Line Master

8/8/2019 Line Master

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MAGUIRE PRODUCTS INC.

EXTRUSION & YIELD CONTROL

LineMaster

Loss-In-WeighEXTRUSION CONTROL& YIELD CONTROL

INSTALLATION OPERATION

Copyright Maguire Products, Inc. 2008


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Maguire Products, Inc.

Edition: February 18, 2008 2

LineMaster


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LineMaster

Maguire LineMaster

Loss-in-Weigh HopperExtrusion Control & Yield ControlWeigh Scale Blender Supplement

2008 Maguire Products Inc.

To every person concerned with use and maintenance of the Maguire LineMaster it isrecommended to read thoroughly these operating instructions. Maguire Products Inc. accepts noresponsibility or liability for damage or malfunction of the equipment arising from non-observanceof these operating instructions.

To avoid errors and to ensure trouble-free operation, it is essential that these operating instructionsare 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.

Manufacturers Contact Information

Maguire Products Inc.11 Crozerville Road

Aston, PA. 19014

Phone: 610.459.4300Fax: 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 18Parts Identification 18

LineMaster Kits 19

LineMaster Installation 20Safety Warnings 20

Loss-In-Weigh Hopper Installation 21General Wiring Installation Notes 23XC-1 Extrusion Control Installation 25XC-1 Extrusion Control Wiring Diagram 26XC-2 Yield Control X or Yield Control T Installation 28XC-2 Yield Control X or Yield Control T Wiring Diagram 29

XC-3 Yield D Installation 31XC-3 Yield D Wiring Diagram 33

LineMaster Operation 35Standalone Operation 35

XC-1 Throughput Control 35XC-2 Yield Control X or Yield Control T 37XC-3 Yield D 41

Gravimetric Gateway Software (G2) 41G2 Software Setup 41G2 Software Operation 44

Controller Description 54Communications 58Controller Keypad 64Star Functions 67Parameters 73Alarms 76Load Cell Zero Weight Calibration 77Load Cell Full Weight Calibration 78

General Information

Updating Controller Firmware 79LIW Model Specifications and Dimension Drawings 82Warranty 91Contact Information 91


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LineMaster

LineMasterTMExtrusion Control

LineMasterTM is for all continuous extrusion processes including film, sheet, pipe, coating andlamination, wire and cable and compounding. LineMasters flexible design provides severalmeasurements 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 lowcost alternative to competitive loss-in-weight systems without compromising performance andcontrol.

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 MaguireBlenderExtrusion line throughput may be determined by monitoring material consumption as recordedby the batch weighing process of the blender divided by the time the batch takes to beconsumed. Throughput is determined by the blender controller when 5 consecutive batcheshave shown a steady throughput rate. If 2 batches show consecutive errors an adjustment ismade 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 lessmechanical 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 HopperThe 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 toone of two control options: Enhanced Extrusion Control with a Maguire blender integrates theextrusion control functions into the blender controller for a single point of control. The secondoption 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 beutilized in a multi-layer control application.

The weight consumption data is communicated directly to the respective controller and updatesconsumption information frequently. The loss-in-weight hopper determines accurate throughputwithin 5 seconds and updates thereafter every 1 second.

XC CONTROL OPTIONSLineMaster is a comprehensive range of products that is designed to serve the vast majority ofextrusion operations that require solutions based at every level of the cost / performancespectrum. The available control options provide throughput control for pounds or kilograms perhour, weight per length control for lb/ft or gm/M and gauge control in microns.

XC-1 Throughput ControlControl is maintained by monitoring the throughput of the process and regulating the extruderspeed. The XCC controller utilizing the consumption data from the LIW hopper communicateswith the XCD-X Extruder Drive Speed Control to adjust the extruder speed via a 0-10 volt signalto maintain the throughput target.

XC-2 Yield ControlXC-2 offers the ability to maintain a products weight per length (lb/ft or gm/M) by monitoring theprocess throughput against the line speed. An XCE Digital Encoder mounted on a take-offdevice monitors the line speed. Control is accomplished by adjusting either the extruder speedwith a XCD-X Drive Speed Control Module by referencing the manually controlled line speed orcontrolling the take-off speed with a XCD-T Line Speed Control Module from a manuallycontrolled extruder.

XC-3 Multi-Layer Yield Control via Computer and G2 SoftwareXC-3 provides complete weight per length control (lb/ft or gm/M), via simultaneous control of theextruder and take-off. Controllers are connected via a high speed serial or Ethernet networkusing the XC Software. Gauge or thickness control can be initiated in set-up utilizing data of thematerials 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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Computer Control and Data OptionsWith the LineMasterTM product range, the Gravimetric Gateway TM (G2) software program isavailable for centralized control and data reporting. The software program is an integral part ofthe XC-3 Extrusion Multi-layer Control and as an option for mono- layer applications ofthroughput or yield control.

A brief overview of G2A Gravimetric GatewayTM Server (G2 Server) provides communication with all Maguirecontrollers for data collection and control. The G2 software enables communication directly fromthe server with one or more blender or loss-in-weight controllers to connect remotely fromanywhere over a TCP/IP network using the Gravimetric GatewayTM Client software. The serverprovides two-way communication with the network of blenders and loss-in-weight controllers forconstant 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 accurateinformation according to a number of factors including: time period (day, shift, etc), processmachine, 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 aredisplayed at the right showing line speed, weight per length and/or gauge.

A more detailed examination of each blenders settings and output can be accessed through theLine Blender Screen by clicking on the individual extruder.

Throughput ReportingThe software also allows reporting on average throughput, total throughput, and the percentageof total uptime of an individual blender or all blenders in the line. Reports are based on start/stopdate and time, weight units and percentage of run time.

Event MonitoringThe computer software also incorporates an event monitoring service allowing users to access ahistory of alarms, actions and changes.

Materials and Blend ManagementThe 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 andinventory management a valuable tool for data regarding quality, certification, costs andproductivity.


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LineMaster

REDUCE RESIN CONSUMPTION WITHENHANCED GRAVIMETRIC EXTRUSION YIELD CONTROL

The diagram on the following page illustrates a 3-layer film line utilizing LineMasterTM ExtrusionControl. Loss-in-weight hoppers are mounted on 3 extruders that are feeding the die producingthe 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 throughputdue to screen pack, back pressure, melt temperature or other variables is detected and adjustedfor. 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 inpayback in as little as 6 months. LineMaster simplifies line start-up, enables rapid job changesand 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 andcommands 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 drivebeing controlled. The XCD Speed Control Modules include a digital potentiometer, whichreplaces the existing manual pot or can communicate with an existing digital speed control. Atoggle switch is included to provide selection of either Manual or Automatic control.

APPLICATIONSWood CompositeCorrugated

Pipe & TubingWire & Cable


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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 interfaceand a drive speed control package.

The mass flow hopper assembly is mounted on the throat of the extruder. A weigh hoppersuspended from a set of load cells provides the material flow data to the LIW controller. Theextruder drive control package, which includes a digital potentiometer to replace the existinganalog extruder speed pot, is mounted in the control cabinet and monitors and controls thesignal to the extruder drive.

Principal of Operation

The XC-1 Extrusion Throughput Control System is designed to maintain a products weight overtime 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 maintainthe desired throughput. The actual throughput is compared to a desired target throughput of theproduct entered on the LIW controller. The LIW controller communicates to the XCD-X ExtruderDrive Control, which adjusts the voltage or reference signal to the extruder drive, which willincrease, or decrease to maintain the desired throughput.

A digital potentiometer replaces the existing rotary drive speed control on the extruder drivepanel and communicates with the XCD-X Extruder Drive Control which is mounted in or on thecontrol cabinet and is connected to the LIW controller.

aspc0910LIW w/ XCC

M EXTRUDER

Product

XCD-X

Drive Speed Control


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LineMaster

Typical Start-up

Upon a first time start-up of the process, the throughput control system is placed in the ManualMode. The LIW controller learns the rate of the material flow through the mass flow hopperwithin 45 seconds and enters the logarithmic value in the control parameters. The controller willdisplay the learned throughput rate and indicate the process can be switched into the Auto orLocked Mode. A target value for the process throughput desired is entered as a set point on theLIW controller. The system can be switched into the Auto or Lock Mode and the speed of theextruder will be adjusted to maintain the target process throughput. If a change to the processthroughput is required the new target is entered and the controller will instruct the extruder driveto increase crease or decrease respectively. The reaction of the LIW system to the process ratechange is almost instantaneous and will settle at the desired throughput within 45 seconds ofthe process reaching the requested target.

