MAGUIRE PRODUCTS INC.
EXTRUSION & YIELD CONTROL
EXTRUSION CONTROL
& YIELD CONTROL
OPERATIONAL SUPPLEMENT
Copyright ã Maguire Products, Inc. 2006
M A G U I R E P R O D U C T S, I N C.
EXTRUSION CONTROL
& YIELD CONTROL
WEIGH SCALE BLENDER SUPPLEMENT
Table of Contents:
GETTING STARTED, READ THIS PAGE. 3
CONFIRM SOFTWARE SETUP 4
YIELD CONTROL - additional set up. 5
YIELD and EXTRUSION CONTROL - INSTALLATION and SETUP 6
CHECK OUT PROCEDURE 7
EXTRUSION or YIELD CONTROL - OPERATION 8
Start Up and Operation from the WSB controller exclusively. 8
Alternate start-up method. 9
MULTI LAYER LINES 10
EXTRUSION and YIELD CONTROL - HOW IT WORKS 11
Standard Operating Sequence. 11
CONTROLS 14
PARAMETERS 15
CHANGING COLORS - or OTHER BLENDER INTERRUPTIONS 19
GETTING STARTED, READ THIS PAGE.
This booklet provides SUPPLEMENTAL INFORMATION only about EXTRUSION or YIELD CONTROL operation of your blender.
The other manual, the WEIGH SCALE BLENDER OPERATION MANUAL, is the primary source of information about the equipment, controller, and software.
Pages 2 through 10 of the WEIGH SCALE BLENDER manual, followed by pages 3 through 7 of this SUPPLEMENTAL manual, WILL GUIDE YOU, STEP BY STEP, TO A SUCCESSFUL STARTUP.
IT WON'T TAKE LONG; SO.... PLEASE, DON'T SKIP AHEAD.
FIRST... in the BLENDER MANUAL, read:
GETTING STARTED: Page 2
SAFETY HAZARD: Page 3
ASSEMBLY INSTRUCTIONS: Page 4
CHECK OUT PROCEDURE: Page 7
LOAD CELL CALIBRATION: Page 10
THEN.... return to this manual for:
CONFIRM SOFTWARE SETUP: This should already be done. You should confirm that it is.
NORMAL OPERATION: Extrusion or Yield control.
After page 10 of that manual return to this manual,
CONFIRM SOFTWARE SETUP
You should confirm that your blender is set for the EXTRUSION or YIELD control correct for your operation. The special Star function "*02" is used to select the correct mode of operation.
Options are:
RATE / Normal Blender operation except the display shows throughput RATE at all times. This option allows an operator to observe actual throughput and make speed corrections manually based on this display. Your Blender does not control extruder or line speed.
EXTCTRL / This mode provides automatic control of THROUGHPUT (pounds or kilos per hour), with output control voltage to adjust EXTRUDER speed.
Note: to display Yield Control options YLD X and YLD T, the CPL parameter must be set to match the "pulses per unit length of measurement" from this shaft encoder. See next page.
YLD X / This mode provides automatic control of YIELD (grams per foot or meter), with output control voltage to the eXtruder speed control. An encoder is required to read line speed.
YLD T / This mode provides automatic control of YIELD (grams per foot or meter), with output of control voltage to the Takeoff speed control. An encoder is required to read line speed.
DNS CTRL / This mode provides automatic control of YIELD with output control voltage to both Takeoff speed and Extruder speed. G2 software and an additional computer are required. See our G2 software manual for more information. An encoder is required to read line speed.
To confirm (select) proper mode:
Selecting Extrusion Control Operation - Keypad Sequence:Press / Display will say: (PASSWORD)
Press / Display will say: (P x)
Press / Display will say: (OFF )
Press / Display will say: (RATE )
Press / Display will say: (EXT CTRL)
Press / Display will say: (YLD X )
Press / Display will say: (YLD T )
Press / Display will say: (DNS CTRL)
Press / / repeatedly / to scroll through the options.
When the correct option is displayed:
Press / Display will say: (P x.x)
YIELD CONTROL - additional set up.
All YIELD control options require the input of a pulse train from a shaft encoder mounted on the Takeoff equipment to provide the software with correct line speed information.
