Rockwell Automation 1771-QDC, D17716.5.86 User Manual

Plastic Molding Module

(Cat. No. 1771QDC)

Inject and Clamp Mode

Important User Information

Because of the variety of uses for this product and because of the
differences between solid state products and electromechanical products,
those responsible for applying and using this product must satisfy
themselves as to the acceptability of each application and use of this
product. For more information, refer to publication SGI–1.1 (Safety
Guidelines For The Application, Installation and Maintenance of Solid
State Control).

The illustrations, charts, and layout examples shown in this manual are
intended solely to illustrate the text of this manual. Because of the many
variables and requirements associated with any particular installation,
Allen–Bradley Company cannot assume responsibility or liability for
actual use based upon the illustrative uses and applications.

No patent liability is assumed by Allen–Bradley Company with respect to
use of information, circuits, equipment or software described in this text.

Reproduction of the contents of this manual, in whole or in part, without
written permission of the Allen–Bradley Company is prohibited.

Throughout this manual we make notes to alert you to possible personal
injury or damage to equipment under specific circumstances.

ATTENTION: Tells readers where people may be hurt,
machinery may be damaged, or economic loss can occur if
procedures are not followed properly.

ATTENTION helps you:

- identify a hazard

- avoid the hazard

- recognize the consequences

Important: Identifies information that is especially important for
successful application and understanding of the product.

Important: We recommend you frequently backup your application
programs on appropriate storage medium to avoid possible data loss.

PLC and ERC are registered trademarks of Allen-Bradley Company, Inc.
Pro-Set, Expert Response Compensation, PanelView, and PanelBuider are trademarks of
Allen-Bradley Company, Inc

Summary of Changes

Summary of Changes

Summary of Changes

We revised this publication to include changes due to upgrading the
1771-QDC/B module to a 1771-QDC/C.

For These Changes Refer to Page or Chapter

Lossofsensor detection
input range changed back to 0.00 to 10V dc

Added the section, Record I/O Ranges.

Changed the title Ground the QDC Module to Ground and
Shield Your I/O Devices to better describe the task.

Added data codes to configuration worksheets. Chapter 3 and Appendix A

Reversed the order of chapters 3 and 4 to present the
download procedure for the MCC block before the download
procedure for the other data blocks.

Revised the download procedure for the MCC block
(chapter 3) and for other command blocks (chapter 4).

Changed the chapter title to better describe the task. Chapter 6

Added data codes to Configuration Block worksheets. Chapter 7 and Appendix A

Added data codes to Profile Block worksheets. Chapter 8 and Appendix A

Placed 2page worksheets on facing pages Chapters 7 and 8

35, 39
A2, 3

21

29

Chapters 3 and 4

Changed our recommendation on module calibration. 113

Added Block ID codes to blank worksheets. Appendix A

Minor corrections as found

To Help You Find Changes

To help you find these changes, we added change bars as shown to the left.

Table of Contents

Summary of Changes 11. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Using This Manual P1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Manual

Objectives
Audience P2
Use
Related

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

of T

erms P2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Publications

Overview of Inject and Clamp Mode 11. . . . . . . . . . . . . . . . . .

P1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

P5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Chapter
Inject and Clamp Mode Operation 11
Inject Control 12
Clamp Control 110

Objectives

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11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Install the QDC Module 21. . . . . . . . . . . . . . . . . . . . . . . . . . .

Chapter
Record
Set Module Jumper Plugs 22
Key Your I/O Chassis 25
Install
Wire
Ground and Shield Your I/O Devices 29
Plan for ESTOPs and Machine Interlocks 211

Configure the QDC Module'

Chapter
Select Module Parameters and I/O Ranges 31
Determine Initial Sensorconfiguration Values 33
Download
Use Setoutput Operation to Move the Ram (screw) and Clamp 37
Complete your Sensor Configuration 38
Select

Objectives

I/O Ranges

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the QDC Module

the QDC Module

Objectives

MCC V

Optional Configurations

alues to the QDC Module

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s I/O

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21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

31. . . . . . . . . . . . . . . . . . . .

31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

35. . . . . . . . . . . . . . . . .

314. . . . . . . . . . . . . . . . . . . . . . . . . .

Overview of Remaining Configuration Procedures 41. . . . . .

Chapter
Configuration Concepts 41
Special Command and Status Blocks 42
Overview of Remaining Configuration Procedures 43
Enter Data Table Values and Download Command Blocks 44

Objectives

41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Table of Contentsii

Jog Your Machine 51. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Chapter
About Jogging 51
Use These Worksheets 51
Determine
Write Ladder Logic 55
Jog Your Ram (Screw) and Clamp 57
Configure Screwrotate and Ejector Jogs for Indirect Control 57
Write Ladder Logic to Assist with Screwrotate and Ejector Jogs 58
Jog the Ejector and Rotate the Screw 510

Objectives

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Initial Jog V

51. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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alues 52. . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Select Command and Status Bits to Sequence

Machine Operation 61. . . . . . . . . . . . . . . . . . . . . . . . . . .

Chapter
Assess Your Logic Requirements 61
Use
Chapter
Use These Worksheets 72
Procedure
Determine

Select the T
Determine Word Selections: Select ERC Values 731
Determine Unselected Valve Setoutput Values 731
Set Your Acceleration/Deceleration Ramp Rates 733
Determine Setoutput Values for End of Profiles 734
Set Pressure Control Limits 735
Set V
Set Profile Gain Constants, PressureAlarm Setpoints,

Enter and Download your Worksheet Values 740

Objectives

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Command and Status Bit T

Objectives

to Determine and Enter Initial V

Bit Selections: Assign Module Outputs for

Your Control Valves 728. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ype of PID Algorithm

elocity Control Limits

and Watchdog Timer Presets 739

ables 62. . . . . . . . . . . . . . . . . . . . . .

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alues 728. . . . . . . . . . . . . .

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61. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

71. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

729. . . . . . . . . . . . . . . . . . . . . . . . .

737. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Load

Initial Profile V

Chapter
Use These Worksheets 81
Determine and Enter Setpoints for Clamp Close Profile (CPC) 82
Determine Bit Selections for Worksheet 8A 84
Determine Word Values for NO TAG 86
Enter and Download Your Worksheet Values 88
Determine and Enter Setpoints for the Injection Profile (IPC) 89
Determine Bit Selections for Worksheet 8B 812
Determine Word Values for Worksheet 8B 813
Enter and Download your Worksheet Values 817
Determine and Enter Setpoints for the Pack/Hold Profile (HPC) 817
Determine Bit Selections for Worksheet 8C 820

Objectives

alues 81. . . . . . . . . . . . . . . . . . . . . . . . .

81. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Table of Contents iii

Determine Word Values for Worksheet 8C 821. . . . . . . . . . . . . . . . . .

Enter and Download your Worksheet Values 822
Determine and Enter Setpoints for Plastication Profile (PPC) 823
Determine Bit Selections for Worksheet 8D 826
Determine Word Values for Worksheet 8D 827
Enter and Download your Worksheet Values 829
Determine and Enter Setpoints for Clamp Open Profile (OPC) 830
Determine Bit Selections for Worksheet 8E 832
Determine Word Values for Worksheet 8E 834
Enter and Download Your Worksheet Values 836

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Span Your V

Chapter
Referenced Worksheets 92
Span Your Low Pressure Close Valve 93
Span Your Clamp Close Pressure Valve(s) 99
Span Your Clamp Close Velocity (Flow) Valve(s) 914
Span Your Injection Pressure Valve 919
Span Your Injection V
Span Your Pack and Hold Pressure Valves 930
Span Your Plastication Pressure Valve 936
Span Your Clamp Open Pressure Valve(s) 941
Span Your Clamp Open Velocity (Flow) Valve(s) 947

alves 91. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Objectives

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elocity V

alve 924. . . . . . . . . . . . . . . . . . . . . . . .

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91. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Tune Your Machine 101. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Chapter
Closedloop Control 102
Tune Closedloop Pressure Control 102
Tune Closedloop V
Injection Tuning Considerations for Producing Parts 1010
Profile Requirements 1010
Cushion, Shot Size, and T
Unselected Valve Setoutput Values 1015
Logical Bridges and Endofprofile Setoutput Values 1016
Decompression Pullback 1017
Acceleration and Deceleration Ramp Rates 1018
Watchdog T
Pressure
Pressurelimited V
Expert Response Compensation 1023
Tuning Considerations for Clamp Operation 1024
Clampcontrol
Profile Requirements 1025
Unselected Valve Setoutput Values 1028
Logical Bridges, and Endofprofile Setoutput Values 1029

Objectives

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elocity Control

imer and Profile Of

Alarm Setpoints

elocity vs. Position Injection

Objectives

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ransition Setpoints

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fsets 1020. . . . . . . . . . . . . . . . . . . . . . .

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101. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

106. . . . . . . . . . . . . . . . . . . . . . . .

1013. . . . . . . . . . . . . . . .

1020. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1021. . . . . . . . . . . . . . .

1024. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table of Contentsiv

Acceleration and Deceleration Ramp Rates 1030. . . . . . . . . . . . . . . . .

Pressure
Profile Watchdog Timer Presets 1033
Expert Response Compensation 1033

Alarm Setpoints

1032. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Troubleshoot with LEDs 111. . . . . . . . . . . . . . . . . . . . . . . . . .

Chapter
Use LEDs to Troubleshoot Your QDC Module 111
Module

Objectives

Calibration

111. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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113. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Blank Worksheets A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Using This Manual

Preface

Manual Objectives

Use this preface to familiarize yourself with this manual so you can use it
effectively. This manual shows you how to apply the QDC module to your
molding machine in a reasonable length of time.

Since this manual is task oriented, we recommend that you perform these
tasks in the following order:

Perform this task: As discussed in this chapter:

Browse through the entire manual to become familiar with
its contents.

Overview the inject and clamp process describes how the
QDC module controls your injection molding system.

Install the QDC module. This includes such tasks as
wiring and setting jumpers.

Configure the QDC module mode off operation to match
your specific application, and configure its communication
with its inputs and outputs.

Overview of remaining configuration procedures that you
perform throughout the remainder of this manual.

Jog the ram (screw) and clamp. This task requires that
you configure jog and pressure alarms setpoints.

Set up communications between your PLC5 processor
and the QDC module. You select command and status
bits that you use to write your ladder logic.

Prepare to run your machine in open loop. This task
requires you to determine and enter initial values into the
ram (screw) and clamp configuration blocks.