Once the LIW controller learns the throughput rate of a material, it is stored in the memory of thecontroller. The controller can be left in the Auto or Locked mode if the same material iscontinued or a similar bulk density material is used. If a new material with a different bulk densityis used, the start-up procedure must be re-initiated.

Components

LIW-XX Mass Flow Hopper (sized for the required throughput)as7190 Surge Hopper (optional)XCC LineMaster Control Operator InterfaceXC-1 LineMaster Extrusion Yield Control w/ Line Speed Control Package

includes the following components: XCD-X Extruder Drive Control, Analog 1-10 Vdc

aspc0910 LIW to Drive Interface Cable, 100 ft.

An optional surge hopper, as7190, which mounts atop the LIW is available if the volume ofmaterial in the transition from the mezzanine mounted blender is less than the capacity of theLIW hopper

LIW MODELTHROUGHPUT

LB/HR KG/HRHOPPER CAPACITY

LIW-05 5 300 2.2 136 .3 ft3 8.5 liters

LIW-10 100 - 600 45 272 .6 ft3

17.0 litersLIW-25 500 1,500 228 682 1.6 ft3 45.3 liters

LIW-40 1,000 3,000 454 1,364 2.5 ft3 70.8 liters


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LineMaster

Overview - XC-2X LineMaster Extrusion Yield Control w/ Extruder Drive ControlMonitors process throughput and take-off speed, controls extruder drive speed to maintainproduct yield (weight per length)

Drive Speed Control


The system is comprised of a mass flow hopper assembly, a controller with operator interface, adrive speed control package and an encoder.

The mass flow hopper is mounted on the throat of the extruder. A weigh hopper suspended froma set of load cells provides the material flow data to the LIW controller. The drive speed controlpackage, which includes a digital potentiometer to replace the existing analog extruder speedpot, is mounted in the control cabinet and monitors and controls the signal to the extruder drive.The encoder or pulse generator is mounted on the haul off to monitor the speed of the line.


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 on

the throat of the extruder in kilos per hour, and collates the data with the line speed monitoredby an encoder mounted on the shaft of the haul off in meters per minute to provide a calculatedactual product yield in grams or kilograms per meter. The actual yield is compared to a desiredtarget yield of the product entered on the LIW controller. The LIW controller communicates tothe XCD-X Extruder Drive Speed Control, which adjusts the voltage or reference signal to theextruder drive, which will increase or decrease with respect to the line speed to maintain thedesired yield.

A digital potentiometer replaces the existing rotary drive speed control on the extruder drivepanel and communicates with the XCD-X Drive Speed Control which is mounted in or on thecontrol cabinet and is connected to the LIW controller.

aspc0910

LIW w/ XCCEncoderXCE-01

MEXTRUDER

Product

XCD-X

aspc2210


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LineMaster

Typical Start-up

Upon a first time start-up of the process, the yield control system is placed in the Manual Mode.The LIW controller learns the rate of the material flow through the mass flow hopper within 45seconds and enters the logarithmic value in the control parameters. The controller will displaythe learned yield rate and indicate the process can be switched into the Auto or Locked Mode.A target value for the product weight per length desired is entered as a set point on the LIWcontroller. The system can be switched into the Auto or Lock Mode and the speed of theextruder will be adjusted to maintain the target weight per length value. As the line speed isincreased to a production level, the LIW controller will acknowledge the change and increasethe signal to the drive to maintain the desired product yield. The reaction of the LIW system tothe process rate change is almost instantaneous and will settle at the desired yield within 45seconds of the process reaching the final speed.


Components

LIW-XX Mass Flow Hopper (sized for the required throughput)as7190 Surge Hopper (optional)XCC LineMaster Control Operator InterfaceXC-2X LineMaster Extrusion Yield Control w/ Extruder Drive Control Package

includes the following components: XCD-X Extruder Drive Speed Control, Analog 1-10 Vdc


XCE-01 Encoder, Pulse Generator

aspc2210 Encoder Interface Cable, 100 ft.

An optional surge hopper, as7190, which mounts atop the LIW is available if the volume ofmaterial in the transition from the mezzanine mounted blender is less than the capacity of theLIW hopper.

LIW MODELTHROUGHPUT


LIW-05 5 300 2.2 136 .3 ft3 8.5 liters

LIW-10 100 - 600 45 272 .6 ft3

17.0 litersLIW-25 500 1,500 228 682 1.6 ft3 45.3 liters

LIW-40 1,000 3,000 454 1,364 2.5 ft3 70.8 liters


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LineMaster

Overview - XC-2T LineMasterExtrusion Yield Control - Take-off Drive ControlProvides control of haul-off to maintain weight per length via feedback from encoder mounted ondownstream haul-off


The system is comprised of a mass flow hopper assembly, a controller with operator interface, aline speed control package and an encoder.

The mass flow hopper is mounted on the throat of the extruder. A weigh hopper suspended froma set of load cells provides the material flow data to the LIW controller. The line speed controlpackage, which includes a digital potentiometer to replace the existing analog take-off speedpot, is mounted in the control cabinet and monitors and controls the signal to the take-off drive.The encoder or pulse generator is mounted on the haul off to monitor the speed of the line.


The XC-2T 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 onthe throat of the extruder in kilos per hour, and collates the data with the line speed monitoredby an encoder mounted on the shaft of the haul off in meters per minute to provide a calculatedactual product yield in grams or kilograms per meter. The actual yield is compared to a desiredtarget yield of the product entered on the LIW controller. The LIW controller communicates tothe XCD-T Take-off Drive Speed Control, which adjusts the voltage or reference signal to theTake-off drive, which will increase or decrease with respect to the extruder speed to maintainthe desired yield.

A digital potentiometer replaces the existing rotary drive speed control on the take-off drivepanel and communicates with the XCD-T Take-off Speed Control which is mounted in or on thecontrol cabinet and is connected to the LIW controller.

Typical Start-upUpon a first time start-up of the process, the yield control system is placed in the Manual Mode.The LIW controller learns the rate of the material flow through the mass flow hopper within 45seconds and enters the logarithmic value in the control parameters. The controller will displaythe learned yield rate and indicate the process can be switched into the Auto or Locked Mode.A target value for the product weight per length desired is entered as a set point on the LIWcontroller. The system can be switched into the Auto or Lock Mode and the speed of theextruder will be adjusted to maintain the target weight per length value. As the line speed is

LIW w/ XCC

EncoderXCE-01

EXTRUDER

Product

M

XCD-Taspc0910

aspc2210

Line Speed Control


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LineMaster

increased to a production level, the LIW controller will acknowledge the change and increasethe signal to the drive to maintain the desired product yield. The reaction of the LIW system tothe process rate change is almost instantaneous and will settle at the desired yield within 45seconds of the process reaching the final speed.


Components

LIW-XX Mass Flow Hopper (sized for the required throughput)as7190 Surge Hopper (optional)XCC LineMaster Control Operator InterfaceXC-2T LineMaster Extrusion Yield Control w/ Line Speed Control Package

includes the following components: XCD-T Take-off Drive Speed Control, Analog 1-10 Vdc


XCE-01 Encoder, Pulse Generator

aspc2210 Encoder Interface Cable, 100 ft.


LIW MODELTHROUGHPUT


LIW-05 5 300 2.2 136 .3 ft3

8.5 litersLIW-10 100 - 600 45 272 .6 ft3 17.0 liters

LIW-25 500 1,500 228 682 1.6 ft3 45.3 liters

LIW-40 1,000 3,000 454 1,364 2.5 ft3 70.8 liters


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XC-3 LineMaster Yield Control Extruder & Take-off Drive ControlMonitors throughput and line speed. Adjusts extruder and line speed to maintain product weightper length. Requires XC-C LineMaster computer controller and is typically used for multi-layer co-ex applications.


