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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



Maguire Products, Inc. 2019

Содержание Gravimetric Gateway LineMaster

Страница 1: ...avimetric Gateway LineMaster Extrusion Control Yield Control Quick Start Tutorial Manual Computer Communications Software for the Maguire WSB WST WSD LIW MGF INSTALLATION OPERATION MAINTENANCE Revisio...

Страница 2: ...Maguire Products Inc 2 LineMaster...

Страница 3: ...rom 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 a...

Страница 4: ...l 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...

Страница 5: ...s 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 weig...

Страница 6: ...auge 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 fr...

Страница 7: ...ing 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...

Страница 8: ...vings 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...

Страница 9: ...Maguire Products Inc 9 LineMaster...

Страница 10: ...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 th...

Страница 11: ...d throughput within 45 seconds of the process reaching the requested target Once the LIW controller learns the throughput rate of a material it is stored in the memory of the controller The controller...

Страница 12: ...al of Operation The XC 2X Extrusion Yield Control System is designed to maintain a products weight per length yield by monitoring the material consumption of the process through the mass flow hopper o...

Страница 13: ...process reaching the final speed Once the LIW controller learns the throughput rate of a material it is stored in the memory of the controller The controller can be left in the Auto or Locked mode if...

Страница 14: ...grams or kilograms per meter The actual yield is compared to a desired target yield of the product entered on the LIW controller The LIW controller communicates to the XCD T Take off Drive Speed Cont...

Страница 15: ...XX Mass Flow Hopper sized for the required throughput as7190 Surge Hopper optional XCC LineMaster Control Operator Interface XC 2T LineMaster Extrusion Yield Control w Line Speed Control Package incl...

Страница 16: ...ntrol cabinet and monitors and controls the signal to the extruder drive The two drive controllers communicate to with one another to provide a synchronous ramp of all drives as directed by the LineMa...

Страница 17: ...ller The controller can be left in the Auto or Locked mode if the same material is continued or a similar bulk density material is used If a new material with a different bulk density is used the star...

Страница 18: ...truder Speed Control Take off Speed Control LineMaster Controller Encoder Encoder Wheel 100 foot cable 24 volt power supply Maguire LIW 5 Maguire LIW 10 Maguire LIW 20 Maguire LIW 40 Optional Componen...

Страница 19: ...lief mounting hardware 24 Volt Power Supply Encoder Encoder Wheel 12 inch circumference Encoder Cable o Yield D LineMaster Controller Extruder Speed Control Interface Take off Speed Control Interface...

Страница 20: ...ion Prior to installation thoroughly review the wiring diagram specific to your installation Wire Installations Preventing Interference or Damage When installing communication wires be sure to avoid a...

Страница 21: ...le the LIW Hopper and the skid are on the ground Reverse procedure to install LIW Hopper on the skid Loss In Weigh Hopper Installation Install LIW Hopper on Extruder The base of the LIW Hopper frame i...

Страница 22: ...e back panel of the controller On LIW 5 models the mount plate is part of the frame Connect Cables Two cables are supplied with the LIW Hopper Connect the 3 foot DB25 cable to the Controller s Load Ce...

Страница 23: ...ngle wire installations and one for 2 wire installations Two hole locations are provided in boxes one at the base and one on the back When installing wires onto the circuit board within the control bo...

Страница 24: ...w voltage lines together 2 It is not necessary to run this wire in conduit If you do run cables without conduit do not wire tie these lines to material conveying lines or other conduit containing high...

Страница 25: ...ns on the Control box Use a stain relief if necessary Strip back approximately inch 6mm per wire and install into the terminal strip see wiring diagram on the following page for exact wire locations R...

Страница 26: ...Maguire Products Inc 26 LineMaster XC 1 Extrusion Control Wiring Diagrams...

Страница 27: ...Maguire Products Inc 27 LineMaster...

Страница 28: ...Strip back approximately inch 6mm per wire and install into the terminal strip see wiring diagram on the following page for exact wire locations Install the Encoder on the shaft of the haul off Run th...

Страница 29: ...Maguire Products Inc 29 LineMaster XC 2 Yield Control X or Yield Control T Wiring Diagrams...

Страница 30: ...Maguire Products Inc 30 LineMaster...

Страница 31: ...approximately 2 inches of the outer shielding from the un terminated side of the cable to expose the 5 wires Run the Controller Cable into the Extruder Speed Control Interface through one of the two h...

Страница 32: ...Ethernet is the recommended method The LineMaster controller has both an Ethernet port and a serial port for communication purposes Decide whether you want to communicate over Ethernet or serial and r...

Страница 33: ...Maguire Products Inc 33 LineMaster XC 3 Yield D Wiring Diagrams...

Страница 34: ...Maguire Products Inc 34 LineMaster...