Prepare to run and tune your machine in open loop. This
task requires you to determine and enter initial values into
the ram (screw) and clamp profile blocks.

Span your ram (screw) and clamp valves. This is done
using setoutput and openloop control.

Tune the machine for parts production. Chapter 10

Troubleshoot problems that may occur with QDC module. Chapter 11

Refer to this appendix for a blank copy of each worksheet
contained in this manual.

All chapters

Chapter 1

Chapter 2

Chapter 3

Chapter 4

Chapter 5

Chapter 6

Chapter 7

Chapter 8

Chapter 9

Appendix A

P-1

Preface

Audience

Use

of T

erms

Before attempting to apply the QDC module to a molding machine we
assume that you are:

an injection molding professional

an experienced PLCprogrammer (especially with the Allen-Bradley

PLC-5 family of processors)

an hydraulics designer or technician

We use these abbreviations:

Abbreviated Name: Title:

QDC module 1771QDC Plastic Molding Module

PLC5 processor PLC5 Programmable Controller

T47 or T50 terminal 1784T47 or 1784T50 Programming Terminal

ProSet 600 Software
PanelView Terminal

6500PS600 ProSet 600 Injection Molding Operator Interface Software

2711KC1 PanelView Operator Interface Terminal

ERC

Expert Response Compensation

The next table presents other terms we commonly use in this manual:

Term: Definition:

Selected Valve In multivalve systems, depending on the configured profile, the QDC

module controls one valve and presets the setting of the remaining
valves to produce moldingmachine profiles. We call the valve being
controlled by the QDC modules algorithms the selected valve.

Unselected Valves In multivalve systems, depending on the configured profile, the QDC

module controls one valve and presets the setting of the remaining
valves to produce moldingmachine profiles. We call the valves that are
preset with an openloop percentage setpoint the unselected valves.

Profile A group of mold/part setpoints which define a given machine operation

to the QDC module.

Command Block Data blocks downloaded from the PLC5 data table to the QDC module

to make configuration changes or to initiate machine actions.

Status Block Data blocks used by the QDC module to relay information to the PLC5

processor about the QDC module's current operating status.

Profile Block Command block containing mold/part setpoints.

Configuration Block Command block containing machine setpoints.

Direct Acting Valve An analog control valve that delivers increasing velocity or pressure with

increasing signal input.

Reverse Acting Valve An analog control valve that delivers increasing velocity or pressure with

decreasing signal input.

P-2

Preface

Command Blocks

Command blocks provide the parameters that control machine operation.
They are transferred from the PLC-5 processor to the QDC module by
means of block transfer write (BTW) instructions in software ladder logic.
Command block abbreviations are:

Acronym: Description:

MCC Module Configuration Block

JGC Jog Configuration Block

FCC First Clamp Close Configuration Block

SCC Second Clamp Close Configuration Block

TCC Third Clamp Close Configuration Block

LPC Clamp Low Pressure Close Configuration Block

CFC Clamp Close Profile Block

INC Injection Configuration Block

IPC Injection Profile Block

PKC Pack Configuration Block

HDC Hold Configuration Block

HPC Pack/Hold Profile Block

PRC Predecompression Configuration Block

PLC Plastication Configuration Block

PPC Plastication Profile Block

PSC Postdecompression Configuration Block

FOC First Clamp Open Configuration Block

SOC Second Clamp Open Configuration Block

TOC Third Clamp Open Configuration Block

OSC Clamp Open Slow Configuration Block

OPC Clamp Open Profile Block

DYC Dynamic Command Block

RLC Inject ERC Values Block

CLC Clamp and Eject ERC Values Block

P-3

Preface

Status Blocks

Status blocks report current status of molding-machine operation. They
are returned from the QDC module to the PLC-5 processor by means of
block transfer read (BTR) instructions in software ladder logic. Status
block abbreviations are:

Acronym: Description:

SYS System Status Block

CPS Clamp Close Profile Status Block

IPS Injection Profile Status Block

HPS Pack/Hold Profile Status Block

PPS Plastication Profile Status Block

OPS Clamp Open Profile Status Block

RLS Inject ERC Values Status Block

CLS Clamp and Eject ERC Values Status Block

Word and bit Numbering

The QDC module stores data in command and status blocks. Each word
location in a command or status block is identified by an alphanumeric
code containing the block acronym and word number. For example, word
09 of the Module Configuration Command Block (MCC) is identified as
MCC09.

Identify bits in a word location by adding bit numbering to the abbreviated
word location. For example:

Specific: MCC09-B15 General: MCCxx-Byy

where:

MCC = Module Configuration Command Block
xx=word number (01-64)
B = bit identifier
yy = bit number (00-15)

P-4

Preface

Related Publications

The following table lists documentation necessary for the successful
application of the QDC Module:

Publication Use this documentation: To:

17856.6.1 PLC5 Family Programmable

Controller Installation Manual

6200N8.001 6200 PLC5 Programming

Software Documentation Set

17714.10 Plastic Molding Module

Application Guide

17716.5.85 Plastic Molding Module User

Manual, Inject Mode

17716.5.87 Plastic Molding Module User

Manual, Clamp & Eject Mode

17716.5.88 Plastic Molding Module

Reference Manual

17716.5.93 Plastic Molding Module User

Manual, Inject, Clamp & Eject
Mode

Install the PLC5 processor and I/O modules.

Select instructions and organize memory when
writing ladder logic to run your machine.

Help select the module mode and match your QDC
module to your hydraulic layout.

Configure, program, install, and operate your QDC
module to control inject operations.

Configure, program, install, and operate your QDC
module to control clamp and eject operations.

Program block transfers between PLC5 processor
and QDC module. PLC5 data transfer logic.

Configure, program, install, and operate your QDC
module to control inject, clamp, and eject
operations.

Take time now to familiarize yourself with the Reference Manual
(publication 1771-6.5.88). The four sections include:

a summary of each data block used by the QDC module

(abbreviated command and status blocks)

programming error codes returned by the QDC module for each data

block, and recommended procedures to correct these errors

detailed listing and explanation of each command word and bit used by,

and each status word and bit returned from, the QDC module

operational, electrical, and environmental specifications of your module

If you purchased the Pro-Set 600 software, you also need the following:

Publication Use this documentation: To:

65006.5.11 ProSet 600 Software

Designers Guide

65006.5.12 ProSet 600 Software

Assembly Manual

65006.5.13 ProSet 600 Software

Overlay Installation Manual

65006.5.14 ProSet 600 Software

Customization Manual

65006.5.15 ProSet 600 Software

Reference Manual

Select the ProSet 600 software that matches
the requirements of your molding machine.

Transfer your ProSet 600 software from a
floppy disk to your hard drive. Add Overlays into
your PLC5 and PanelView application files.

Install ProSet 600 overlays into your application
files.

Customize your ProSet 600 build for your
machine control requirements.

Support customizing your software control
system.

P-5

Chapter

1

Overview of Inject and Clamp Mode

Chapter Objectives

This chapter presents an overview of the 1771-QDC Plastic Molding
Module in the inject and clamp mode. We present a summary of inject and
clamp features followed by sample applications.

Important: This manual assumes you have already read your Plastic
Molding Module Application Guide (publication 1771-4.10) and have
chosen inject and clamp as your QDC module’s mode of operation.

Inject and Clamp Mode

When you select inject and clamp mode, you can use the following phases:

Operation

Table 1.A
Glossary

Inject Phase: Description:

Injection The ram (screw) injects plastic into the mold. You can vary the velocity of the ram (screw), or the pressure

driving it, to fill areas of the mold cavity at different rates to achieve uniform quality of the molded part. This
phase can be critical to part quality. The pattern of velocity or pressure variation during injection is called the
injection profile.

Transition Detects when injection is complete.

Pack (optional) Packing pressurizes the plastic to a specified density which determines the flexibility of the molded part. To

achieve uniform density, you can release or increase pressure in steps according to cooling gradients across
the mold. Thus, as the plastic cools unevenly, the pack profile can compress the plastic uniformly.

of Inject and Clamp Mode

Hold Holding lets the plastic cool and shrink slightly from the mold cavity in preparation for ejection. The effect is

similar to packing. You can hold at predetermined pressures for predetermined lengths of time throughout
the hold phase.

Predecompression (optional) This single, backward movement of the ram (screw) separates plastic solidifying in the mold from molten

cushion remaining in the barrel prior to plastication. This phase is also called sprue break or suckback.

Plastication Phase The machine reloads by drawing plastic beads into the barrel containing the ram (screw). The mechanical

action of the rotating ram (screw) grinds and melts the beads. The longer it grinds, the hotter it melts. You
can vary the backpressure on the ram (screw) causing it to remain longer in an area. Thus, you can induce
any desired temperature gradient along the length of the shot by controlling ram (screw) backpressure.

Postdecompression
(optional)

This single, backward movement of the ram (screw) guards against drooling molten plastic into the open
mold during ejection prior to clamp close. This phase is also called melt pullback or suckback.

1-1

Chapter 1

Overview of Inject and Clamp Mode

Clamp Phase:

1st Close
2nd Close
3rd Close

Low Pressure Close To guard against damaging the mold when the two mold surfaces make contact and to detect obstructions to mold

1st Open
2nd Open
3rd Open

Open Slow

Inject Control

Description:

You can program a singlestep clampclose profile and not use a second or third profile. Or, you can program up to
three clampclose profiles that let you do the following at up to three different points in the clampclose phase:

• pick up a third mold plate

• set cores

• pick up or drop out pumps to change clamp speed or pressure

closure, you close the mold slowly with low pressure and closedloop or openloop control. Low Pressure Close
can only be controlled through a pressure vs. position profile.

You can program a singlestep clampopen profile and not use a second or third profile. Or, you can program up
to three clampopen profiles that let you do the following at up to three different points in the clampopen phase:

• drop out a third mold plate

• pull cores

• drop out or pick up pumps to change clamp speed or pressure

To decelerate the moving platen to accurately position it before ejecting the part.

You control inject operation with these phases:

injection
transition
pack
hold
pre-decompression
plastication
post-decompression

1-2

Clamp
& Eject
Operation

Figure 1.1

Operation of a T

Inject

Injection Pack Hold

Transition to
Pack or Hold

Post- Pre­Decompression Decompression

ypical Machine Cycle

Plastication

(Reload)

Chapter 1

Overview of Inject and Clamp Mode

Injection Phase

You can vary the velocity of the ram (screw), or the pressure driving it, so
the leading edge of the melt moves through the mold cavity at the desired
speed. The pattern of velocity or pressure variation during injection is
called the injection profile. The QDC module lets you chose from four
different injection profiles:

velocity vs. position
pressure-limited velocity vs. position
pressure vs. position
pressure vs. time

Figure 1.2
Example

Injection Profile

11 10 9

Velocity or Pressure

87654321

Position or Time

You enter setpoints to create a profile. You can select from 1 to 11
segments of position or time. Segment numbers represent the order of
operation. By convention the ram (screw) injects plastic by moving from
right to left.