The system is comprised of a mass flow hopper assembly, a controller with operator interface,an extruder drive speed control package, a line speed control package and an encoder. TheLineMaster XC-LMC computer control is required for simultaneous control of both extruder drivespeed and line speed.

The mass flow hopper is mounted on the throat of the extruder. A weigh hopper suspended froma set of load cells provides the material flow data to the LIW controller. The line speed controlpackage, which includes a digital potentiometer to replace the existing analog take-off speedpot, is mounted in the control cabinet and monitors and controls the signal to the take-off drive.The encoder or pulse generator is mounted on the haul off to monitor the speed of the line. The

extruder drive speed control package, which includes a digital potentiometer to replace theexisting analog extruder speed pot, is mounted in the control cabinet and monitors and controlsthe signal to the extruder drive. The two drive controllers communicate to with one another toprovide a synchronous ramp of all drives as directed by the LineMaster XC-LMC computer.


The XC-3 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 onthe throat of the extruder in kilos per hour, and collates the data with the line speed monitoredby an encoder mounted on the shaft of the haul off in meters per minute to provide a calculated

actual product yield in grams or kilograms per meter. The actual yield is compared to a desiredtarget yield of the product entered on the LIW controller. The LIW controller communicates tothe XCD-X Extruder Drive Speed Control which adjusts the voltage or reference signal to theextruder drive to increase or decrease with respect to the line speed to maintain the desiredyield.

Digital potentiometers replaces the existing rotary drive speed control on the take-off drive andextruder drive and communicate with the XCD-T Take-off Speed Control and XCD-X ExtruderDrive Speed Control which is mounted in or on the control cabinet and is connected to the LIWcontroller.

EncoderXCE-01

EXTRUDER

ProductM

LIW

XCD-T

XCD-X

aspc0910 aspc2210

aspc2510

ComputerXC-LMC

Line Speed Control

Drive Speed Control


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Typical Start-up

Upon a first time start-up of the process, the yield control system is placed in the Manual Mode.The LIW controller learns the rate of the material flow through the mass flow hopper within 45seconds and enters the logarithmic value in the control parameters. The controller will displaythe learned yield rate and indicate the process can be switched into the Auto or Locked Mode.A target value for the product weight per length desired is entered as a set point on the LIWcontroller. The system can be switched into the Auto or Lock Mode and the speed of theextruder will be adjusted to maintain the target weight per length value. As the line speed isincreased to a production level, the LIW controller will acknowledge the change and increasethe signal to the drive to maintain the desired product yield. The reaction of the LIW system tothe process rate change is almost instantaneous and will settle at the desired yield within 45seconds of the process reaching the final speed.

Once the LIW controller learns the throughput rate of a material, it is stored in the memory of thecontroller. The controller can be left in the Auto or Locked mode if the same material iscontinued or a similar bulk density material is used. If a new material with a different bulk densityis used, the start-up procedure must be re-initiated. According to the configuration of the XCprogram the drives will simultaneously increase or decrease as either the line speed, throughputor gauge requirements are changed.

Components

LIW-XX Mass Flow Hopper (sized for the required throughput)as7190 Surge Hopper (optional)XCC LineMaster Control Operator InterfaceXC-3 LineMaster Extrusion Yield Control w/ Drive & Line Speed Control

includes the following components:

XCD-X Extruder Drive Speed Control, Analog 0 10 Vdc

aspc0910 LIW to Drive Interface Cable, 100 ft. XCD-T Take-off Drive Speed Control, Analog 0 -10 Vdc aspc2510 Drive Communications Cable, 100 ft. XCE-01 Encoder, Pulse Generator aspc2210 Encoder Interface Cable, 100 ft.


LIW MODEL THROUGHPUTLB/HR KG/HR HOPPER CAPACITY

LIW-05 5 300 2.2 136 .3 ft3 8.5 liters

LIW-10 100 - 600 45 272 .6 ft3 17.0 liters

LIW-25 500 1,500 228 682 1.6 ft3 45.3 liters

LIW-40 1,000 3,000 454 1,364 2.5 ft3 70.8 liters


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LineMasterTMKits and Components

Parts Identification

Extruder 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 Components:

Throat Mount Adapterwith drain port

Surge Hopper1.25 ft

3- LIW-05 & 10

2.25 ft3

- LIW-25 & 40


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LineMasterTM Kits

Depending on the application your kit may include the following:

o Extrusion Control LineMaster Controller, Extruder Speed Control Interface,Cabling and strain relief.

o Yield-X - LineMaster Controller, Extruder Speed Control Interface, Cabling, cablestrain relief, mounting hardware, 24 Volt Power Supply, Encoder, Encoder Wheel (12inch circumference), Encoder Cable.

o Yield T - LineMaster Controller, Take-off Speed Control Interface, Cabling, cablestrain relief, mounting hardware, 24 Volt Power Supply, Encoder, Encoder Wheel (12inch circumference), Encoder Cable.

o Yield D - LineMaster Controller, Extruder Speed Control Interface, Take-off SpeedControl Interface, Cabling, cable strain relief (2), mounting hardware, 24 Volt PowerSupply, Encoder, Encoder Wheel (12 inch circumference), Encoder Cable. Requiresthe G2 software and dedicated computer system. G2 Not included with kit but may beprovided separately.

Additional Options

o LineMaster 12 Software Controller Up to 12 components, controlling a blender anda LIW hopper (Loss-In-Weight hopper).

o LIW Stand Alone LineMaster Controller Controls a single LIW hopper (Loss-In-Weight hopper) tracking throughput of the LIW.


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LineMaster Installation

In this section:

Safety Warnings

Loss-In-Weigh Hopper Installation General Wiring Installations Notes and Considerations XC-1 Extrusion Control Installation XC-2 - Yield Control X or Yield Control T Installation XC-3 Yield D Installation

Safety Warnings

Electrical Connection

RISK OF INJURY!Only qualified technicians should make electricalconnections. These instructions provide wiring diagrams.Wiring installations should only be performed by a qualifiedelectrician who is familiar with these types of installation.Prior to installation, thoroughly review the wiring diagramspecific to your installation.

Wire Installations Preventing Interference or DamageWhen installing communication wires, be sure to avoid any sources ofinterference such as vacuum loader lines (discharged static), high voltagelines and transformers and florescent lights. You should avoid thesesources by a distance of a foot or more so that communication is notdisrupted by interference and sensitive electronic components are notdamaged.

Lifting

DANGER OF INJURY!

If the weight is unevenly distributed, the LIW Hopper may tip and injurepeople when it is lifted.

Weights of the LIW Hopper Models range from 56 pounds (25.5 Kg) to 140pounds (63.6 Kg). Lift points are the vertical supports of the black metalframe.


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Unpacking and Setup

Unpacking - Removing from Carton

Cut sides and top flaps, unscrew screws and washers from the sides at the skid. Removecarton, remove cardboard tray at the top of the carton. Cut and remove plastic wire ties

from the LIW hopper located at the top of the hopper inside the black frame member. Cutand remove plastic wire ties from the base LIW hopper and remove the cardboard tubinsert from the base of the LIW hopper. Remove any packing material from around theLIW hopper and brackets.

Return Shipping Information

Save the carton and cardboard if at all possible, reuse for return tofactory. Use strong plastic wire ties to affix the LIW Hopper to the top ofthe black frame member and place the cardboard insert under the base ofthe LIW hopper and wire tie it tight to elevate LIW hopper up and off ofthe load cells. Use packing material around the individual components.

To remove the skid, unbolt the four bolts that secure the LIWHopper to the skid. The bolts are located at the bottom of theLIW Hopper frame and go through the wooden skid.

These bolts can be loosened while the LIW Hopper and the skidare on the ground. Reverse procedure to install LIW Hopper onthe skid.

Loss-In-Weigh Hopper Installation

Install LIW Hopper on Extruder

The base of the LIW Hopper frame is pre-drilled with 4 holes.The LIW 5 has a smaller hole pattern while the LIW 10, LIW25 and LIW 40 have a larger pattern. The LIW Hopper ismeant to be install directly onto the throat of the extruder. Boltpatterns and dimensions for the base of the LIW models aswell as the optional Throat Mount Adapter can be found in theback of this manual. The LIW Hopper may be installeddirectly onto the optional Throat Mount Adapter with drainport.

