain product weight per hour
Component Installation
The system is comprised of a mass flow hopper assembly, a controller with operator interface and
a drive speed control package.
The mass flow hopper assembly is mounted on the throat of the extruder. A weigh hopper
suspended from a set of load cells provides the material flow data to the LIW controller. The
extruder drive control package, which includes a digital potentiometer to replace the existing
analog extruder speed pot, is mounted in the control cabinet and monitors and controls the signal
to the extruder drive.
Principal of Operation
The XC-1 Extrusion Throughput Control System is designed to maintain a products weight over
time by monitoring the material consumption of the process through the mass flow hopper on the
throat of the extruder in pounds or kilos per hour, and adjusts the extruder speed to maintain the
desired throughput. The actual throughput is compared to a desired target throughput of the
product entered on the LIW controller. The LIW controller communicates to the XCD-X Extruder
Drive Control, which adjusts the voltage or reference signal to the extruder drive, which will
increase, or decrease to maintain the desired throughput.
A digital potentiometer replaces the existing rotary drive speed control on the extruder drive panel
and communicates with the XCD-X Extruder Drive Control which is mounted in or on the control
cabinet and is connected to the LIW controller.
aspc0910
LIW w/ XCC
M
EXTRUDER
Product
XCD
-
X
Dri
ve Speed Control
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