Страница 35: ...Drive Speed Control XC 1 Startup Before startup make sure material is available at the fill valve of the Loss in weight hopper 1 With the LineMaster Extruder Speed Control in the MANUAL position turn...

Страница 36: ...er the value of throughput in pounds or kilograms using all 5 digits the last digit is in 10ths Be sure to include any leading zeros example 330 0 pounds hour would be entered as 03300 Keypad entries...

Страница 37: ...uder speed to maintain yield Linemaster XCC Controller Encoder Encoder Wheel XCD X Extruder Drive Speed Control XCD T Take off Drive Speed Control XC 2 Startup Before startup make sure material is ava...

Страница 38: ...value of grams per length g l using all 5 digits the last digit is in 10ths Be sure to include any leading zeros example 120 0 grams per length g l would be entered as 01200 Keypad entries can only be...

Страница 39: ...Take off voltage are made by the LineMaster XCC Controller to maintain the locked rate of grams per length g l Adjustments When in the locked mode manual adjustments to the rate of grams per length g...

Страница 40: ...Take off Speed Control into MANUAL position Then rotate the ADJUST pot counterclockwise at your desired rate of decrease eventually reaching zero line speed XC 3 Yield D XC 3 Multi Layer Yield Control...

Страница 41: ...se remote clients connect to the G2 Server and offer remote access to the data as well as control Gravimetric Gateway Server G2 Server The Gravimetric Gateway Server G2 Server is the name we give to t...

Страница 42: ...n be serial or Ethernet depending on how they are equipped WSB Controllers produced from 1992 to 2006 6811 processor red display are equipped with serial only These controllers can be retrofitted with...

Страница 43: ...want desktop icons click Next Then Install 8 Java Installation The next step starts the Java Installer This installation is necessary to run G2 version 5 0 or later Click Install to continue 9 When th...

Страница 44: ...er is installed open the Device Manager If the driver is install correctly you will find USB Serial Port under Ports COM and LPT If the driver is not found please install the driver separately and che...

Страница 45: ...interface to the G2 software This part of the program is where all of the G2 actions are executed including adding and monitoring blenders modifying settings sending recipes and running reports The G...

Страница 46: ...function 66 to set the ID number On the controller keypad press 22222 default program mode password then 66 Touchscreen Controller Press OPTIONS 22222 default program mode password then Special Funct...

Страница 47: ...t Refer to the converter s instructions for port number After IP and port have been entered click Add Update Successful communication can be verified by highlighting the blender in the list State shou...

Страница 48: ...ces below however they may be adjusted to suit your process After making changes to the Line Rules click Add Update to save the rule changes MGF Offset to LIW If there is an MGF Feeder that is part of...

Страница 49: ...midnight 12 00 AM Retrieval Times In the G2 Client menu under Edit Retrieval Times is the list of times that G2 will log data automatically By default G2 has 24 retrieval times one per hour at the to...

Страница 50: ...from the blender hoppers and store the usage under the name of the material rather than a hopper number This can be useful when trying to understand Material Usage reports Materials are added in the M...

Страница 51: ...pe Additive Enter the desired setting for that material Settings follow the rules of the Maguire blenders Regrinds colors and additives by default use a setting with whole numbers and tenths If the se...

Страница 52: ...er blenders must be set to EXT CRTL slave 3 All Blenders within the Co Extrusion process must have a unique I D set using the 66 function 4 All Blenders within the Co Extrusion process must be added t...

Страница 53: ...Start Date and Stop Date The calendar date to begin and end the report if no time is specified the time is from the earliest time with the start date to the final ending time of the stop date To speci...

Страница 54: ...line are shown In Live view cycles display as they occur from the point when the blender is selected In History view you may select a date and time range to search for records in the database Click Ex...

Страница 55: ...fields If any blender is listed as OFFLINE meaning G2 cannot communicate with that blender for any reason the corresponding table of information for that blender will be grayed out Before proceeding w...

Страница 56: ...voltage is attained 4 After the Line running for a period of time view your Yield Screen in G2 Verify that G2 is showing your Extruder Speed Control voltages your throughput values your take off volta...

Страница 57: ...ut and then click OK Adjusting Total Throughput will automatically make adjustments to individual layer throughputs based on their percentages Based on the default Line Rules a change to Throughput wi...

Страница 58: ...l layers To use G2 s Lock or Unlock option the LTP parameter in all LineMaster XCC Controllers must be set to LTP 1xxxx where the first digit in this parameter is set to a 1 Setting the LTP parameter...

Страница 59: ...a specific gravity manually click the Specific Gravity field then enter the Specific Gravity for that layer Then click OK Repeat this step for each layer Alternately the specific gravity can be automa...

Страница 60: ...ht of the Yield screen the Calculated Yield Box requires information to be entered Overall Specific Gravity is displayed at the top of this box and is calculated from the layers by their percent You w...

