From a mechanical standpoint, extruders are just about the same creatures as they were 30 years ago. They may have a more powerful motor, and a jazzier paint job, but fundamentally they are not that much different.

The control systems, however are as different as night and day. Modern closed loop control systems do entirely different things, and in entirely different ways. The most effective way you can modernize your existing extrusion lines is to replace the original controls with modern, hi-tech closed loop control systems. Harrel, Incorporated has been the pioneer in hi-tech controls for over 41 years:

• Harrel introduced the very first PID (3 mode) temperature controls to the plastics industry in 1967.
  
• The very first microprocessor control for total control of an extrusion line in 1975.
• The first totally controlled melt pumps for plastics extrusion in 1976.
• The first plant-wide control system for the plastics industry in 1968.
• The first total control system for controlling all the dimensions of a tube in the 80's.
• The first commercial system for control of the cross-machine profile in sheet extrusion, using control of the lip temperature of the die zones -- in the early 70's.
• The first barrel temperature control system that could control the temperature of the extruder barrel from a deep well -- down near the plastic, where it counts!
• The first DUOSENSE^® deep-and-shallow well cascade control system which controls from a deep well sensor and can still respond rapidly to changes in the environment -- line voltage, cooling water changes, ambient temperature changes, etc.
  ......And Harrel still offers the most sophisticated extrusion control systems in the industry!!!
  

HOW HARREL CONTROL SYSTEMS DIFFER FROM OTHERS:
Most people naturally assume that all vendors' control systems are more or less the same and differ only in detail. This is definitely not true with extrusion controls. Harrel offers a completely unique system of TOTAL control.

• Take tubing extrusion as an example: With other control systems, the operator sets the parameters of the extruder -- temperature, line speed, air pressure, etc., and then adjusts them by trial and error until the product dimensions are on target. This can take an hour or more, even with experienced operators and on straight tubing. For such applications as bump tubing it is far worse, and for double bump tubing it simply becomes impractical.


• Harrel control systems control the dimensions and other characteristics of the product directly and automatically. The operator sets the dimensions of the product, presses a button, and the system brings the product on spec -- typically in 3-5 minutes. Double bump tubing is no more difficult than single bump.

CP-644 DIGIPANEL^® controller for extruder and melt pump control

• 10" color LCD shows all zones at once, or just the most important ones.
• Temperature control module includes:
  • Up to 22 zones of RTD sensing for stability and accuracy.
  • Separately adjustable deviation and high-limit alarms on each zone.
  • Configurable as heating-and-cooling, heating-only, or monitor zones.
  • Full 3 mode (PID) control, with separate trim adjustments on heating and cooling for best performance.
  • Optional DUOSENSE^® deep-and-shallow well cascade control.
  • AUTOTRIM automatic setting of heat control trim values.
  • Keep-warm mode.
  • Melt temperature process control.
• Melt Pressure module includes:
  • Up to 3 zones of melt pressure are monitored.
  • Simple, on-screen calibration. No jumpers required!
  • Two stage melt pressure alarm: First level warns operator, second level shuts system down.
  • Optional die pressure process control for use without melt pump.
• Melt Pump Control module includes:
  • Fast-acting inlet pressure control synchronizes extruder to melt pump.
  • Differential pressure control around melt pump: stabilizes throughput to 0.1%.
  • Pressure and temperature interlocks ensure safe operation.
  • On screen check list leads inexperienced operators through the start-up routines, step by step.
• Speed Controller module includes:
  • Commands and monitors screw RPM; monitors extruder motor amps with high limit alarm.
  • DIGISYNCH control of melt pump RPM; monitors melt pump motor amps with high limit alarm.
  • Speed ramping capability.
• Central display of out-of-tolerance zones, and of alarm history.
• Computer compatible.
• Plug-in 100 watt power modules for operation of external mechanical contactors, solenoid valves, or light heater loads. (Use with remote power modules for higher power loads.)
  