With this Profile: You Control Injection: With up to 11 Segments

Velocity vs. Position Speed Length of the shot

Pressurelimited1
Velocity vs. position

Speed with a
maximum pressure

Distributed over the:

Length of the shot

Pressure vs. Position Pressure Length of the shot

Pressure vs. Time Pressure Time for a shot

1

Pressurelimited velocity vs. position profile differs from the velocity vs. position profile as follows:
During any segment, if the pressure exceeds a preset limit, the module switches to PID pressure
control with the pressure limit as the setpoint. Then if velocity exceeds the velocity setpoint, the
module returns to velocity control.

1-3

Chapter 1

Overview of Inject and Clamp Mode

Example Benefits of Profiling an Injection Phase

The injection phase should force the melt through the mold as fast as
possible without flashing the mold or burning the melt at a mold gate.
Here are two examples of how you can achieve this by profiling the
injection phase:

Velocity Example - As the leading edge of the melt enters different mold
cavities, the flow of plastic through the gate should increase or decrease
accordingly to keep the melt front at maximum desired speed without
flashing the mold. This reduces injection time and minimizes surface
stress due to surface cooling. You achieve this by shaping the injection
profile to suit the mold cavity (Figure 1.3).

Mold Cavity

54 3

Flow into mold

Figure 1.3
Velocity

1

2

Example

Gate

Mold
End

Injection Profile

5

4

Position

Sequence of execution

Velocity

23

1

Back
Point

1-4

Chapter 1

Overview of Inject and Clamp Mode

Flash Prevention Example - With a velocity profile (Figure 1.4 part 1),
the pressure may reach a peak and flash the mold at ram (screw) position
segments that correspond to events such as:

the initial surge (2.a)
when the melt front enters a constriction in the mold cavity (2.b)

You can remedy this (part 3) by decreasing the ram (screw) velocity at
segments (3.a) and (3.b) that correspond to flash points. Conversely, you
can boost velocity at segment (3.c) where the resulting pressure is well
below the flash point.

Figure 1.4

Prevention Example

Flash

1. Initial Velocity Profile

Velocity

bca

Position Position

3. Final Velocity Profile

Velocity

b ca

Position

2. Resulting Pressure Profile

ba

4. Resulting Pressure Profile

ba

Position

Flash
Point

Pressure

c

Flash
Point

c

Pressure

Optionally, you may select pressure limited velocity versus position as
your method of injection control. With your pressure limit setpoint just
below the flash point, the module switches over to pressure control prior to
flashing the mold.

1-5

Chapter 1

Overview of Inject and Clamp Mode

Injectiontopack Transition

The QDC module ends the injection phase and automatically starts the
pack or hold phase when it detects the first of up to three events occurred:

Ram (screw) position exceeds a preset limit
Ram (screw) pressure exceeds a preset limit
Injection phase elapsed time exceeds a preset limit

You select which of these events you want monitored for transition by
entering the appropriate setpoint, or zero for ignoring the event. You also
may specify the zone of ram (screw) travel over which the QDC module
inhibits or allows a pressure transition.

Pack Phase

The QDC module controls the pack phase with a pressure vs. time profile.
You create the profile based on controlling the hydraulic pressure against
the ram (screw). The pressure can be controlled using up to five segments.
By convention, events occur from right to left on the time axis
(Figure 1.5). You determine the pressure setpoints and time durations for
the pack profile based on molding requirements. The pack phase is
optional.

Figure 1.5

Phase Example

Pack

Pressure

4

5

Time

123

1-6

Lower density
(last zone filled)

Chapter 1

Overview of Inject and Clamp Mode

Example Benefit of Profiling the Pack Phase

Molten plastic may cool unevenly in the mold causing variations in density
with the end result of warpage and distortion as shown in Figure 1.6.

Figure 1.6
Uneven

Density in Mold Cavity

Cooling in Pack Phase

Pack Profile

Higher density
(gate zone,
greater pressure)

Gate

Pressure

You can remedy this by decreasing the pack pressure with time so plastic
can back out of the mold as shown in Figure 1.7. This is to alleviate
gradations in density as the plastic cools from the low-density end of the
mold (last zone filled) to the high-density end of the mold cavity (gate
zone where pressure is greater).

Figure 1.7

Cooling in Pack Phase

Even

Constant Pressure over entire Mold Cavity

Density in Mold Cavity

Gate

5

5

Pack Profile

Time

Time

234

1

Pressure

234

1

After completing the last segment of the pack phase, the QDC module
automatically starts the hold phase.

1-7

Chapter 1

Overview of Inject and Clamp Mode

Hold Phase

The QDC module controls the hold phase with a pressure vs. time profile.
You create the profile based on controlling the hydraulic pressure against
the ram (screw). The pressure can be controlled using up to five segments.
You determine the pressure setpoints and time durations for the hold
profile based on molding requirements.

After completing the last segment of the hold phase, the QDC module
either immediately starts the optional pre-decompression movement, skips
the pre-decompression movement if none is required and immediately
starts the plastication phase, or waits for a command from your PLC-5
program to continue.

Predecompression Movement

You select a length of pullback for the ram (screw) prior to the plastication
phase to separate plastic solidifying in the sprue from molten cushion
remaining in the barrel.

After completing the pre-decompression movement, the QDC module
either immediately starts the plastication phase or waits for a command
from your PLC-5 program to continue.

Plastication Phase

The plastication phase lets you achieve a melt temperature gradient in the
barrel containing the ram (screw). To program the desired temperatures,
you consult backup rate (backpressure) vs. temperature tables. You can
create the profile with up to 11 segments of position or time (figure 1.8).

You chose from two plastication profiles:

Backpressure vs. position
Backpressure vs. time

1-8

Chapter 1

Overview of Inject and Clamp Mode

Figure 1.8
Plastication

BackPressure

Mold
End

Phase Example

12 345

Position or Time

hotter

Temperature Gradient

Barrel Containing the Melt

6

7891011

cooler

Back
Point

Example Benefits of Profiling a Plastication Phase

The higher the backpressure during plastication, the slower the backup rate
and higher the resultant temperature of the melt. You can achieve the
desired temperature gradient by lowering ram (screw) backpressure to
accelerate the backup rate and decrease the temperature of the melt along
the length of the barrel.

After completing the last segment of the plastication phase, the QDC
module either immediately starts the post-decompression movement or
waits for a command from your PLC-5 program to continue.

Postdecompression Movement

You select a length of pullback of the ram (screw) after the plastication
phase to guard against drooling molten plastic into the open mold during
ejection. The QDC module notifies your PLC-5 program when the
post-decompression movement is complete.

1-9

Chapter 1

Overview of Inject and Clamp Mode

Clamp Control

Ejector retract

Ejector advance

You control clamp operation with these phases:

clamp close
low pressure close
clamp open
open slow

Figure 1.9
Clamp

1st
Close

Open
Slow

Portion of a T

ypical Machine Cycle

2nd
Close

3rd
Open

3rd
Close

2nd
Open

Low Pressure
Close

1st
Open

Clamp Close

Inject

Three separate clamp close profiles may be configured:

first close
second close
third close

You may select from these control modes:

velocity vs. position
pressure vs. position

Use clamp close to move the platen from the fully open position (L) to
some position X at a relatively high velocity or pressure. X is a position
relatively close to the stationary platen yet far enough away to allow
deceleration into low pressure close. This prevents the platens from
coming together at a high velocity (Figure 1.10).

1-10

Chapter 1

Overview of Inject and Clamp Mode

Clamp
Cylinder

L

Moving
Platen

Figure 1.10
Example

Clamp Close

0

X

Stationary
Platen

Velocity

1st Close
Profile

2nd

Close

Profile

Position

3rd

Close

Profile

You may start these operations between the three clamp close profiles:

pick up the 3rd plate of a mold (on a floating 3-plate mold) or set cores
program other events for all valves
automatically bridge between profiles, or let ladder logic decide when to

begin the next profile

Each of the clamp close profiles can be subdivided into three position
segments (Figure 1.11). You can change clamp velocity or pressure up to
three times in each profile, or up to nine times for the entire clamp close
phase.

Clamp
Cylinder

L

Moving
Platen

Figure 1.11
Example

Clamp Close Position Segments

Stationary
Platen

0

X

11

1st Close
Profile

Velocity

Segments

2

3

2nd
Profile

Position

2

1

3

Close

2

3rd

Close

Profile

3

Important: You may use as many or as few profiles and/or segments
within profiles as needed for your molding application. If using a single
close fast motion, use the first segment of the 1st close profile. The low
pressure close profile must follow.

After completing the last segment in each profile, the QDC module either
switches immediately to the next programmed segment of the next
programmed profile or waits for a command from your PLC-5 program to
continue.

After completing the last configured close profile, the QDC module either
switches immediately to the first programmed segment of low pressure
close, or waits for a command from your PLC-5 program to continue.

1-11

Chapter 1

Overview of Inject and Clamp Mode

Low Pressure Close

Use the low pressure close profile to decelerate closing motion to guard
against damaging the mold halves and detect for part obstructions. The
pressure setpoint(s) that you select to control low pressure close should
prohibit the mold from fully closing if there is an obstruction. Up to two
low pressure close profile segments may be used (Figure 1.12).

You will use pressure vs. position for low pressure close.

Clamp
Cylinder

Figure 1.12
Example

Low Pressure Close

Moving
Platen

L

0

X

Stationary
Platen

Low Pressure Close

Segments

1

2

Pressure

Position

Important: If you need only one low pressure close segment, configure
the 1st segment of the low pressure close profile.

The QDC notifies your PLC-5 program when this profile is complete and
automatically uses set-output values at the end of low pressure close to
build tonnage (hydraulic machine) or lockup your toggle (toggle machine).

Clamp Open

1-12

You can open the mold fast with three profiles of the clamp open phase:

first open
second open
third open

You may select from these control modes:

velocity vs. position
pressure vs. position

Use clamp open to move the platen from the fully closed position (0) to
some position Y at a relatively high velocity or pressure (Figure 1.13). Y
is close to your fully open position (L), yet far enough away for
deceleration into the open slow profile. This aids positioning accuracy at
the full open position (L).