Страница 61: ...nction A 0 00V B 0 00V A 0 00V B 0 00V Depending on the Mode the controller is in Pressing the CE key will display one of the following A 0 00V B 0 00V or A 0 00V B 0 00V with actual voltage of the ex...

Страница 62: ...ns COMPUTER SERIAL Port This port can be used for computer or PLC communications to the controller Data can be gathered from the controller or commands sent to the controller using either Maguire s Gr...

Страница 63: ...routines 54 flag must be on to allow this 5 Print Display This is useful for obtaining printed verification of load cell accuracy ISO and other international quality program rules Press 88 before and...

Страница 64: ...ounds when a component fails to meter properly Alarms begin after a number of retries have occurred this number determined by the parameter table see Parameters _AL These alarms can also indicate an o...

Страница 65: ...or commands sent to the controller using either Maguire s Gravimetric Gateway software or using the MLAN Protocol The Gravimetric gateway Software G2 allows downloading settings and retrieval of info...

Страница 66: ...cessive press of the VIEW key displays the next item The last displayed line will say 00 CLEAR for 5 seconds During this time you may press 0 0 to clear the data Waiting 5 seconds or pressing any othe...

Страница 67: ...he LineMaster XCC Controller Press and release once of the arrow keys increments up or down by one tenth of a gram Pressing and holding of the arrow keys will rapidly increase or decease the value Inc...

Страница 68: ...the GENERAL group and contains 49 GENERAL parameters The other 12 groups are the COMPONENT groups and contain 14 COMPONENT parameters each FILL This key allows you manually actuate the Fill Valve loc...

Страница 69: ...FORMAT Sets System Date and Time Press 1 1 to set the date format and to enter the correct date and time into the real time clock Correct date and time is helpful if you are retrieving information us...

Страница 70: ...ar and Clear All Routines see the Backup Restore Factory Reset section This is useful for retrieving correct information that you may have stored earlier in the User Backup Settings Also if you have b...

Страница 71: ...internal rate numbers used by the computer to determine dispense time and the actual dispense time of each component This is excellent information to track the accuracy of each dispense cycle and the...

Страница 72: ...ticular weigh scale blender This I D number will appear on all printed reports If you have more than one unit this helps to identify reports If you are using a computer to automatically gather data th...

Страница 73: ...nder no matter what Now with this star function you have the option to select from 10 different backdoor passwords If your current backdoor password is known by the wrong person you can call us for a...

Страница 74: ...place of gram readout of scale weight Power On will always set this flag to OFF Use the key to toggle flag ENABLE or DISABLE Press EXIT when done A raw signal readout is useful to demonstrate the extr...

Страница 75: ...arameter should not be altered PRT Automatically print out of current LIW summary When enabled a summary will be printed appended to the printer txt file located on the flash drive To enable enter a v...

Страница 76: ...l adjustments to the voltage are made by rotating the ADJUST pot on the XCD X Extruder Drive Speed Control These manual voltage adjustment update the XCV parameter In the LOCK mode the software contro...

Страница 77: ...mber of pulses per METER that the encoder generates The encoder we supply standard is a 600 pulses per revolution and the wheel is 1 foot in circumference So the standard setting in AMERICA for CPL wo...

Страница 78: ...the Loss In Weight bin to a total weight of 10 000 grams for example and allowing it to drop to 5000 grams for example before refilling then the batch is 5000 grams If LTP is set to 00005 then this is...

Страница 79: ...oughput of the extruder to account for material not metered by the LIW The percentage offset is added to the LIW s actual throughput that is displayed on the LIW controller and reported in Get Steady...

Страница 80: ...r is missing No Rate The No Rate Alarm occurs in the locked mode when the controller fails to measure a loss in weight This could be caused by a blockage at the throat No Pulse The No Pulse alarm occu...

Страница 81: ...the pressing the CE will display the grams and raw count for 30 seconds before returning to the normal display If this does not happen there is interference and the weigh hopper is not entirely free...

Страница 82: ...Display will say CALIBRATION MODE LIW LOAD CELLS Press Display will say PROGRAM Press Display will say LIW CELL ZERO WAIT Followed by SUCCESSFUL The display will then show the raw load cell count and...

Страница 83: ...one firmware version is stored on the flash drive Press to toggle between firmware versions If you only have a single copy of firmware stored on the flash drive the controller will default to display...

Страница 84: ...96 9 12 0 304 8 14 2 360 7 18 2 462 3 6 0 x 6 0 152 4 56 25 5 LIW 10 0 6 17 0 100 600 45 272 26 5 673 1 17 7 449 1 16 0 406 4 20 0 508 0 10 0 x 10 0 254 0 74 33 6 LIW 25 1 6 45 3 500 1500 228 682 34 5...

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Страница 93: ...d most expedient to overcome any problems they may have in connection with Maguire equipment Technical Support and Contact Information Maguire Products Inc 11 Crozerville Road Aston PA 19014 Tel 610 4...

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