Prices:
CP-644A DIGIPANEL^® extruder controller $6900.00
CP-644B DIGIPANEL^® extruder and melt pump controller $8100.00
PM-102C 100 watt plug-in power modules $25.00 per zone
DUOSENSE deep-and-shallow-well sensing: $110.00 per zone
Consult factory for higher power modules.

CP-875 DIGIPANEL^® controller for TOTAL control of a complete extrusion line

• Big 15" flat screen LCD full color display.  Put away your spectacles!
• Schematic diagram of the entire extrusion system, with out-of-tolerance parameters highlighted in red.
• Great for co-extrusion! Has capacity for 2-3 extruders.
• NEW Internal storage for up to 100 recipes. Unlimited additional recipe storage on 3 1/2" disks.
• Temperature control module includes:
  • Up to 30 zones (in base model) of RTD sensing for stability and accuracy.
  • Separately adjustable deviation and high-limit alarms on each zone.
  • Configurable as heating-and-cooling, heating-only, or monitor zones.
  • Full 3 mode (PID) control, with separate trim adjustments on heating and cooling for best performance.
  • Optional DUOSENSE^® deep-and-shallow well cascade control.
  • AUTOTRIM automatic setting of heat control trim values.
  • Keep-warm mode.
  • Melt temperature process control.
• Melt Pressure module includes:
  • Up to 4 zones (in base model) of melt pressure are monitored.
  • Simple, on-screen calibration. No jumpers required!
  • Two stage melt pressure alarm: First level warns operator, second level shuts system down.
  • Optional die pressure process control for use without melt pump.
• Melt Pump Control module includes:
  • Fast-acting inlet pressure control synchronizes extruder to melt pump.
  • Differential pressure control around melt pump: stabilizes throughput to 0.1%.
  • Pressure and temperature interlocks ensure safe operation.
  • On screen check list leads inexperienced operators through the start-up routines, step by step.
• Speed Controller module includes:
  • Commands and monitors screw RPM; monitors extruder motor amps with high limit alarm.
  • DIGISYNCH control of melt pump RPM; monitors melt pump motor amps with high limit alarm.
  • DIGISYNCH control of take-off speed, ratioed to melt pump speed for exact synchronization (0.000% steady state synchronization error) of gear pump speed to line speed. Stabilizes cross sectional area of product.
  • Speed ramping capability.
• TUBE-TROL automatic control of product diameter and wall thickness.
• Speaks 4 languages. A touch of a button brings up all legends in English or any of three other languages.
• Trend plots of any 4 parameters of the line.
• Computer compatible.
• Fully customizable for unique applications such as BUMP tubing.

Prices:
CP-875 DIGIPANEL^® extrusion line controller: $21,500.00
Power modules priced separately.

CP-874 touch screen DIGIPANEL^® controller for TOTAL control of a complete extrusion line

• Flat screen LCD full color display with context-sensitive controls.  Fast and easy to use!
• Includes all features of the CP-875 controller listed above

Prices:
CP-874 Touch screen DIGIPANEL^® extrusion line controller: $21,500.00

CP-667 CONTROL CABINETS

• Your choice of CP-870 series DIGIPANEL^® controller, as described above.
• ....plus AC vector or Harrel digital SCR drive.
  • DIGISENSE (0.05%) or DIGISYNCH^® (0.001%) speed regulation.
  • Exact synchronization (0.000% steady state synchronization error) of gear pump speed to external puller. Stabilizes cross sectional area of product.
  • Differential pressure control around melt pump stabilizes throughput to 0.1%.
• Ultra high precision control of temperature.
• Solid state power modules provide power control to heaters.
• Automated, closed loop control of product dimensions.
• All mounted in an attractive 6-ft NEMA cabinet with a handy shelf and controls in easy reach on the sloping front panel.
• .... Contact factory for quotation on upgrading your specific system!

To order an upgrade system, fill in the form below and click on "submit". Harrel will enter your order and send you an Email or FAX acknowledgement giving engineering data and credit information. Terms are 1/3 with order,1/3 immediately prior to shipment, and 1/3 net, 30 days. Enter accessories and options as separate items 2, 3, 4., etc.