Chapter 1

Overview of Inject and Clamp Mode

Clamp
Cylinder

Moving
Platen

Figure 1.13
Example

L0

Y

Clamp Open

Stationary
Platen

You may start these operations between the three clamp open profiles:

drop the third plate of a mold (on a floating 3-plate mold) or pull cores
program other events for all valves
automatically bridge between profiles, or let ladder logic decide when to

begin the next profile.

Each of the clamp open profiles can be subdivided into three position
segments (Figure 1.14). You can change clamp velocity or pressure up to
three times in each profile, or up to nine times for the entire clamp open
phase.

Velocity

3rd

Open

Profile

2nd

Open

Profile

Position

1st Open
Profile

Clamp
Cylinder

Moving
Platen

Figure 1.14
Example

L0

Y

Clamp Open Position Segments

Stationary
Platen

Velocity

33

3rd Open
Profile

Segments

2

1

2nd Open
Profile

Position

2

1

3

1st Open
Profile

Important: You may use as many or as few profiles and/or segments
within profiles as needed. If using a single open motion, use the first
segment of the 1st open profile. The open slow profile must follow.

After completing the last segment in each profile, the QDC module either
switches immediately to the next programmed segment of the next
programmed profile or waits for a command from your PLC-5 program to
continue.

2

1

1-13

Chapter 1

Overview of Inject and Clamp Mode

After completing the last configured open profile, the QDC module either
switches immediately to the first programmed segment of the open slow
profile, or waits for a command from your PLC-5 program to continue.

Open Slow

Use the open slow profile to accurately position the clamp for ejecting the
part(s). You may decelerate clamp motion twice with this profile using up
to two profile segments (Figure 1.15).

You may select from these control modes:

velocity vs. position
pressure vs. position

Figure 1.15
Example

Clamp
Cylinder

Open Slow

Moving
Platen

L0Y

Stationary
Platen

Open Slow

Segments

2

Velocity

Position

Important: If you need only one open slow motion, configure only the 1st
segment of the open slow profile.

1

1-14

Chapter

Install the QDC Module

2

Chapter

Objectives

Record I/O Ranges

This chapter guides you through the following procedures:

record I/O ranges
set module jumper plugs
key your I/O chassis
install the QDC module
wire the QDC module
ground your system
plan for E-STOPs and machine interlocks

To match your QDC module to your I/O devices, record the I/O ranges of
your I/O devices on Worksheet 2-A. You will use this information in this
chapter for hardware configuration (setting jumper plugs) and in chapter 4
to configure the module’s inputs and outputs with software.

Circle or check the I/O ranges on Worksheet 2-A. Cross off I/O not used.

Worksheet 2A

I/O Ranges

Record

I/O Connection: Voltage 1: Voltage 2: Current:

Input 1 (Screw position) 0 to 10 Vdc 1 to 5 Vdc 4 to 20 mA

Input 2 (Screw pressure) 0 to 10 Vdc 1 to 5 Vdc 4 to 20 mA

Input 3 (Clamp position) 0 to 10 Vdc 1 to 5 Vdc 4 to 20 mA

Input 4 (Clamp pressure) 0 to 10 Vdc 1 to 5 Vdc 4 to 20 mA

Output 1 10 to 10 Vdc 0 to 10 Vdc 4 to 20 mA

Output 2 10 to 10 Vdc 0 to 10 Vdc 4 to 20 mA

Output 3 10 to 10 Vdc 0 to 10 Vdc 4 to 20 mA

Output 4 10 to 10 Vdc 0 to 10 Vdc 4 to 20 mA

2-1

Chapter 2

Install the QDC Module

Set Module Jumper Plugs

Before installing the QDC module, you must select with jumper plugs the
I/O ranges that you recorded on Worksheet 2-A.

Access and Position the Jumpers

Access the jumpers and set them as follows:

ATTENTION: To avoid damage to internal circuits, observe
handling precautions and rid yourself of any electrostatic
charge. Use an anti-static work station when setting jumper
plugs.

1. Remove the label-side cover plate by removing the four screws.

2. Remove the circuit board from the module housing by removing the

two screws located center-front at the swingarm catch.

3. Carefully turn over the circuit board so it is oriented as in figure 2.1.

Handle it by the edges to avoid touching conductors or components.

4. Use figure 2.1 to locate the jumper plugs.

5. Set the jumper plugs (Table 2.A) using a small needle-nose pliers.

6. After setting the jumper plugs, re-assemble the module.

2-2

Chapter 2

Install the QDC Module

Figure 2.1
Jumper

LEFT

Locations on the QDC Module'

TOP

E5

s Circuit Board

E1

E6

RIGHT

E7

E8

E9

E10

E11

E12

E15

E16

E14

E13

E17

BOTTOM

10908I

Important: We define jumper plug positions as left, right, top, and bottom.
This represents the position of the jumper plug on the 3-pin connector as
relative to the sides of the circuit board shown above.

2-3

Chapter 2

Install the QDC Module

Table 2.A
Jumper

Settings

Jumper: Function: Setting:

E1 Run/Calibrate Calibrate = right

E5 I/O Density Standard = top

E6
E7
E8
E9

E10
E14
E13
E17

E11
E12
E15
E16

1

Factory Defaults

Input 1 (Screw position)
Input 2 (Screw pressure)
Input 3 (Clamp position)
Input 4 (Clamp pressure)

Output 1 (Valve 1)
Output 2 (Valve 2)
Output 3 (Valve 3)
Output 4 (Valve 4)

Output 1 (Valve 1)
Output 2 (Valve 2)
Output 3 (Valve 3)
Output 4 (Valve 4)

Run = left

Do not use bottom position

Voltage = right
Current = left

Current = top
Voltage = bottom

-10 to +10 Vdc = top
0 to +10 Vdc or

1

4 to 20mA = bottom

1

1

1

1

Important: If you select current output with jumper plugs E10, E14, E13,
and/or E17, then you must select the 4 to 20mA jumper position with E11,
E12, E15, and/or E16.

ATTENTION: If an output is unconnected, set the jumper
(E11, E12, E15, and/or E16) that corresponds to that output to
0 - 10 Vdc (bottom position). Setting the jumpers for –10 to
+10 Vdc and later configuring the output as “unconnected”
causes the QDC module to output –10 Vdc on that channel
when a system reset occurs and all outputs are forced to 0%
(i.e. 0% output equals –10 Vdc).

2-4

Chapter 2

Install the QDC Module

Important: Selecting –10 to +10 Vdc with jumper E11, E12, E15, and/or
E16 sets the QDC module for bi-directional valve operation. The
relationship to percentage output is as follows:

10

8
5
3
0

-3

Output Voltage

-5

-8

-10

0 102030405060708090100

%

Output Requested

Key Your I/O Chassis

Use the plastic keying bands, shipped with each I/O chassis, for keying I/O
slots to accept only one type of module. This is done to prevent the
inadvertent installation of the wrong module into the wrong slot.

The QDC module is slotted in two places on the rear edge of the circuit
board. The position of the keying bands on the backplane connector must
correspond to these slots to allow insertion of the module.

Place keying bands between the following terminal numbers labeled on the
backplane connector of your I/O chassis (see Figure 2.2):

between 20 and 22
between 26 and 28

Figure 2.2

Positions

Keying

2
4
6
8
10
12
14
16
18
20

Keying
Bands

22
24
26
28
30
32
34
36

1771QDC

12676

2-5

Chapter 2

Install the QDC Module

Install the QDC Module

To install your QDC module in an I/O chassis, complete the following:

1. Turn off power to the I/O chassis.

ATTENTION: Remove power from the 1771 I/O chassis

backplane and wiring arm before removing or installing a QDC
module.

Failure to remove power from the backplane could cause injury
or equipment damage due to possible unexpected operation.

Failure to remove power from the backplane or wiring arm
could cause module damage, degradation of performance, or
injury.

2. Place the module in the plastic guides on the top and bottom of the

slot that slides the module into position.

Important: Be aware that Pro-Set 600 software expects your Inject and
Clamp QDC module to be placed in slot 0 of your I/O rack 0. If you
choose to install your QDC module in some other slot, some modifications
to your PLC-5 application program will be necessary (refer to your Pro-Set
600 documentation for details).

3. Do not force the module into its backplane connector. Apply firm,

even pressure on the module to seat it properly.

4. Snap the chassis latch over the top of the module to secure it.

5. Connect the wiring arm to the module.

2-6

Chapter 2

Install the QDC Module

Wire the QDC Module

+

Customer
PS

–

Screw
Position
Sensor

Screw
Pressure
Sensor

Clamp
Position
Sensor

Clamp
Pressure
Sensor

Use the wiring arm (1771-WF) supplied with the QDC module to wire I/O
devices (Figure 2.3). The wiring arm lets you install or remove the QDC
module from the I/O chassis without rewiring. Wiring arm terminals are
numbered in descending order, from the top down, starting with terminal
18 (Table 2.B).

Figure 2.3

W

iring and Grounding

I/O

+

–

+

–

+

–

+

–

Input 3

Input 4

Input 1

Input 2

–

Customer
PS

18

+

–

+

Amplifier
Valve 1

+

–

+

–

To Valve 1

+

–

Amplifier
Valve 2

Amplifier
Valve 3

+

–

To Valve 2

+

–

17
16
15
14
13
12

11

10
9

8
7

6

5
4

3
2
1

Output 1

Output 2

Output 3

Earth Ground

Wiring Arm
1771WF

Output 4

+

–

Amplifier
Valve 4

To Valve 3

+

–

To Valve 4

10909I

2-7

Chapter 2

Install the QDC Module

Table 2.B

T

erminal Designations

I/O

Transducer: I/O Designation: Terminal:

Screw position Input 1 (+)

(-)

Screw pressure Input 2 (+)

(-)

Input common 14

Clamp position Input 3 (+)

(-)

Clamp pressure Input 4 (+)

(-)

Valve 1 Output 1 (+)

Output common

Valve 2 Output 2 (+)

Output common

Valve 3 Output 3 (+)

Output common

Valve 4 Output 4 (+)

Output common

Not used 01

18
17

16
15

13
12

11
10

09
08

07
06

05
04

03
02

ATTENTION: The QDC module has ESD protection to 20kV,
but you can damage the module by accidental application of the
wrong voltage to the I/O terminals. Do not exceed:

This voltage: On these terminals: When in:

+12 Vdc input (18 thru 10) any mode

+12 Vdc output (09 thru 02) voltage mode

+24 Vdc output (09 thru 02) current mode

2-8

Chapter 2

Install the QDC Module

Ground and Shield

our I/O Devices

Y

Input Sensor

Analog inputs and outputs are sensitive to electrical noise interference.
Take care to shield them properly.