The CPL parameter must be set to match the "pulses per unit length of measurement" from this shaft encoder.
If your pulse generator has a standard "one foot" wheel and this wheel rests on the pull roll surface, then one turn of the wheel is one foot of line travel. Thus, a typical 600 pulse-per-revolution wheel will generate 600 pulses per foot of line travel. For this the correct parameter setting would be CPL 00600.
If your pulse generator is coupled directly to the end of the takeoff roll shaft, then you must calculate pulses per foot (or meter). Assuming a typical pulse generator of 600 pulse per revolution:
Pulses per foot = 600 / (Roll Diameter in feet x 3.1416)
Pulses per meter = 600 / (Roll Diameter in meters x 3.1416)
For example:
A 12 inch diameter roll coupled directly to a 600 pulse per revolution
shaft encoder, would require a parameter entry of CPL 00191.
600 / 1 foot x 3.1416 = 190.985 (191)
To set the CLP parameter - Keypad Sequence:Be in the PROGRAM mode:
Press / Display will say: (P x)
Press / repeatedly until the CPL parameter is displayed.
Enter / pulses per unit
Note: correct entry depends on your device and how it is installed.
Press / Display will say: (P x.x)
YIELD and EXTRUSION CONTROL - INSTALLATION and SETUP
Speed Control Pot Wiring:
Follow the wiring diagrams provided to connect our blender to your extruder or takeoff control.
BLENDER CONTROL:
Using the (*02) function, the correct flag must be turned on:
EXTRUSION CONTROL (EXT CTRL),
YIELD CONTROL -X, (YLD X ),
YIELD CONTROL -T, (YLD T ),
or DOWNSTREAM CONTROL (DNS CTRL).
To do so:
Selecting Extrusion Control Operation - Keypad Sequence:Press / Display will say: (PASSWORD)
Press / Display will say: (P x)
Press / Display will say: (OFF )
Press / Display will say: (RATE )
Press / Display will say: (EXT CTRL)
Press / Display will say: (YLD X )
Press / Display will say: (YLD T )
Press / Display will say: (DNS CTRL)
Press / repeatedly / to scroll through the options.
When the correct option is displayed:
Press / Display will say: (P x.x)
Extrusion Control Operation - Keypad Sequence:
Press / In Lock Enter New Rate via Keypad
Press / UP to increase
Press / LOCK to lock rate
Press / DOWN to decrease
NOTE: DOWNSTREAM (Yield D) control is only selected when G2 software is connected and controlling. Yield D allows BOTH extruder speed adjustment and takeoff speed adjustment from the same blender control.
When G2 is connected, and when multiple blenders / extruders are feeding a single extrusion LINE, (a single line will have only ONE takeoff speed control), then ONLY ONE of the blenders is set to (Yield D) mode. This will be the controlling or primary blender. The other (secondary) blenders will be set to (EXT) mode, extrusion control only, as they must adjust their extruder speeds to maintain correct throughput ratios with the primary controller / extruder.
In other words:
The primary extruder controls its own extruder speed as well as controlling takeoff speed. Whether this blender makes ongoing adjustments to extruder speed or downstream speed depends on how you have configured your G2 software. In either case, secondary extruders follow the lead of the primary extruder and make small extruder speed adjustments to hold throughputs correct based on the throughput of the primary extruder. For this reason secondary blenders must control their extruder's speed and are, therefore, set up as extrusion control only (EXT).
EXTRUSION or YIELD CONTROL - OPERATION
Start Up and Operation from the WSB controller exclusively.
1. Turn on your WSB controller.Display will say: 00.00VYou are in the VOLTAGE mode.The display indicates the voltage being output to the Extruder speed control circuit. VOLTAGE mode allows MANUAL adjustment of extruder speed using the adjustment pot on the Speed control box.
ARROW keys operate BETWEEN CYCLES ONLY, sensor covered. If necessary, switch to STOP END-OF-CYCLE to make changes.2. When adjusting the pot, the display will update the voltage output to the extruder.
02.00V (example)
3. WAIT for the "T" to be displayed.
At some point during this learning process, a "T" will be added to the display indicating a RATE has been established for operation in THROUGHPUT mode.
You cannot switch to LOCK THROUGHPUT(or YIELD) mode until "T" is displayed.