Optional ThroatMount Adapter with

drain port

Install material lineThe LIW Hopper comes equipped with a Stub Tube adapter. On the LIW 5 and

LIW 10, the Stub Tube is 3 inch. On LIW 25 and LIW 40 the Stub tube is 4 inch.If you using a direct material line connect it to this adapter. Note: If you areusing a material supply line be sure that the volume of material held within thesupply line is adequate to fill the LIW Hopper to prevent material starvation.

Install Optional Surge HopperIf you are using the Optional Surge Hopper to supply material to the LIW,remove the Stub Tube Adapter (if equipped) and bolt the Surge hopper to theLIW using the 4 boltholes and the supplied hardware.


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Install LIW ControllerUnpack the LIW controller and hang the controller box to theController Mount plate located on the side of the LIW frame.Have the controller using the protruding screw heads on theback of the controller and the notches on the mount plate. Thecontroller can be secured in place using one -20 x screwand threading it through the back of the mount plate and into the

back panel of the controller. On LIW 5 models, the mount plateis part of the frame.

Connect CablesTwo cables are supplied with the LIW Hopper. Connect the 3 foot DB25cable to the Controllers Load Cell port and the LIW Loadcell port locatedon the LIW frame. On LIW 5 models, this cable is attached to the LIWframe and should be connected to the controllers Load Cell port.Connect the 3 foot 4-Pin Amp cable to the Fill Valve on the Controller andthe LIW Valve on the frame.

Connect Air LineConnect a clean, oil-free, regulated 80 psi (5.5 bar) air line to the AirSolenoids Nylon Quick Connect using a 5/32 nylon airline.


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LineMaster

General Wiring Installations Notes:

Wire Installations Preventing Interference or DamageWhen installing communication wires, be sure to avoid any sources ofinterference such as vacuum loader lines (discharged static), high voltagelines and transformers and florescent lights. You should avoid these

sources by a distance of a foot or more so that communication is notdisrupted by interference and sensitive electronic components are notdamaged.

To access the circuit board for the wiring installation, remove the 6screws located on the face of the Extruder Speed Control or Take-off Speed Control box.

If the wire installation into the Speed Control boxes will have anexposed wire, use of a cable strain relief is recommended. Twosizes of strain relief may be provided depending on yourapplication, one for single wire installations and one for 2 wireinstallations. Two hole locations are provided in boxes, one at thebase and one on the back.

When installing wires onto the circuit board within the controlboxes, strip the outer wire insulation back approximately 2.5inches (63mm) and the inner individual wire insulation backapproximately inch (6mm) per wire.

This recommendation is to prevent wires from shorting with eachother or internal electronic components.

Each application (Extrusion Control, Yield-X, Yield T or Yield D)has a unique wiring diagram in the installation section of thismanual.

Refer to the provided wiring diagrams within this manual forexact wire locations for your application.

Use of a 24-volt power supply. If you are using the 24-volt powersupply to power your control boxe(s), follow the wiring diagramprovided with the 24 volt power supply for specific wire attachmentlocations. For demonstration purposes the images in this manualare wired with the Brown wire attached to the +24 volt and the bluewire attached to the common.


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Wiring Consideration

The wiring of your communication lines is very important for reliable operation. To minimizeproblems, consider the following:

1. Communication lines are low voltage lines. Be sure that these lines are not bundled toany high voltage lines. If you run them in conduit, do not run high and low voltage linestogether.

2. It is not necessary to run this wire in conduit. If you do run cables without conduit, do notwire tie these lines to material conveying lines or other conduit containing high voltage orhigh amperage electrical lines.

3. Keep all communication lines away from all vacuum loader-conveying lines.Conveying plastic produces extreme static charges. A communication line, even in conduit thatruns next to a vacuum line can introduce extreme static pulses into the processor. Keep theselines separated from conveying lines.


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XC-1 Extrusion Control Installation

The XC-1 kit involves the installation of the following components:

LineMaster Controller Extruder Drive Control Cabling Optional 24 volt power supply

Install the XCD-X Extruder Drive Control in your desired location.

Remove the front cover from the Extruder Drive Control box (see General InstallationsNotes).

Run the Controller Cable from the LineMaster Controllers 7-pin receptacle to theExtruder Drive Control. The un-terminated side of the cable will be on the ExtruderDrive Control side and should be cut to length leaving enough cable to run into theExtruder Drive Control box.

Strip back approximately 2 inches of the outer shielding from the un-terminatedside of the cable to expose the 5 wires. Run the Controller Cable into the ExtruderDrive Control box, through one of the two hole locations on the Control box. Use astain relief if necessary. Strip back approximately inch (6mm) per wire and installinto the terminal strip (see wiring diagram on the following page for exact wirelocations).

Run the Extruder Drive wire into the Extruder Drive Control box and install into the specified terminalstrip as indicated in the wiring diagram.

If you are using the optional 24 volt power supply to power theExtruder Drive Control, install the power supply in a desired location.Run a length of shielded, 2-conductor 18 gauge wire from the powersupply to the Extruder Drive Control and wire according to the XC-1Extrusion Control Wiring Diagram.

If the Extruder Drive Control will be powered by your 0-10 volt Extruder Drive Cable, REMOVE thejumper between J14 and J15 located on the On the Extruder Speed Control Interface circuit board.

If the Extruder Drive Control will be powered by the optional 24 volt power supply (to provide an isolatedpower source), DO NOT remove the jumper between J14 and J15 located on the On the ExtruderSpeed Control Interface circuit board.


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XC-1 Extrusion Control Wiring Diagrams


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XC-2 - Yield Control X or Yield Control T Installation


LineMaster Controller Extruder Drive Control Take-Off Drive Control Control Cabling Mounting hardware 24 Volt Power Supply Encoder, Encoder Wheel (12 inch circumference) Encoder Cable

Mount the XCD-X Extruder Drive Control in your desired location.

Mount the XCD-T Take-Off Drive Control in your desired location.

Remove the front cover from the Extruder Drive Control (see General Installations Notes).

Run the Controller Cable from the LineMaster Controllers 7-pin receptacle to the ExtruderDrive Control box. The un-terminated side of the cable will be on the Extruder Drive Controlbox side and should be cut to length leaving enough cable to run into the Extruder DriveControl box and to the terminal strip.

Strip back approximately 2 inches of the outer shielding from the un-terminated side of thecable to expose the 5 wires. Run the Controller Cable into the Extruder Speed ControlInterface, through one of the two hole locations on the Control box. Use a stain relief ifnecessary. 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 the Encoder signal cable from the

Encoder back to the XCD-X Extruder Drive Control. At the XCD-X Extruder Drive Control wirethe Encoder signal cable according to the wiring diagram on the next page.

Run the Extruder Drive wire into the Extruder Speed Control Interface box and install into the specified terminalstrip as indicated in the wiring diagram.

If you are using the optional 24 volt power supply to power the ExtruderSpeed Control Interface, install the power supply in a desired location. Runa length of shielded, 2-conductor 18 gauge wire (not included in kit) fromthe power supply to the Extruder Speed Control Interface and wireaccording to the XC-1 Extrusion Control Wiring Diagram.

If the Extruder Speed Control Interface will be powered by your 0-10 volt Extruder Drive Cable, REMOVE the

jumper between J14 and J15 located on the On the Extruder Speed Control Interface circuit board.

If the Extruder Speed Control Interface will be powered by the optional 24 volt power supply (to provide anisolated power source), DO NOT remove the jumper between J14 and J15 located on the On the Extruder SpeedControl Interface circuit board.


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XC-2 - Yield Control X or Yield Control T Wiring Diagrams


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XC-3 Yield D Installation


LineMaster Controller Extruder Speed Control Interface

Take-off Speed Control Interface LineMaster Cabling Mounting hardware 24 Volt Power Supply Encoder, Encoder Wheel (12 inch circumference) Encoder Cable G2 Software Cabling Installation of G2 Software on dedicated PC (PC not included with kit)

Mount the XCD-X Extruder Drive Control in your desired location.

Mount the XCD-T Take-Off Drive Control in your desired location.

Remove the front cover from the Extruder Drive Control (see GeneralInstallations Notes).