Guidelines:

Use 22-gage (or larger) twisted-pair cable, 100% shielded with drain

wire, such as Belden 8761. For cable distances over 50 ft, use 18-gage
cable such as Belden 8760.

Ground the cable shield at one end only; generally at the sensor or

amplifier end of the cable, not at the I/O chassis (see Figure 2.4 and
Figure 2.5)

Figure 2.4
Shielding

Differential Inputs

QDC Module Input

18
17

+15V

+

–

Connect the cable shield
and case ground to earth
ground at the Input Sensor

14

No User Connectiions.
For Test Purposes, only.

-15V

Input Module Common
should float

109102

2-9

Chapter 2

Install the QDC Module

Figure 2.5
Shielding

QDC Module Output

Singleended Outputs

Customer Valve Amplifier

+

–

9

8

Connect the cable shield
to earth ground at the valve
amplifier

Input
Ground
Chassis Ground

17182

ground the cable shields to a low-impedance earth ground of less than

1/8 ohm

do not connect any ground to input common (terminal 14) except as

specified below under Grounding Exceptions

place high-voltage class A wiring and low-voltage class B wiring in

separate grounded conduits

in parallel runs, separate the class A and B conduit by at least 1 foot

where conduit runs must cross, cross them at right angles

For additional grounding recommendations, refer to the Allen-Bradley
Programmable Controller Wiring and Grounding Guidelines (publication
1770-4.1).

Exceptions

If you experience unacceptable electrical noise interference, then try one or
both of the following alternative grounding connections:

connect the input cable shield to input common (terminal 14) after

disconnecting the shield from the transducer

connect the output cable shield to output common (terminal 8, 6, 4,

and/or 2) after disconnecting it from the valve amplifier

2-10

Chapter 2

Install the QDC Module

Plan for ESTOPs and
Machine Interlocks

You must consider the installation of Emergency Stop switches and
machine interlocks when you:

design your system

assemble mechanical/hydraulic components

wire system components

develop system ladder logic

ATTENTION: The Electrical Standard for Industrial
Machinery (NFPA 79-1987) requires an emergency stop that,
when actuated, de-energizes all electrical power circuits which
provide electrical energy to sustain machine motion.
Maintained contact “Emergency Stop” push buttons are
recommended.

ATTENTION: The American National Standard for Plastics
Machinery — Horizontal Injection Molding Machines — for
Construction, Care, and Use (ANSI B151.1-1984) requires
hydraulic, mechanical, and electrical interlocks to prevent
inadvertent clamp closing with a safety gate in an open position.

In addition, we strongly recommend that the electrical
interlocks consist of redundant devices and that the control
circuit be so arranged that malfunction or improper sequencing
of either redundant device prevents further operation of the
machine.

ATTENTION: NEMA Standards Publication ICS1.1, Safety
guidelines for the Application, Installation, and Maintenance of
Solid State Control recommends that the emergency stop and
safety gate electrical interlocks should directly control their
appropriate functions through an electromechanical device
independent of the solid state logic.

The next page shows an illustration of a typical grounded PLC-5 power
distribution circuit. For ungrounded systems or for more information on
grounding and wiring guidelines, refer to Allen-Bradley Programmable
Controller Wiring and Grounding Guidelines (publication 1770-4.1).

2-11

Chapter 2

Install the QDC Module

Disconnect

Figure 2.6

PLC5 Power Distribution with Interlocks

Typical

L1

L2
L3

Incoming
AC

Use any number
of E-Stop switches
in Series

CRM

Input
Device

1FU
2FU

3FU

H

H

1

H

H

3

4

2

Step-down
Transformer

4

FUSE

X

X

1

2

Start

CRM

I/O Chassis

Power Supply

1

LN

GND

3

** See WARNING for Interlock Wiring Instructions **

2

Output

Input

Device

Module
Wiring
Arm

Output
Module

Wiring
Arm

CRM

1

Back-Panel
Ground Bus

5

L1

L2
L3

To Motor
Starters

Equipment
Grounding
Conductors

User DC

CRM

To DC I/O
Devices

Enclosure
Wall

Grounding Electrode
Conductor to
Grounding Electrode
System

Connect
When
Applicable

Supply

+–

1

To minimize EMI generation, you should connect a suppression network: for 120V AC, use Allen-Bradley
cat. no. 700-N24; for 220/240V AC, use cat. no. 599-KA04.

2

To minimize EMI generation, you should connect a suppression network: for 120V AC, use Allen-Bradley
cat. no. 599-K04; for 220/240V AC, use cat. no. 599-KA04.

3

For a power supply with a groundable chassis, this represents connection to the chassis only. For a power supply
without a groundable chassis, this represents connection to both the chassis and the GND terminal.

In many applications, a second transformer provides power to the input circuits and power supplies for isolation from the

4

output circuits.

Reference the current NEC code and ANSI B151.1 for additional wiring guidelines.

•

5

To minimize EMI generation, suppression networks should be connected across coils of electromagnetic devices.

•

2-12

10907I

Chapter

3

Configure the QDC Module's I/O

Chapter

Objectives

Your QDC module needs to know the characteristics of your ram (screw)
and clamp sensors. In this chapter, we describe how to determine these
characteristics and download them to the QDC module. Topics include:

signal ranges from pressure and position sensors
minimum and maximum sensor signals corresponding to

minimum and maximum pressures and positions

alarm values and travel limits

We describe how to configure the QDC module in these sections:

select module parameters and I/O ranges
determine initial sensor configuration values
download configuration values to the QDC module
use the set-output operation to move the ram (screw) and clamp
complete your sensor configuration
use optional sensor configurations

Important: You must properly configure the QDC module using
procedures in this chapter before attempting further configurations.

Important: If you have not already done so, install Pro-Set 600 software.
The procedures in this and the next several chapters assume that you have.

Select Module Parameters
and I/O Ranges

You select module parameters and I/O ranges by setting configuration bits
in control words. First, determine and write down correct settings using
Worksheet 3-A through Worksheet 3-C as follows:

To Configure: In Control Word: Starting At Addr: Use this Worksheet:

Module Parameters MCC02 B34/528 Worksheet 3A

Input Range MCC03 B34/544 Worksheet 3B

Output Range MCC04 B34/560 Worksheet 3C

3-1

Chapter 3

Configure the QDC Module's I/O

Worksheet 3A
Select Module Parameters

Control W

ProSet 600 Addr. B34/bit

ord MCC02Bxx

15 14 13 12

11 10

09 08 07 06 05 04 03 02 01 00

543 542 541 540 539 538 537 536 535 534 533 532 531 530 529 528

Value 0 0 0 0 0 0 0 0 0 0 0 1 1 0 0

Select

System Operation with bits 05 and 04

Inject and Clamp 0 1

Code:

0

or 1

Your value

Required initial value
loaded by ProSet 600

Select Singleunit Operation with bit 03 = 1
(0 generates a programming error)

Select English = 0 or
metric = 1 with bit 00

Example: If you select Inject and Clamp operation with English units:

MCC02 = 00000000 00011000

Select I/O Ranges for your Sensors

Next, configure the QDC module’s I/O ranges to match the machine
sensors and valves. Refer to Worksheet 2-A from chapter 2 which you
filled out when setting the QDC module’s jumpers. Apply this information
to Worksheet 3-B for input ranges and Worksheet 3-C for output ranges.

Worksheet 3B

Input Ranges for your Sensors

Select

Control W

ProSet 600 Addr. B34/bit

ord MCC03Bxx

15 14 13 12

11 10

09 08 07 06 05 04 03 02 01 00

559 558 557 556 555 554 553 552 551 550 549 548 547 546 545 544

Value 1 1 1 1 1 1 1 1

Select Input 4 (Clamp Pressure) Range with bits 07, 06
Select Input 3 (Clamp Position) Range with bits 05, 04
Select Input 2 (Screw Pressure) Range with bits 03, 02
Select Input 1 (Screw Position) Range with bits 01, 00

Code:

Your value

0

or 1

Required initial value
loaded by ProSet 600

Example: If you select an input range of 4-20 mA for all four inputs:

MCC03 = 11111111 10101010.

Important: Software input selections must match the jumper settings for
each respective input.

Input Range
0 - 10V dc 0 0
1 - 5V dc 0 1
4 - 20 mA 1 0
Not connected 1 1

3-2

Worksheet 3C
Select Output Ranges for your V

Chapter 3

Configure the QDC Module's I/O

alves

Control W

ProSet 600 Addr. B34/bit

Value 1 1 1 1 1 1 1 1

Code:

0

or 1

ord MCC04Bxx

Your value

Required initial value
loaded by ProSet 600

15 14 13 12

575 574 573 572 571 570 569 568 567 566 565 564 563 562 561 560

Select Output 4 Range with bits 07, 06

Select Output 3 Range with bits 05, 04
Select Output 2 Range with bits 03, 02
Select

Output 1 Range with bits 01, 00

11 10

09 08 07 06 05 04 03 02 01 00

Example: If you select 0-10V dc for all four output ranges:

MCC04 = 11111111 01010101.

Important: Software output selections must match the jumper settings for
each respective output.

Determine

Initial

Sensorconfiguration Values

To determine initial sensor configuration values, refer to Table 3.A, and
specifications that accompanied your sensors, valves, and cylinders. Write
down applicable values on Worksheet 3-D.

Output Range

-10 to +10V dc 0 0
0 to +10V dc 0 1
4 to 20 mA 1 0
Not connected 1 1

Important: You must enter floating-point numbers and percentages as
integers, so we recommend that you write them in Worksheet 3-D in the
following format: Use an assumed decimal point position that depends on
the range value. For example:

If the Range is: And You Want to

Enter this Value:

0  099.99% 75% 07500

0  99.99 inch 7.32 inch 00732

0  0999.9 mm 432.6 mm 4326

4.00  020.00 mA 16 mA 01600

0  010.00V dc 5.6V dc 00560

0  009.99 sec 0.47 sec 00047

0  09999 psi 321 psi 00321

0  0999.9 Bar 222 Bar 2220

Use this
Format:

3-3

Chapter 3

Configure the QDC Module's I/O

Table 3.A
Determine

Category: If your: Then Use a Value Equal to:

Minimum Position
(Lines 1 and 9)

Maximum Position
(Lines 2 and 10)

Analog Signal @ Min Position sensor is forwardacting low end of your selected range

(Lines 3 and 11) sensor is reverseacting high end of your selected range

Analog Signal @ Max Position sensor is forwardacting high end of your selected range

(Lines 4 and 12) sensor is reverseacting low end of your selected range

Minimum Pressure
(Lines 5 and 13)

Maximum Pressure
(Lines 6 and 14)

Analog Signal @ Min Pressure sensors are forwardacting low end of your selected range

(Lines 7 and 15) sensors are reverseacting high end of your selected range

Initial Sensorconfiguration V

N/A zero

ram

(screw) is fully extended to the
mold end (ram bottom), and the
mold closed position is zero.