Display will say: T02.00V
4. SWITCH to THROUGHPUT (or YIELD) MODE.
When to switch:
If the extruder is running exactly as you want and you want it to stay that way, unchanged (in other words you are not concerned with achieving a predetermined throughput rate), then we suggest waiting for five or ten additional minutes or blend cycles before switching to LOCK THROUGHPUT mode. This will ensure the current rate is very accurately measured and recorded. Then switch to LOCK THROUGHPUT mode to hold this rate over time.
On the other hand, if you know exactly the throughput (or yield) rate that you desire, as expressed in pounds or kilos per hour, (or grams per foot or meter) you might as well switch to LOCK THROUGHPUT mode immediately. The current learned RATE will be displayed, and you can then immediately adjust this rate number, up or down, to the desired target, and the extruder will adjust as required until actual output exactly matches the target you have entered.
When the time to switch is right, place manual/Lock switch Located on the Speed Control Box to the LOCK position.
(pounds) / (kilos)
or for YIELD mode:
Display will say: / 123 G
(grams)
This is your current throughput in Pounds (or Kilos) per hour, or current yield in grams per foot (or meter).
If this is not the exact rate you want, increase or decrease this rate by using the arrow keys.
MULTI LAYER LINES
Multi Layer lines require 1 blender for each extruder/layer.
If you desire to tie these blenders together, so that a single adjustment at one location will effect simultaneous changes at each blender, and to each extruder, then a computer is required with our G2 software installed.
With a G2 software configuration, in addition to the PC a standard MLAN set up is required, including the amplifier box and the communications wire to the blender serial port. Our MLAN or G2 manual has more information on this.
A computer is not required if you are willing to make individual changes to each blender/line when you wish to have the entire line ramp up or down in speed.Contact Maguire Products for more information about the G2 software.
EXTRUSION and YIELD CONTROL - HOW IT WORKS
Extrusion Control: / Operator specifies a THROUGHPUT rate (lbs/hour). Blender controls the extruder speed.Yield Control - X: / Operator specifies a product YIELD (grams/foot or grams/meter). Blender controls the extruder speed.
Yield Control - T: / Operator specifies a product YIELD (grams/foot or grams/meter). Blender controls the Takeoff speed.
Yield Control - DNS: / Same as "T" above but all inputs are by separate computer using G2 software, and both extruder speed and takeoff speed can be controlled.
The key to all modes of automatic control is knowing the actual throughput of the extruder and detecting changes when they occur.
When a Maguire blender is mounted directly to the throat of an extruder, or to a surge hopper mounted directly above the throat, it can detect, very accurately, the throughput rate of that extruder. It does this by tracking and accumulating the exact weight of each batch (in grams), and the exact time (in tenths of seconds) required for each batch to be consumed by the process.
Typically, the speed of an extruder is controlled by a 0-10 vdc signal, adjustable through a manually operated speed control potentiometer.
With "EXTRUSION CONTROL" and "YIELD CONTROL - X" your Maguire blender is connected to your extruder and takes over the job of supplying the extruder's speed control voltage.
With "YIELD CONTROL - T", your Maguire blender is connected to your takeoff or downstream equipment and takes over the job of supplying the speed control voltage for that equipment.
With "DNS control", your Maguire Blender controls both extruder speed and Takeoff or downstream speed. A separate computer with G2 software must be connected.
When a target throughput, or yield rate is specified, the blender detects variances from this target and adjusts extruder speed (or takeoff speed) accordingly.
Software math algorithms assure that speed control is held constant, adjusting only when conditions change sufficiently to signal a real need for adjustment.
Standard Operating Sequence.
In EXTRUSION CONTROL mode, extruder throughput (pounds per hour or kilos per hour) is held steady.
In all YIELD modes, YIELD (grams per foot or grams per meter) is held steady. In YIELD X mode, extruder speed is controlled. In YIELD T mode, takeoff speed is controlled.
When your BLENDER is first turned on, the VOLTAGE mode is active.
Extruder (takeoff) speed is controlled directly from the Speed Control Potentiometer by varying the 0-10 vdc speed control signal. In the VOLTAGE mode, voltage and extruder (takeoff) speed hold steady, changing only if an operator makes an adjustment to the potentiometer.