Run the Controller Cable from the LineMaster Controllers 7-pin receptacle tothe Extruder Drive Control box. The un-terminated side of the cable will be onthe Extruder Drive Control box side and should be cut to length leavingenough cable to run into the Extruder Drive Control box and to the terminalstrip.

Strip back approximately 2 inches of the outer shielding from the un-terminated side of the cable to expose the 5 wires. Run the Controller Cableinto the Extruder Speed Control Interface, through one of the two holelocations on the Control box. Use a stain relief if necessary. Strip backapproximately inch (6mm) per wire and install into the terminal strip (seewiring diagram on the following page for exact wire locations).

Install the Encoder on the shaft of the haul off. Run the Encoder signal cablefrom the Encoder back to the XCD-X Extruder Drive Control. At the XCD-XExtruder Drive Control wire the Encoder signal cable according to the wiringdiagram on the next page.

Run the Extruder Drive wire into the Extruder Speed Control Interface box and install into thespecified terminal strip as indicated in the wiring diagram.

If you are using the optional 24 volt power supply to power theExtruder Speed Control Interface, install the power supply in adesired location. Run a length of shielded, 2-conductor 18gauge wire (not included in kit) from the power supply to theExtruder Speed Control Interface and wire according to theXC-1 Extrusion Control Wiring Diagram.


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If the Extruder Speed Control Interface will be powered by your 0-10 volt Extruder Drive Cable,REMOVE the jumper between J14 and J15 located on the On the Extruder Speed ControlInterface circuit board.

If the Extruder Speed Control Interface will be powered by the optional 24 volt power supply (toprovide an isolated power source), DO NOT remove the jumper between J14 and J15 locatedon the On the Extruder Speed Control Interface circuit board.

G2 Software Cabling

The G2 software is designed for communications with the LineMaster controller to work withand control the LineMaster equipment. Communication with the LineMaster controller can bedone using serial communication lines or Ethernet communication lines with Ethernet being thepreferred method. The LineMaster controller has both an Ethernet port and a serial port forcommunication purposes. Decide whether you want to communicate over Ethernet or serialand read the following brief outline for installing communication lines.

The basic G2 Software Starter kit will include a G2-SA, which is a serial signal amplifier andsecurity key. The G2-SA will be used in both serial and Ethernet applications. For Serialapplications the G2-SA is necessary for both the signal amplifier and a security key. ForEthernet applications the G2-SA will only be used as a security key and the communication willroute through the Ethernet line.

The following diagrams provide an overview of typical serial and Ethernet communicationnetworks. With Ethernet, standard, off the shelf Ethernet components can be used. MaguireProducts does not supply Ethernet components. With serial networks, Maguire Products cansupply pre-terminated standard lengths of serial cable and connector boxes. Please speak toa Maguire sales person or review the Pre-sales Guide on our website for more information.http://www.maguire.com/page.php/g2manuals.htm

Ethernet application Serial applications


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XC-3 Yield D Wiring Diagrams


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LineMaster Operation

Standalone Operation Standalone operation uses the hardware only to control theequipment.

G2 Software Operation G2 software operation uses both the hardware and G2 software tocontrol the equipment.

Standalone Operation

XC-1 Throughput Control

XC-1 Throughput Control is where control is maintained bymonitoring the throughput of the process and regulating theextruder speed. The XCC controller utilizing the consumption

data from the LIW hopper and communicates with the XCD-XExtruder Drive Speed Control to adjust the extruder speed viaa 0-10 volt signal to maintain the throughput target. LinemasterXCC Controller

XCD-X ExtruderDrive Speed

Control

XC-1 StartupBefore 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 MANUALposition, turn main power of LineMaster (XCC) ControllerON

Display will read: 0.0 K/h EXTRUSION UNLOCKED

2. At the LineMaster Extruder Speed Control begin increasing thevoltage by rotating the ADJUST pot clockwise. Rotate ADJUSTpot until desired RPM (voltage) is attained. As material begins toflow through the Loss-in-weight hopper and into the extruder, anactual rate of throughput is displayed.

3. When the desired rate of flow is attained, the LineMasterExtruder Speed Control can be put into the LOCK position tomaintain the current rate of throughput. In LOCK position,

automatic adjustments to the (0-10v) extruder voltage are made bythe LineMaster (XCC) Controller to maintain the locked rate ofthroughput.


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Adjustments

When in the locked mode, manual adjustments to the rate of throughput can be entered throughthe LineMaster (XCC) Controller. Adjustments can be made two ways:

Incremental Adjustments

Incremental adjustments are made using the up and down arrows on thekeypad of the LineMaster (XCC) Controller. Press and release once of thearrow keys increments up or down by one tenth of a pound or kilogram.Pressing and holding of the arrow keys will rapidly increase or decease thevalue. Incremental entries can only be made in the locked mode.

Keypad Entry

Keypad adjustments are made using the keypad button located above the up and down

arrows on the keypad. Pressing the keypad button, will display:

1880.2 gENTER TARGET _ _ _ _ _

Enter the value of throughput in pounds or kilograms using all 5 digits (the last digit is in10ths). Be sure to include any leading zeros (example: 330.0 pounds/hour would beentered as 03300.) Keypad entries can only be entered in the locked mode.

LOCK Options

On the LineMaster (XCC) Controller keypad, between the up and downarrows, is a LOCK key. This LOCK key can be used to Lock throughput,overriding the LineMaster Extruder Speed Control MANUAL / LOCK switch.To use the keypad LOCK option, the LTP parameter in the LineMaster (XCC)Controller must be set to LTP 1xxxx, where the first digit in this parameter isset to a 1. Setting the LTP parameter to use this option will de-activate (andignore) the LineMaster Extruder Speed Control MANUAL / LOCK switch.

Shutdown

Normal Shutdown Procedure First switch the LineMaster Extruder Speed Control intoMANUAL position. Then rotate the ADJUST pot counterclockwise (at your desired rateof decrease), eventually reaching zero volts (zero RPM).


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XC-2 - Yield Control X or Yield Control T

LinemasterXCC Controller

Encoder, EncoderWheel

XC-2 offers the ability to maintain a products weight perlength (lb/ft or gm/M) by monitoring the process throughputagainst the line speed. An XCE Digital Encoder mounted on atake-off device monitors the line speed. Control is

accomplished by adjusting either the extruder speed with aXCD-X Drive Speed Control Module by referencing themanually controlled line speed or controlling the take-offspeed with a XCD-T Line Speed Control Module from amanually controlled extruder.

XC-2 has two options for control of grams per length.

YLDX The Take-off drive speed is controlled manually.When in lock mode, LineMaster Extruder Speed Control willadjust the extruder automatically to follow the line speed to

maintain yield.

YLDT The Extruder drive speed is controlled manually.When in lock mode, LineMaster Take-off Speed Control willadjust the take-off automatically to follow the Extruder speedto maintain yield.


Control

XCD-T Take-offDrive Speed

Control

XC-2 StartupBefore startup, make sure material is available at the fill valve of the Loss-in-weight hopper.

YLDX Mode

1. With the LineMaster Extruder Speed Control in the MANUALposition, turn main power of LineMaster (XCC) ControllerON

Display will read: 0.0 g/lYLDX UNLOCKED

2. At the LineMaster Extruder Speed Control begin increasing thevoltage by rotating the ADJUST pot clockwise. Rotate ADJUSTpot until desired RPM (voltage) is attained. Material begins to flowthrough the Loss-in-weight hopper and into the extruder. Once the

take-off is running and rotating the Encoder, producing feedbackto the LineMaster (XCC) Controller, an actual rate of grams perlength (g/l) is displayed.

3. When the desired rate of flow is attained, the LineMasterExtruder Speed Control can be put into the LOCK position tomaintain the current rate of grams per length (g/l). In LOCKposition, automatic adjustments to the (0-10v) extruder voltage aremade by the LineMaster (XCC) Controller to maintain the lockedrate of grams per length (g/l).


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AdjustmentsWhen in the locked mode, manual adjustments to the rate of grams per length (g/l) can beentered through the LineMaster (XCC) Controller. Adjustments can be made two ways:


Incremental adjustments are made using the up and down arrows on thekeypad of the LineMaster (XCC) Controller. Press and release once of thearrow keys increments up or down by one tenth of a gram. Pressing andholding of the arrow keys will rapidly increase or decease the value.Incremental entries can only be made in the locked mode.