N/A minimum range value specified by the

N/A maximum range value specified by

alues for W

orksheet 3D

maximum range value specified by the
manufacturer (full travel of the sensor

manufacturer

manufacturer

Analog Signal @ Max Pressure sensors are forwardacting high end of your selected range

(Lines 8 and 16) sensors are reverseacting low end of your selected range

3-4

Worksheet 3D
Determine Initial Sensorconfiguration V

Enter Your Initial Values Here

Chapter 3

Configure the QDC Module's I/O

alues

Input Line Control Word ProSet

600 Addr

. Value Description Units

1 1 MCC09 N40:5 0 Minimum Screw Position Screw Axis Measured from zero

2 MCC10 N40:6 Maximum Screw Position Screw Axis Measured from zero

3 MCC11 N40:7 Analog Signal @ Min Screw Position Input Signal Range

4 MCC12 N40:8 Analog Signal @ Max Screw Position Input Signal Range

2 5 MCC17 N40:13 0 Minimum Screw Pressure Screw Pressure

6 MCC18 N40:14 Maximum Screw Pressure Screw Pressure

7 MCC19 N40:15 Analog Signal @ Min Screw Pressure Input Signal Range

8 MCC20 N40:16 Analog Signal @ Max Screw Pressure Input Signal Range

2

2

3

3

2

2

3 9 MCC23 N40:19 0 Minimum Clamp Position Clamp Axis Measured from zero

10 MCC24 N40:20 Maximum Clamp Position Clamp Axis Measured from zero

11 MCC25 N40:21 Analog Signal @ Min Clamp Position Input Signal Range

12 MCC26 N40.22 Analog Signal @ Max Clamp Position Input Signal Range

4 13 MCC31 N40:27 0 Minimum Clamp Pressure Clamp Pressure

14 MCC32 N40:28 Maximum Clamp Pressure Clamp Pressure

15 MCC33 N40:29 Analog Signal @ Min Clamp Pressure Input Signal Range

16 MCC34 N40:30 Analog Signal @ Max Clamp Pressure Input Signal Range

1

Incremental Distance

00.00

to 99.99in

000.0 to 999.9mm

2

Input Signal Range

00.00 to 10.00VDC or

01.00 to 05.00VDC or

04.00 to 20.00MADC

3

Pressure

0000 to 9999 PSI

000.0 to 999.9 Bar

2

2

3

3

2

2

1

1

1

1

Download MCC Values
to the QDC Module

Use this download procedure now and later in this chapter. The procedure
requires you to complete the following general steps:

enter MCC values into the PLC-5 data table
download them to the QDC module (PLC-5 processor in run mode)
correct any data entry (programming) errors

Next we describe the general steps:

Enter MCC Values into Your PLC5 Data Table

With your programming terminal, enter values from Worksheet 3-A thru
Worksheet 3-D into your PLC-5 data table as follows:

1. Switch the PLC-5 processor to program mode.

2. Display your PLC-5 data table.

3. Locate the data file for storing the MCC block. PLC-5 data table

word addresses are listed on the worksheets.

3-5

Chapter 3

Configure the QDC Module's I/O

4. Enter the value for each word and bit.

When you enter bit selections in words prefixed with file identifier B
(example: B34), the PLC-5 processor automatically switches the radix to
binary format so you can conveniently enter binary data.

Download MCC Values to the QDC Module

To download the MCC block to the QDC module, switch the PLC-5
processor from program to run mode. Pro-Set 600 software downloads the
MCC block to the QDC module for you.

Important: You can verify that the MCC block was successfully down­loaded or that you made a data entry (programming) error by evaluating
the following words that Pro-Set 600 software continuously reports to the
PLC-5 processor.

If: And: Then:

SYS01B08 = 1
(B34/8)

SYS19B00 = 1
(B34/288)

N/A QDC module accepted a valid MCC.

SYS61 = 1
(ID code for MCC block
stored in N40:213)

You made a programming error in MCC.
Read the error code in SYS62 (N40:214) , and
look up the error in Section 2 of QDC Module
Reference Manual, publication 17716.5.88.

Important: Pro-Set 600 software downloads all command blocks when
your PLC-5 processor enters run mode after a valid MCC block is
accepted. All programming errors reported in SYS62 (N40:214) are
referenced to the MCC block until SYS01-B08 = 1.

Correct Any Dataentry (Programming) Errors in MCC

Upon receipt of the MCC block, the QDC module tests data for data-entry
errors, such as a value out of range. When it detects an error, the QDC
module halts operation until you correct the error. For a complete list of
error codes to help you correct a programming error, refer to Section 2 of
the Plastic Molding Module Reference Manual, publication 1771-6.5.88.

You must correct errors by entering the changed configuration values into
your PLC-5 data table and downloading the new values to the QDC
module as outlined above. Pro-Set 600 software continues to attempt to
download the MCC block to the QDC module until an MCC block is
accepted and the QDC module returns SYS01-B08 = 1.

3-6

Important: The QDC module must receive a valid MCC block before you
can download additional blocks.

Chapter 3

Configure the QDC Module's I/O

Use Setoutput Operation to
Move the Ram (screw) and
Clamp

To finish configuring the QDC module, you actuate the ram (screw) and
clamp with the QDC module’s set-output operation that applies percentage
values to your QDC module’s outputs to move the ram (screw) or clamp in
a controllable fashion. To do this, you apply %-output signals to all
module outputs so you can move the actuator over its intended range.
Sensor spanning values can then be refined per the actual values monitored
by the QDC module.

ATTENTION: Do not rely on pressure valves connected to the
QDC module for pressure relief. Use them only for pressure
control below the setting of the system pressure-relief valve.

ATTENTION: A value of zero in set-output words N40:121 ­N40:124 does not necessarily correspond to zero pressure or
flow. If you have configured jumper E11, E12, E15, and/or E16
for bi-directional valve operation, an output of 0% gives
–10 vdc, 50% gives 0 vdc (see chart). Amplifier electronics or
spool-null offsets may also allow pressure or flow at zero volts
signal input. Consult your valve and amplifier specifications.

10

8
5
3
0

-3

Output Voltage

-5

-8

-10

0 102030405060708090100

%

Output Requested

ATTENTION: As soon as you enable set-output operation, the
QDC module’s outputs drive the connected valves according to
the values you entered into DYC09-12 (N40:121-124). Be sure
these values RESULT IN NO MOVEMENT until you adjust
them one-at-a-time with your programming terminal in the
procedures that follow.

3-7

Chapter 3

Configure the QDC Module's I/O

Actuate the Ram (screw) and Clamp with Setoutput Operation

1. Enter values that result in no motion in these DYC words:

Output: In Data Word: At ProSet 600

Address:

1 DYC09 N40:121

2 DYC10 N40:122

3 DYC11 N40:123

4 DYC12 N40:124

2. Enable set-output operation by entering a 1 in DYC01-B08

(B34/392). The QDC module sets outputs 1 - 4 to percentage values
that you entered in DYC09-12 respectively.

Complete your Sensor
Configuration

3. With your programming terminal, slowly change the %-output value

of one output as you observe the corresponding movement.

Important: The DYC is constantly transferred to the QDC module by
Pro-Set 600 software, so changes you make to %-output values are
immediately implemented.

Complete the procedure for configuring the QDC module to match its
sensors by spanning them over their intended range with the machine in
operation. Here we describe how you determine:

clamp position sensor values
clamp pressure sensor values
screw position sensor values
screw pressure sensor values

In the procedures that follow, measure and record:

minimum and maximum positions
corresponding signal values
minimum and maximum pressures
corresponding signal values

After determining these values from the procedures, write them down on
Worksheet 3-E.

3-8

Important: You must complete this configuration before proceeding to
any other chapters on module configuration.

Worksheet 3E
Final Sensorconfiguration V

Chapter 3

Configure the QDC Module's I/O

alues

Enter Your Final V

alues Here

Input Line Control Word ProSet 600 Addr. Value Description Units

1 1 MCC09 N40:5 0 Minimum Screw Position Screw Axis Measured from zero

2 MCC10 N40:6 Maximum Screw Position Screw Axis Measured from zero

3 MCC11 N40:7 Analog Signal @ Min Screw Position Input Signal Range

4 MCC12 N40:8 Analog Signal @ Max Screw Position Input Signal Range

2 5 MCC17 N40:13 0 Minimum Screw Pressure Screw Pressure

6 MCC18 N40:14 Maximum Screw Pressure Screw Pressure

7 MCC19 N40:15 Analog Signal @ Min Screw Pressure Input Signal Range

8 MCC20 N40:16 Analog Signal @ Max Screw Pressure Input Signal Range

2

2

3

3

2

2

3 9 MCC23 N40:19 0 Minimum Clamp Position Clamp Axis Measured from zero

10 MCC24 N40:20 Maximum Clamp Position Clamp Axis Measured from zero

11 MCC25 N40:21 Analog Signal @ Min Clamp Position Input Signal Range

12 MCC26 N40:22 Analog Signal @ Max Clamp Position Input Signal Range

4 13 MCC31 N40:27 0 Minimum Clamp Pressure Clamp Pressure

14 MCC32 N40:28 Maximum Clamp Pressure Clamp Pressure

15 MCC33 N40:29 Analog Signal @ Min Clamp Pressure Input Signal Range

16 MCC34 N40:30 Analog Signal @ Max Clamp Pressure Input Signal Range

1

Incremental Distance

00.00

to 99.99in

000.0 to 999.9mm

2

Input Signal Range

00.00 to 10.00VDC or

01.00 to 05.00VDC or

04.00 to 20.00MADC

3

Pressure

0000 to 9999 PSI

000.0 to 999.9 Bar

2

2

3

3

2

2

1

1

1

1

Determine Values for Ram (Screw) Position Sensor

ATTENTION: Incorrect values entered in DYC09-12 may
result in rapid ram (screw) motion and potential damage to your
barrel and seals of your injection cylinder.

