NEXiS® CS2G Series Extrusion Controller

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NEXiS® CS2G Series Extrusion Controller

Extrusion Control

The Proton Products NEXiS® CS2G Series of controllers are for use on wire insulation or other extrusion production lines.

NEXiS® CS2G Series controllers connect to Proton Products diameter gauges and speed and length gauges for measurement of insulation diameter and line speed respectively. These measurements are then fed into a PI feedback controller whose fully-isolated and floating output may be used to drive insulation extruders or capstan drives.

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Features

  • Provides PI control of insulation thickness on wire and cable insulation extrusion lines.
  • Controls insulation extruders or capstan drives.
  • May be used in other diameter-controlled extrusion processes.
  • Integrates seamlessly with one Proton Products InteliSENS®DG series diameter gauges for insulation diameter measurement (also compatible with diameter gauges from other manufacturers for integration into existing production lines).
  • Integrates seamlessly with Proton Products InteliSENS®SL and SLR Series Speed and Length Gauges for line speed measurement.
  • Independent setting of tolerances, shrinkage, alarm functions and speed input.
  • Housed in a rack-mountable enclosure (optional stand-alone mounting case is available).

Introduction

The Proton Products NEXiS® CS2G Series of controllers are for use on wire insulation or other extrusion production lines.

NEXiS® CS2G Series controllers connect to Proton Products diameter gauges and speed and length gauges for measurement of insulation diameter and line speed respectively. These measurements are then fed into a PI feedback controller whose fully-isolated and floating output may be used to drive insulation extruders or capstan drives.

Insulation diameter is thus actively controlled and kept in tolerance by the NEXiS® CS2G controller.

CS2G Series Diagram

Operating Modes

Cold diameter measurement

Cold diameter measurement

The NEXiS® CS2G is connected to the Cold DG diameter gauge after the water cooling trough. The Cold diameter measurement is used to control the extruder so that the final insulation diameter is held within tolerance. Since the Cold diameter measurement is located far from the extruder, this control system response time is relatively slow (and dependent on the line speed), but no shrinkage offset is required.

Cold diameter measurement

Cold diameter measurement

The NEXiS® CS2G is connected to the Hot DG diameter gauge before the water cooling trough. A shrinkage offset due to cooling is set by the operator and used in conjunction with the Hot diameter measurement to control the extruder so that the final insulation diameter is held within tolerance. Since the Hot diameter measurement is located close to the extruder, this control system response time is relatively fast.

Specifications

Variants Control algorithm
NEXiSTM CS2G-10 For connection to single-axis (DG1xxx) Proton Products DG Series Diameter Gauges.
NEXiSTM CS2G-10XY For connection to dual-axis (DG2xxx) Proton Products DG Series Diameter Gauges; controls the average of the X and Y diameter.
Screen 2 row, 7 segment, 5 digit display Upper row 0.8” (20.32mm) high; lower row 0.5” (12.7mm) high
Serial communications RS232 USB CANbus – (for connection to 1× DG Series gauge)
Line speed inputs Analogue Two inputs available for 0 to 10V and 0 to 50V analogue line speed signals; end-user configurable scaling
Pulse Two inputs available for 0 to 3V and 0 to 10V pulsed line speed signals; maximum frequency 250 kHz; end-user configurable scaling
4×Relay contact outputs Function (end-user configurable) Gauge OK SSFD lump or neck flaw detected
X or Y upper tolerance exceeded X or Y lower tolerance exceeded
X upper tolerance exceeded X lower tolerance exceeded
Y upper tolerance exceeded Y lower tolerance exceeded
Electrical Maximum voltage 50VDC / 30VAC
Maximum current 500mA
On resistance (@ 100mA) < 0.1Ω
Off resistance > 10 Ω
Analogue output 1 Function (end-user configurable) ØX ØXY
Electrical Output voltage range 0V to +10V
Maximum output current 2mA
Resolution 16-bit
Output voltage scaling is end-user configurable
Analogue output 2 Function (end-user configurable) ØY Average Error
Electrical Output voltage range ØY: 0V to +10V
Average Error: -10V to +10V
Maximum output current 2mA
Resolution 16-bit
Output voltage scaling is end-user configurable
Control algorithm Advanced Control Algorithm (ACA)
Specification Minimum Typical Maximum Units
Weight 2.5 kg
5.5 lb
Length 230 mm
9.1 inch
Width 213.1 mm
8.4 inch
Height 128.5 mm
5.1 inch
Power supply voltage (rms) 84 264 VAC
Power supply frequency 47 440 Hz
Power supply current (rms) 1 A
Power consumption 35 W
Ambient temperature 5 45 °C
41 113 °F
Relative humidity @ 38°C / 105°F 90 %
Ingress Protection (IP) rating IP50
PI Controller output voltage -10 10 V
PI Controller output current 10 mA
PI Controller output resistance 10 Ω
PI Controller resolution 12 bit

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