Keypad Entry

Keypad adjustments are made using the keypad button located above the upand down arrows on the keypad (pic). Pressing the keypad button, will

display: ENTER TARGET _ _ _ _ _.

Enter the value of grams per length (g/l) using all 5 digits (the last digit is in10ths). 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 entered in thelocked mode.

LOCK Options

On the LineMaster (XCC) Controller keypad, between the up and downarrows, is a LOCK key. This LOCK key can be used to Lock grams per length

(g/l), overriding the LineMaster Extruder Speed Control MANUAL / LOCKswitch. To use the keypad LOCK option, the LTP parameter in theLineMaster (XCC) Controller must be set to LTP 1xxxx, where the first digitin this parameter is set to a 1. Setting the LTP parameter to use this optionwill de-activate (and ignore) the LineMaster Extruder Speed Control MANUAL

/ LOCK switch.

ShutdownNormal Shutdown Procedure First switch the LineMaster Extruder Speed Control intoMANUAL position. Then rotate the ADJUST pot counterclockwise (at your desired rateof decrease), eventually reaching zero volts (zero RPM).


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YLDT Mode

4. With the LineMaster Take-off Speed Control in the MANUALposition, turn main power of LineMaster (XCC) ControllerON.

Display will read: 0.0 g/lYLDT UNLOCKED

5. Once the Extruder is running, material will start to flow through theLoss-in-weight hopper. At the LineMaster Take-off SpeedControl begin increasing the voltage by rotating the ADJUST potclockwise. Rotate ADJUST pot until desired line speed isattained. Once the take-off is running and rotating the Encoder,producing feedback to the LineMaster (XCC) Controller, anactual rate of grams per length (g/l) is displayed on theLineMaster (XCC) Controller.

6. When the desired rate of flow is attained, the LineMaster Take-offSpeed Control can be put into the LOCK position to maintain thecurrent rate of grams per length (g/l). In LOCK position, automaticadjustments to the (0-10v) Take-off voltage are made by theLineMaster (XCC) Controller to maintain the locked rate ofgrams per length (g/l).

Adjustments

When in the locked mode, manual adjustments to the rate of grams per length (g/l) can beentered through the LineMaster (XCC) Controller. Adjustments can be made two ways:


Incremental adjustments are made using the up and down arrows on thekeypad of the LineMaster (XCC) Controller. Press and release once of thearrow keys increments up or down by one tenth of a gram. Pressing andholding of the arrow keys will rapidly increase or decease the value.Incremental entries can only be made in the locked mode.

Keypad Entry

Keypad adjustments are made using the keypad button located above the upand down arrows on the keypad (pic). Pressing the keypad button, willdisplay: ENTER TARGET _ _ _ _ _. Enter the value of grams per length (g/l)using all 5 digits (the last digit is in 10ths). Be sure to include any leadingzeros (example: 120.0 grams per length (g/l) would be entered as 01200.)Keypad entries can only be entered in the locked mode.


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LOCK Options

On the LineMaster (XCC) Controller keypad, between the up and downarrows, is a LOCK key. This LOCK key can be used to Lock grams per length(g/l), overriding the LineMaster Extruder Speed Control MANUAL / LOCKswitch. To use the keypad LOCK option, the LTP parameter in theLineMaster (XCC) Controller must be set to LTP 1xxxx, where the first digitin this parameter is set to a 1. Setting the LTP parameter to use this optionwill de-activate (and ignore) the LineMaster Extruder Speed Control MANUAL

/ LOCK switch.

Shutdown

Normal Shutdown Procedure First switch the LineMaster Take-off Speed Control intoMANUAL position. Then rotate the ADJUST pot counterclockwise (at your desired rate ofdecrease), eventually reaching zero line speed.


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XC-3 Yield D

LinemasterXCC Controller

Encoder, EncoderWheel

XC-3 Multi-Layer Yield Control via Computer

XC-3 provides complete weight per length control (lb/ft orgm/M), via simultaneous control of the extruder and take-off.

Controllers are connected via serial or Ethernet using the XCSoftware. Gauge or thickness control can be initiated in set-uputilizing data of the materials or blend specific gravity.

XC-3 (Yield-D) requires the G2 Software as the linkbetween the layers. The following section is an overview ofthe G2 software and will explain the use of G2s Yield Screenfor XC-3 operation.


Control

Take-OffSpeed Control

G2 Software Operation - Using the G2 Software with LineMaster

G2 Software Setup

The following information is a brief overview of the setup and use of the G2 Software and specifically, theYield Screen within G2. For more in-depth information about the G2 Software, read the GravimetricGateway Manual available online at www.maguire.com/page.php/g2manuals.htm

Starting the Software

After installing the G2 Software, the program group, Gravimetric Gateway, will be createdin the Start menu. Within this program group are G2 Server and Client.

Start the G2 Server. In the G2 Server programs menu, click Mode, then Licensed.Choose the COM port that your G2-SA (serial signal amplifier / security key) is pluggedinto. Click Start G2 Server. This portion of the software must be running for G2 tocollect data from the controllers.

Start the Client. The G2 Client is the user interface of the G2 Software. The Clientwill automatically connect to the G2 Server when run on the same PC. To connect G2Clients installed on PCs located on the same network as the G2 Server must enter the IP

address of the G2 Server in the Gateway Edit Screen, check Default host, clickAdd/Update, then restart the G2 Server.

Adding Blenders

In the Clients menu, click Edit, then Blenders. For Serial CommunicationControllers enter the ID number of your blender controller, then press Add/Update. ForEthernet Communication Controllers, enter your ID number, and then check the boxTCP/IP access. Enter the IP address you assigned to the controller or Ethernet to Serialconverter, into the field labeled WSB I.P. then enter the Port number, then press


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Add/Update. For more information on configuring Ethernet, see the GravimetricGateway Manual. Note: The ID number is programmed into your controller(s) using the*66 star function at the blender keypad. ID numbers are between 1 and 254 and must beunique.

Adding Materials (optional)

The G2 Software can assign material usage to a particular material. Tracking material byname requires material to be pre-entered into the software. To enter materials, in theClient menu go to the Edit, then Materials to enter each material you will use. Enter aMaterial Code (this is the name), select a material type, enter the Specific Gravity of thismaterial (only necessary if you will have G2 automatically calculate Specific Gravity), andthen click Add/Update to add it to the database. Recipes will then be created from thesematerials.

Creating Recipes (optional)

Materials added to the G2 software are then built into recipes. A recipe is the group ofmaterials with the material type and settings to produce a particular product. Recipes arethen downloaded to the Maguire Controller using the G2 software. To create a recipe,click Edit, then Blender Recipes in the Client menu. Enter a Recipe Name. Recipesare either 4 (max 4 components) or 12 (max 12 components) software. Select yourrecipe type. Each numbered row in this screen represents a component or hopper in thecontroller. You will assign a material name to a component. To assign a material to acomponent, click the field to the right of the component number under the Materialcolumn. Select the material from the material list on the right of the screen. Next selectthe material Type and then click the Settings field to the right of that material. Enterthe setting that is required for this component and click OK. Do the same for eachcomponent in the recipe. When all components have been entered with their respectiveType and Setting, click the Add/Update button. The recipe is then added to thedatabase.

With the LIW system, a LIW controller is processing a single material or blend ofmaterials. When you create a recipe for the LIW system, specific gravity is calculatedfrom the percentages of multiple materials in your recipe. For reporting purposes, the LIWcontroller will use component 12 as an accumulator and the hopper 12 will show a typeand setting in the recipe download screen. With the current G2 configuration, we suggestadding a material name that you would consider calling the blended material in the LIWhopper. Add this to your recipe in component 12 with the type Natural and a setting ofzero. This will make sense once you run a material usage report.