To complete the configuration for your ram (screw) position sensor, do the
following and enter the results on Worksheet 3-E:

Important: If your position sensor has zero and span potentiometers for
setting the zero reference and linear resolution, set them in this procedure.

1. Move the ram (screw) forward until it reaches its mechanical stop at

the nozzle end. This is the zero position.

2. Remove ram (screw) pressure and/or flow to stop movement.

3-9

Chapter 3

Configure the QDC Module's I/O

3. Record this position value (normally 0000) on line 1 for MCC09 on

Worksheet 3-E.

4. With your programming terminal, read the signal level returned in

SYS33 (N40:185) from your position sensor. You may wish to zero
your position sensor at this time.

5. Record this value on line 3 for MCC11 (should be at minimum signal

if you zeroed your position sensor in step 4).

6. Move the ram (screw) backward to the backpoint mechanical stop.

7. Remove ram (screw) pressure and/or flow to stop movement.

8. Measure the distance travelled.

9. Record this distance on line 2 for MCC10.

10. With your programming terminal, read the signal level returned in

SYS33 (N40:185) from your positioning sensor. You may wish to
span your position sensor at this time.

11. Record this value on line 4 for MCC12.
You may now download your adjusted values to the QDC module using

the MCC download procedure presented earlier in this chapter.

Determine Values for the Clamp Position Sensor

Important: Use the following procedure and subsequent set-up
information for each different mold used on a hydraulic machine. On a
toggle clamp (with die height adjust), complete it only once.

ATTENTION: Incorrect values entered in DYC09-12 may
result in rapid clamp motion and potential damage to your mold
or cylinder seals. We strongly recommend using a “dummy”
mold on hydraulic machines and no mold on toggle machines.

Important: If your position sensor has zero and span potentiometers to set
the zero reference and linear resolution, do so during this procedure.

3-10

1. Move the clamp forward until it reaches its mechanical close stop.

This is the zero position.

2. Remove clamp pressure and/or flow to stop clamp movement.

Chapter 3

Configure the QDC Module's I/O

3. Record this position value (usually 0000) on line 9 for MCC23 on

Worksheet 3-E.

4. With your programming terminal, read the signal level returned in

SYS35 (N40:187) from your position sensor. You may wish to zero
your position sensor at this time.

5. Record this value on line 11 for MCC25 (should be at minimum

signal if you zeroed your position sensor in step 4).

6. Move the clamp backward to the mechanical open stop.

7. Remove clamp pressure and/or flow to stop clamp movement.

8. Measure the distance travelled.

9. Record this distance on line 10 for MCC24.

10.With your programming terminal, read the signal level returned in

SYS35 (N40:187) from your positioning sensor. You may wish to
span your position sensor at this time.

11. Record this value on line 12 for MCC26.
You may now download your adjusted values to the QDC module using

the MCC download procedure presented earlier in this chapter.

Determine Values for the Ram (Screw) Pressure Sensor

To complete the configuration for your ram (screw) pressure sensor, enter
on Worksheet 3-E minimum and maximum pressures and corresponding
signal levels from manufacturer’s specifications in MCC17-20. Most
applications require no further spanning. If your application requires
greater accuracy, follow the procedure below:

1. Release system pressure to obtain minimum ram (screw) pressure.

2. Read the pressure gauge at the ram (screw).

3. Record minimum pressure (normally 0000) on line 5 for MCC17 on

Worksheet 3-E.

4. With your programming terminal, read the signal level returned in

SYS34 (N40:186) from your pressure sensor. You may wish to zero
your pressure sensor at this time.

5. Record this signal level on line 7 for MCC19. It should be at

minimum signal if you zeroed your pressure sensor in step 4.

3-11

Chapter 3

Configure the QDC Module's I/O

ATTENTION: Use extreme caution during the next steps
because you stress the hydraulic system to its maximum rated
pressure. Loose fittings or faulty components could fail, causing
possible damage to equipment and/or injury to personnel.

6. Re-torque all hydraulic connections and joints before proceeding.

7. Boost system pressure to obtain maximum ram (screw) pressure.

Obtain maximum system pressure by positioning the ram (screw) at
its fully forward (nozzle end) or fully retracted (backpoint) position
while keeping its pressure valve in the maximum open position. This
forces the cylinder to press against the mechanical limits of its travel
and builds max system pressure.

8. Read the ram (screw) pressure gauge. Do this while the ram (screw)

is mechanically bound from moving.

9. Record this maximum pressure on line 6 for MCC18.

10.With your programming terminal, read the signal level returned in

SYS34 (N40:186) from your pressure sensor. You may wish to span
your pressure sensor at this time.

11. Record this signal level on line 8 for MCC20.

12.Release pressure.

You may now download your adjusted values to the QDC module using
the MCC download procedure presented earlier in this chapter.

Determine Values for the Clamp Pressure Sensor (if used)

To complete the configuration for your clamp pressure sensor, enter on
Worksheet 3-E minimum and maximum pressures and corresponding
signal levels from manufacturer’s specifications in MCC31-34. Most
applications require no further spanning. If your application requires
greater accuracy, follow the procedure below:

1. Release system pressure to obtain minimum pressure at the clamp.

2. Read the pressure gauge at the clamp.

3-12

3. Record this minimum pressure value (usually 0000) on line 13 for

MCC31 on Worksheet 3-E.

4. With your programming terminal, read the signal level returned in

SYS36 (N40:188) from your pressure sensor. Also, you may wish to
zero your pressure sensor at this time.

Chapter 3

Configure the QDC Module's I/O

5. Record this signal level on line 15 for MCC33 (should be at

minimum signal if you zeroed your pressure sensor in step 4).

ATTENTION: Use extreme caution during the next steps
because you stress the hydraulic system to its maximum rated
pressure. Loose fittings or faulty components could fail, causing
possible damage to equipment and/or injury to personnel.

6. Re-torque all hydraulic connections and joints before proceeding.

7. Boost system pressure to obtain maximum pressure at the clamp.

Obtain maximum system pressure by positioning the clamp at full
open while keeping the clamp open valve in the maximum open
position. This forces the cylinder to press against mechanical limits
of its travel and builds maximum system pressure. Also, you may
wish to move the clamp to its full forward (mold close) position, and
allow full system pressure to force the mold closed.

8. Read the clamp pressure gauge. Do this while the clamp is

mechanically bound from moving.

9. Record this maximum pressure on line 14 for MCC32.

10. With your programming terminal, read the signal level returned in

SYS36 (N40:188) from your pressure sensor. You may wish to span
your pressure sensor at this time.

11. Record this signal level on line 16 for MCC34.

12. Release pressure.

You may now download your adjusted values to the QDC module using
the MCC download procedure presented earlier in the chapter.

3-13

Chapter 3

Configure the QDC Module's I/O

Select Optional
Configurations

You also have the option of configuring the following QDC features:

Use this Option: For this Benefit:

Software Travel Limits to guard against damaging the nozzle assembly or seals

Pressure Alarm Time Delay to warn of excessive pressure without nuisance alarms

Digital Filter to compensate for noise on position inputs

Configure Software Travel Limits

You may want to use the software restrictions, Figure 3.1, to stop the travel
of your ram (screw) or clamp before either reaches its maximum limits
(configured earlier in this chapter).

Figure 3.1
Software

Restrictions

Physical Travel Range

dd

Safe Zone

d = deadband

Max SWTL Min SWTL

Max Position Min Position

Important: The orientation shown (movement left to right) is for clamp
SWTLs. By convention, ram (screw) orientation is reversed.

During normal machine operation and whenever your cylinder travels
outside the safe zone (outside the specified software travel limits, SWTL),
the QDC module:

sets an alarm status bit
forces its outputs to zero
ignores all profile commands (except set-output and jogs) until you jog

the cylinder back through the deadband into the safe zone at either end

The deadband guards against sensor noise flickering the SWTL alarms and
requires that the operator jog the cylinder a set distance away from the
software overtravel limit. We recommend a value of 00.10 inch as a
starting deadband. Your sensor may require a greater deadband.

ATTENTION: The QDC module ignores SWTL alarms when
jogging or when performing a set-output operation.

3-14

Chapter 3

Configure the QDC Module's I/O

Configure the QDC module for SWTL as follows:

1. Determine these SWTL values for ram (screw) and/or clamp travel

with respect to the range of physical travel.

SWTL deadband
Maximum SWTL
Minimum SWTL

2. Record non-zero SWTL values on Worksheet 3-F. Zero values

disable the corresponding SWTLs.

ATTENTION: Leaving your SWTL settings at zero (MCC13,
14, 27, and 28) inhibits the QDC module from performing this
safety function.

Worksheet 3F

Configuration V

SWTL

alues

Enter Your SWTL Configuration Values Here

Control Word ProSet 600 Addr. Value Description Units

MCC13 N40:9 Screw Minimum SWTL Screw Axis Measured from zero

MCC14 N40:10 Screw Maximum SWTL Screw Axis Measured from zero

MCC15 N40:11 10 Screw SWTL Deadband As noted

MCC27 N40:23 Clamp Minimum SWTL Clamp Axis Measured from zero

MCC28 N40:24 Clamp Maximum SWTL Clamp Axis Measured from zero

MCC29 N40:25 10 Clamp SWTL Deadband As noted

1

Incremental Distance

00.00 to 99.99 Inches

000.0 to 999.9 Millimeters

1

1

You may now download your adjusted values to the QDC module using
the MCC download procedure presented earlier in this chapter.

1

1

1

1

3-15

Chapter 3

Configure the QDC Module's I/O

Set Up Maximum Pressure Alarms and Time Delays

The QDC module continuously monitors ram (screw) and clamp pressure
inputs. When it detects that the process input equals or exceeds a preset
alarm setpoint, the QDC module sets an alarm bit. A setpoint of zero
disables the associated alarm.

To guard against nuisance alarms caused by noise spikes or pressure
transients, you can set a time delay so the QDC module must monitor
continuous excessive pressure for an amount of time before setting the
high pressure alarm. A setpoint of zero disables this delay.

Configure the QDC module for pressure alarms as follows:

1. Determine these values for ram (screw) and/or clamp pressure

alarms:

pressure-alarm setpoint
time-delay setpoint

2. Record non-zero setpoints on Worksheet 3-G for the pressure alarms

and time delays you want to use.

3. Download them to the QDC module using the procedures presented

earlier in this chapter.