Creating Lines

Lines are groups of LIW hoppers that work together to produce a product. For XC-3Multi-Layer Yield Control using the G2 Yield Screen, one or more LIW hoppers must bepart of a Line for the Yield Screen to be able to control that Line. To enter a line, clickEdit, then Lines in the Client menu. Enter a Line Name. Next click position 1 in theBlenders column (highlights yellow). Select a Blender from the list of active blenders.The Blender ID moved into the column. Click position 2 in the Blenders column and clickthe next active blender from the list. Do this for each LIW Hopper in the Line. When


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complete, click Add/Update. After a Line has been created, selecting the Line from thelist will display Line Rules. Line Rules refer to how the Yield screen will react toadjustments. The Line Rules will default to the choices below, however they may beadjusted to suit your process. After making changes to the Line Rules, click Add/Updateto save the rule changes.

Adding Line Recipes (optional)

Line Recipes allow for multiple downloads of recipes to multiple blenders in a single click.This is optional. Recipe download typically are downloaded using the Download ToBlender Screen. To enter a line, click Edit, then Line Recipe in the Client menu.Line Enter a Line Recipe name. Click the top position in the column to the right. In this

screen each line of that column is the position of a Blender in the Line you created withinthe Line Edit screen. After clicking the top position, select recipe that you would want todownload to the blender in that position. After selecting each recipe for the Line, clickAdd/Update.

Setup Requirements

Before the Co-Extrusion process can be used in G2, the following requirements must be met.Steps 2 through 6 are outlined in the Quick Start Guide. For information on YDLX (singleextruder), YDLT (single extruder), or YLDD (co-extruders), refer to your Blender Manual.

1. All Blenders must have the *02 function set to EXT CRTL, YLDX, YLDT, or YLDD. Seeyour blender manual for addition information on these parameter values and theirfunction.

2. In a Co-Extrusion setup, one blender (master) must have the *02 function set to YLDD.The blender set to YLDD must have the CPL parameter set prior to selecting any yieldconfiguration. See Control Setup for Extrusion section in this manual for furtherinformation on CPL. All other 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 *66function.

4. All Blenders within the Co-Extrusion process must be added to the Blender Edit screen.

5. All blenders must have a State of On Line in the Blender Edit screen.

6. A Line must be created using the Blenders that are part of the Co-Extrusion process.

The following steps are optional and not require to run extrusion control.

7. If materials are to be tracked by a material name, the materials need to be entered intothe G2 database using the Material Edit screen.


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8. Blender Recipes are then built from Materials in the Materials list and then added to theRecipe Database. If you plan to use the blender recipe feature of G2 with LIW controllerssee the above section on creating recipes.

After following the above steps, you are now ready to begin using the Yield screen to control theextruder(s) and the downstream equipment.

G2 Software Operation

The G2 software is designed to do a wide range of things with the Maguire Weigh ScaleBlenders and LIW Blenders. This section of the manual is specifically written to describe how touse the G2 software with the LIW Blenders and more specifically, how to use the Yield Screenwithin the G2 Software. This section also talks about using recipes, and generating reports.

Downloading Recipes (optional)

When recipes are downloaded to the LIW blender controllers, the G2 software associates

the recipe and the material contained within that recipe, with the LIW blender ID. G2 thenbegins tracking material usage by the material name that you specified in the recipe.Reports that are generated from the G2 software will specify these material names foreasy identification of you material and their usage. Since LIW controllers are processinga single material, your material will be accumulated under hopper 12 and the materialname associated with hopper 12.

If you are using recipes and want to track by recipe and material names, you mustdownload a new recipe when material is changed at the blender so that the softwareknows to track your new material.

To download a recipe, select Download, Recipe to Blender in the G2 Client menu.Select your blender ID from the dropdown menu. On the left of the screen you will seewhat is currently loaded in the blender as well as the current Operator Number (or name)and current Work Order number (if either are applicable). To download a recipe, clickselect Recipes to show your recipe list. Select the recipe you want to send to theblender from the list. Click Hide Recipe to hide the list. If you would like to associate anOperator and/or Work Order to the job, you may enter it at this time. Click Send toBlender to send the recipe to the blender.

Using the Yield Screen

Yield Control offers to the operator, the ability to control Co-Extrusion Lines consisting of 1 to 7extruders while intelligently controlling the downstream Take-Off equipment.

Yield Screen - Startup Process:

In the G2 Client, select from the menu above, Control then Yield to open the Yield Screen. Inthe Yield Screen, select your line from the dropdown menu in the upper-right. This will displayyour line and all blenders within the line.


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Explanation of the Yield Screen

The Yield Screen - On the left side of the screen are informationtables, one for each extruders WSB/LIW controller. Depending onthe number WSB/LIW controllers you are using, 1 to 7 tables willbe displayed. Verify that all blenders are ONLINE. All blenderIds and their corresponding information will be loaded into theappropriate fields. If any blender is listed as OFFLINE meaningG2 cannot communicate with that blender for any reason, thecorresponding table of information for that blender will be grayedout. Before proceeding with Yield Control, you will must bring thatblender ONLINE.

Each table consists of the blenders unique ID number, theThroughput %, the current voltage, the current throughput, and analarm indicator.

Clicking on the WSB/LIW ID field will bring up a screen where you

can further examine the line. This screen will display an moredetailed examination of each blenders settings and outputs.

At the right are your take-off controls. Displayed are: two columnsof information, Target and Actual. The fields within the columnsare Voltage (Actual voltage only), Line Speed, and Yield. LineSpeed is displayed meters per minute (m/min) or in feet per

minute (ft/min). Yield is displayed in grams per meter (grs/m), orgrams per foot (grs/ft). Measurement units are set in the SetupScreen when choosing your Weight Units.

All lines will visually merge where your Total Throughput will bedisplayed.


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XC-3 Startup Using G2s Yield ScreenBefore startup, make sure material is available at the fill valve of the Loss-in-weight hopper.

Setting Voltages for each Extruder

1. With the LineMaster Extruder Speed Control in the MANUAL

position, turn main power of LineMaster (XCC) ControllerON

Display will read: 0.0 K/h EXTRUSION UNLOCKED

2. At the LineMaster Extruder Speed Control begin increasing thevoltage by rotating the ADJUST pot clockwise. Rotate ADJUSTpot until desired RPM (voltage) is attained. As material begins toflow through the Loss-in-weight hopper and into the extruder, anactual rate of throughput is displayed.

Do this for each extruders LineMaster Extruder Speed Control.

3. At the LineMaster Take-Off Speed Control begin increasing thevoltage by rotating the ADJUST pot clockwise. Rotate ADJUSTpot until desired Line Speed (voltage) is attained.

4. After the Line running for a period of time, view your Yield Screenin G2. Verify that G2 is showing your Extruder Speed Controlvoltages, your throughput values, your take-off voltage and linespeed, and your grams per length.

5. Adjust your target percent for each extruder To adjust yourtarget percent, click the Target % field of any of your extruders.

6. A Target Percent keypad window will appear. On the right of thiswindow will be a list of your extruders by ID number. To the rightof each ID number is the current percent of each extruder (columnis labeled %). The far-right column is where your new TargetPercent will be enter. To enter a new percent, click the row ofyour extruders IDs row to select that extruder. Using the keypad,enter the new percent. Select each extruder by clicking the row,then using the keypad, enter the percent. The total of allpercentages must add up to 100%, indicated by Red (not = to100% or Green (= to 100%) color of the total percent field). Whensatisfied with the percentages, click the Close and Download AllPercentages button.


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7. All LineMaster Extruder Speed Controls can now be put into theLOCK position to maintain the current rate of throughput and yield.In LOCK position, automatic adjustments to the (0-10v) extrudervoltage and (0-10v) Take-off are made by the LineMaster (XCC)Controller to maintain the locked rate of throughput and yield.

Adjustments

When in the locked mode, adjustments to the rate of Throughput or Yield will be enteredthrough the G2 Yield Screen. These adjustments will follow the Lines Yield rules (see CreatingLines in the previous section).

Keypad Entry

Making Throughput Adjustments

Keypad adjustments to Total Throughput are madewithin the G2 Yield screen. Throughput adjustmentsare made by clicking the Total Throughput field, whichwill display a Set Total Throughput keypad. Using thekeypad, enter the new target Total Throughput, andthen click OK. Adjusting Total Throughput willautomatically make adjustments to individual layerthroughputs based on their percentages. Based on thedefault Line Rules, a change to Throughput willautomatically adjust Line Speed to maintain yield.

Adjusting Line Speed

Keypad adjustments to Line Speed are made within theG2 Yield screen. Line Speed adjustments are made byclicking the Line Speed target field, which will display aSet Line Speed keypad. Using the keypad, enter thenew target Line Speed, and then click OK. Based onthe default Line Rules, a change to Line Speed willautomatically adjust Total Throughput to maintain yield.The Line Speed adjustments are made to the 10ths.

Adjusting Yield

Keypad adjustments to Yield are made within the G2Yield screen. Yield adjustments are made by clickingthe Yield target field, which will display a Set Yieldkeypad. Using the keypad, enter the new target Yield,and then click OK. Based on the default Line Rules, achange to Yield will automatically adjust Line Speed.The Yield adjustments are made to the 10ths.


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LOCK Options through the G2 Yield Screen

On the G2 Yield Screen Current Throughput and Yieldcan be Locked. Clicking any of the layer throughputfields will display a keypad panel with a Lock or Unlockbutton (depending on the current state). Clicking onthis button will either lock or unlock all layers. To useG2s Lock or Unlock option, the LTP parameter in allLineMaster (XCC) Controllers must be set to LTP1xxxx, where the first digit in this parameter is set to a1. Setting the LTP parameter to use this option willde-activate (and ignore) the LineMaster ExtruderSpeed Control MANUAL / LOCK switch.

Shutdown

Normal Shutdown Procedure First switch the LineMaster Extruder Speed Control intoMANUAL position. Then rotate the ADJUST pot counterclockwise (at your desired rateof decrease), eventually reaching zero volts (zero RPM).


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XC-3 with Gauge Control using G2s Yield Screen

Gauge control allows G2 to control the individual layers by volume and by percent using thelayers specific gravity to calculate each layers gauge.

G2 Setup for Gauge Control

To enable Gauge Control in the G2 Client, go toMain/Setup then the System Tab. Click the Checkboxlabeled Enable Gauge Control. Click Add/Update tosave the change in Setup.

Enabling Gauge Control will make several new fieldsvisible in the Yield Screen. With each Layersinformation box, the field Specific Gravity will bedisplayed. The Specific Gravity can be manuallyentered here in the Yield Screen.

Also a calculated yield box will display in the upper-rightof the Yield Screen.

All fields must be set before the layers can be locked.

To enter a specific gravity manually, click the SpecificGravity field then enter the Specific Gravity for thatlayer. Then click OK. Repeat this step for each layer.

Alternately the specific gravity can be automaticallycalculated and displayed in this field based on the recipedownloaded to the controller. This feature is useful ifyour recipes contain more than one material. To havethe Specific Gravity automatically calculated anddisplayed, the following steps are required.

In the Line Edit screen, select your line, then click the

checkbox Automatically Calculate Specific Gravitythen click Add/Update to save the change to your line.

Recipes are generally made up of one or morematerials. All materials in a recipe must have a specificgravity entered for automatic calculation to occur.Within the recipe, the settings entered for multiplematerials are used to calculate the Specific Gravity ofthe recipe. Specific gravity for each material is enteredin the Material Edit Screen. Enter the specific gravity of


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a given material in the Specific Gravity field. ClickAdd/Update to save changes to a material.

Once a Specific Gravity has been entered for all lines,the actual percent per layer will be displayed.

If the actual is not the correct percent that you will berunning, a target can be entered. Once all layers arelocked, the actual percent will be adjusted to meet thetarget. To adjust the target percent, click any of thelayers Target % fields to display the Target Percentbox. Enter the new percent (must total 100%) then clickClose and Download All Percentages. Locking all

layers will apply the new percentages.

In the upper-right of the Yield screen, the CalculatedYield Box requires information to be entered. OverallSpecific Gravity is displayed at the top of this box and iscalculated from the layers by their percent.

You will need to enter the Width and gauge of theproduct. To do this, click the Width box to display akeypad. Enter the Width, of your product, then click OK.

To set the gauge, click the Gauge box to display akeypad. Enter the Gauge of your product, then clickOK.

Once these values are entered, a Calculated Yield willdisplay.

After all layers are in the lock position, Total Throughputwill be locked. This will be indicated by the TotalThroughput field turning green.

Also the Calculated Yield will be sent below to the

Target Yield field. The Actual Yield will be adjusted tomeet the target yield value in order to maintain theentered gauge.

Its Rolling Rock Time.


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Material Usage ReportsGenerating Material Usage reports from the data collected from the blenders.

This screen is where you generate material usagereports. All material usage reports are based uponthe data collected by the G2 Server. The G2 Server,when running, is constantly collecting data. Thisdata is then used to produce all of the reports. Thereports are limited to information that can be derivedfrom this data.

G2 produces material usage reports showingseparate totals for all materials blended between twodates broken down by date, time period, machinenumber, line, recipe, line recipe, work order, operatornumber, and end of day tag. All reports may belimited to certain a date range and then broken downby each category. Further limiting of reports may beused in the advanced reports by buildingmathematical and and or statements.

The Report Generation

screen looks like this:

OUTPUT DEVICE: Reports will be generated to a separate satellite window. Printingfrom this window will allow the user to choose a printer or send the report to afile. This window will give the user the option of choosing the report to be inpounds, ounces, kilograms, or grams.

Start Date / Stop Date: All material usage reports request a start date and stop date.To enter dates click on the start and stop dates. A calendar will appear andusing the arrows you the user can change the date. Formats are specified in thesetup screen, such as MM/DD/YY. All reports are limited to information betweenand including these two dates.

Percentage Breakdown: When percentage breakdown is checked, reports will displaya percentage column as well as totals.

Limiting Reports: When limiting a report, begin with the upper dropdown of limiting parametersand moving down the user may further limit a report. If you want to build a report and limit it tospecific values such as blender and operator you must specify these limiting parameters in thedropdown menus. Selecting Retrieval Times as a limiting parameter in the dropdown menuswill display all available retrieval times in a table. Retrieval times may be selected individually

for further breakdown.

Additional advanced control over reports generating may be attained by checking off thewhere checkbox. This will display very flexible and powerful report generating operations.Your choices in the advanced reports are based on what is selected above under the Limit Byrules. For instance, if you limit the report by Work Order and then by Blender, you choices inthe advanced report under field will be Work Order and Blender. By using the Report FilterScreen, report limiting filters may be created and saved for repeated use. These filters may beviewed by clicking the Show Report Filter button and selecting a pre-defined filter from thereport filter list.


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How to use the Where featureTo use the advanced report building operations, you must first understand how tocorrectly read and build an advanced report. Under the Advanced Reports (where)are four columns labeled Field, Logical Operation, Valueand Logical Connector. Whenbuilding an advanced report, start in the left column, Field, and select what your firstreport statement will pertain to. Your choices may be one or more of the following;Blender, Line, Recipe, Line Recipe, Work Order, Operatoror Retrieval Time. Aftermaking your selection for the first statement move to the next column labeled LogicalOperator. Logical Operators choices consist of > (greater than), >= (greater than orequal to), = (equal to), (greater than) and < (lessthan) operators as well as the = to include the targeted value. The nextcolumn, Value, contains a field to enter a value. Your value will depend on what youselected in column one, Field. For instance, if you selected Blender in column one(Field), you will enter a blender I.D. If you selected Work Order, enter a work ordernumber exactly as it was entered into the G2 database. The value for a Retrieval Timeis entered as a 24-hour format (i.e. 17:00 for 5 pm). Other values such as the name ofa Recipe, Line, Line Recipeand Operatormust be entered the same as it is entered intothe G2 Database. Only values for Retrieval Time, Blender, and Work Order will workwith Logical Operators of > (greater than), >= (greater than or equal to),


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Printing Reports

To print a generated report, click the Print button. To print to a flat file, select Formattedor Non-Formatted File. A formatted file contains the header information including thedata/time range. A Non-Formatted file does not contain the header information.

Opening a Report in ExcelA Formatted or Non-Formatted file can be opened in Excel. To do this, start by saving areport as a Formatted or Non-Formatted file without typing an extension to the filename. An example would be a file called report but NOT repor

Documents

Line Master