Worksheet 3G
Pressurealarm

Enter Your Pressurealarm and T

Control Word ProSet 600 Addr. Value Description Units

MCC21 N40:17 Screw Pressurealarm Setpoint Ram (screw) Pressure

MCC22 N40:18 Screwpressure Timedelay Setpoint Time

MCC35 N40:31 Clamp Pressurealarm Setpoint Clamp Pressure

MCC36 N40:32 Clamppressure Timedelay Setpoint Time

1

Time

Measured in Seconds

00.00

to 00.99

and T

imedelay Setpoints

imedelay Values Here

2

Pressure
0000 to 9999 PSI

000.0 to 999.9 Bar

Measured in Seconds

2

Measured in Seconds

2

1

1

3-16

Chapter 3

Configure the QDC Module's I/O

Configure Digital Filters for Position Inputs

You may enable an optional digital filter on position inputs to reduce
electrical noise from a potentiometer-type position sensors or picked up by
your input circuits.

To determine if you need a digital filter, move the ram (screw) or clamp
very slowly. With your programming terminal, look for erratic position
numbers reported for ram (screw) and/or clamp position by examining
these words:

For this Input: In Word: Look at this ProSet 600 Address:

Ram (Screw) SYS25 N40:177

Clamp SYS27 N40:179

Configure the QDC Module for a Digital Input Filter as Follows:

To determine the time constant (0 - 00.10 sec), start with a small value
such as 00.01. A value of zero disables the filter.

To Filter this Input: In Word: Enter a Filter Time Constant in:

Ram (Screw) MCC16 N40:12

Clamp MCC30 N40:26

ATTENTION: Increasing the value of the time constant
decreases the QDC module’s capability to respond quickly to
travel limits and/or to accurately locate programmed positions.
We recommend that you keep the time constant under 00.10.

For example, with a clamp velocity of 20”/sec, a 00.01 time constant
allows 0.20” of travel before the QDC module can react to a travel limit.

Important: If you have a noisy potentiometer-type position sensor and
digital filtering slows the QDC module’s response time too much, consider
replacing the sensor with a non-contact, linear-displacement type.

Download time constants to the QDC module using the procedures
presented earlier in this chapter.

3-17

Chapter

Overview of Remaining
Configuration Procedures

4

Chapter

Objectives

Configuration Concepts

This chapter introduces you to the remaining procedures necessary to
successfully configure your QDC module. You must follow the
procedures in the given order. Please use this chapter as a guide.

The QDC module communicates with your PLC-5 processor through data
“blocks”. These blocks are made up of several 16-bit words stored in the
PLC-5 data table. The QDC module accesses these areas of data table
through the 1771 backplane. There are two types of data blocks:

Command Blocks - these blocks are downloaded from the PLC-5 data

table to the QDC module to make configuration changes or initiate
machine actions

Status Blocks - the QDC module uses these blocks to send information

to the PLC-5 processor about current operating status

The configuration procedure detailed over the next several chapters makes
extensive use of command and status blocks. You will:

enter important operating data into all applicable command blocks
read machine operating data in status blocks to assist you in the

configuration procedure

Command Blocks

You configure the QDC module with a series of command blocks.
Command blocks are an area of the PLC-5 data table containing machine
commands, set-up, and operating information for the QDC module. On
power-up, or when initiated by a user, command blocks are downloaded
from the PLC-5 data table to the QDC module.

4-1

Chapter 4

Overview of Remaining
Configuration Procedures

There are two basic types of command blocks. They are presented in the
following table:

Type of Command Block: Which Contain: Examples:

Configuration Blocks Information necessary to configure your

module to run a certain portion of a profile.

Profile Blocks Actual process setpoints necessary to

produce a desired part.

Valve spanning
information for the 1st
clamp close profile.

1st clamp close profile
operating setpoints.

Status Blocks

The QDC module returns critical operating status and values to the PLC-5
data table through status blocks. Like configuration blocks, status blocks
are areas of PLC-5 data table. Status blocks, however, contain actual
machine operation information rather than machine setpoints and action
commands.

Type of Block: Which Contain: Examples:

Status Blocks Information about machine operation and

QDC module operating status.

The molding machine is
currently performing an
injection operation.

Special Command and
Status Blocks

A few special command and status blocks are the Module Configuration
Block, Dynamic Command Block, and the System Status Block.

Type of Block: Description: Examples:

Module Configuration
Block (MCC)

Dynamic Command
Block (DYC)

System Status Block
(SYS)

Contains configuration information used
throughout all phases of machine
operation.

Includes all commands necessary to jog,
run, and stop any applicable machine
phase or operation.

Returns to the PLC5 processor
information relevant to common module
parameters.

Sensor spanning information
and global alarm setpoints.

Command to start the injection
phase.

Actual voltages and
engineering units read at the
four QDC module inputs.

4-2

Chapter 4

Overview of Remaining
Configuration Procedures

Overview of Remaining
Configuration Procedures

Step: Procedure: Enter this Information: Refer to:

1 Jog Your Machine Machine jog pressure and flow setpoints are

2 Write a PLC5 Program to

3 Enter Initial

4 Enter Initial Profile Values Initial machine operation setpoints (pressure,

Configuration procedures detailed over the next several chapters are
outlined below. The procedures are sequential in nature: configuration
information determined in initial chapters is needed in later chapters.

Coordinate Phases

Configuration Values

entered into the Jog Configuration (JGC) block.

You actually jog your inject and clamp with
commands in the Dynamic Command Block (DYC)
to further refine your jog configuration.

Jog pressure alarm setpoints are configured.

The QDC module offers many machine operation
options to meet nearly any injection molding
machine's requirements.

PLC5 ladder logic is required to cycle the machine
in the desired manner.

Valves/Outputs responsible for controlling pressure
or flow, valve spanning values and ramp rates.

velocity, position, time setpoints, other partspecific
information)

Chapter 5

Chapter 6

Chapter 7

(Used in
Chapters 9 & 10)

Chapter 8

(Used in
Chapters 9 & 10)

5 Span your Valves Configuration parameters necessary to accurately

span your inject and clamp valves. You also set
profile pressure alarms.

6 Tune your Machine for

Producing Parts

Topics to consider when machine and part tuning
are discussed.

Chapter 9

Chapter 10

4-3

Chapter 4

Overview of Remaining
Configuration Procedures

Enter Data T

able V

alues and

Download Command Blocks

We refer to these procedures throughout this manual whenever you must:

enter data table values
download command blocks

Enter Values into Your PLC Data Table

With your programming terminal, enter worksheet values into your PLC-5
data table as follows:

1. Switch the PLC-5 processor to

PROGRAM mode.

2. Display your PLC-5 data table

3. Locate the data files for storing the subject block as specified on

individual worksheets.

4. Enter the value for each word and bit.

When you set bits in words prefixed with file identifier B (example: B34),
the PLC-5 processor automatically switches the radix to binary format.

Download Command Blocks

Use this procedure to send one or more command blocks from PLC-5 data
table to QDC module while leaving the PLC-5 processor in Run mode.
(As an alternative, Pro-Set 600 software forces the PLC-5 processor to
download all command blocks to the QDC module when you switch the
processor from

PROGRAM to RUN

or power it up.)

Important: The following procedure does NOT apply to the MCC block.
It has its own download procedure described in chapter 3.

Important: Before you can use the following procedure, you must first
have successfully downloaded a valid MCC block to the QDC module.

We define the following data words and functions used in the procedure to
download command blocks.

This Word: At Address: Provides this Function:

DYC61 N40:173 Requests that the QDC module return an error if it finds one in the

designated data block. The QDC module reports the error in SYS61
and SYS62.

SYS61 N40:213 The QDC module reports the ID of the data block containing the

error (identified in SYS62). This word will match a nonzero DYC61.

SYS62 N40:214 The QDC module reports the error code in this word. This error

code relates to the data block whose ID is reported in SYS61.

4-4

Chapter 4

Overview of Remaining
Configuration Procedures

Learn the following procedure because you will use it often.

1. For the block you want to download (subject block), get its ID

number from Table 4.A and enter it into DYC61.

Table 4.A
Information

Required to Download a Command Block

Block to
Download:

JGC 02 B21/1

FCC 03 B21/2 CPC

SCC 04 B21/3 CPC

TCC 05 B21/4 CPC

LPC 06 B21/5 CPC

CPC 07 B21/6

INC 08 B21/7 IPC

IPC 09 B21/8

PKC 10 B21/9 HPC

HDC 11 B21/10 HPC

HPC 12 B21/11

PRC 13 B21/12

PLC 14 B21/13 PPC

PPC 15 B21/14

PSC 16 B21/15

FOC 17 B21/16 OPC

SOC 18 B21/17 OPC

TOC 19 B21/18 OPC

OSC 20 B21/19 OPC

OPC 21 B21/20

ProSet 600
Block ID.:

ProSet 600
Download Command Bit:

Companion
Block:

2. Confirm that the QDC module returns the ID in SYS61.
Important: If the value returned in SYS61 is NOT the ID number

you entered, you have an error in the MCC or DYC block:

If SYS61 has
this value:

1 MCC Refer to chapter 3 Correct Any Dataentry Errors in MCC"

25 DYC Go to steps 8 and 9 of this procedure.

This block
has errors:

Fix them as follows:

Fix MCC and DYC errors before starting the download procedure
MCC and DYC errors are corrected when SYS61≠ 1 or 25, but

when SYS61=DYC61=ID number of the subject block

4-5

Chapter 4

Overview of Remaining
Configuration Procedures

When you have done all three:

1. Corrected all errors in MCC and DYC blocks

2. Entered the ID of the subject block in DYC61

3. Downloaded the subject block

Then:

The QDC module immediately
reports any programming errors it
detected in the subject block

3. Start the download procedure by setting the corresponding download

bit (Table 4.A) in your PLC-5 data table.

4. Watch the bit you set in step 3 and wait for Pro-Set 600 software to

reset it to zero. This indicates the PLC-5 processor has transferred
the block to the QDC module.

5. Observe the value of SYS62 (N40:214) in your PLC-5 data table:

If SYS62 = 0, the QDC module detected no errors. Go to step 6.
If SYS62 ≠ 0, the QDC module detected an error. Go to step 8.

6. Since the QDC module did not detect a programming error, check

Table 4.A to see if the subject block has a required companion block.

Important: When downloading multiple subject blocks that share the
same companion block, you may download the companion block:

after each subject block
once after the last subject block

To simplify troubleshooting your data entry (programming) errors during
initial configuration procedures, we recommend that you download the
companion block after each subject block. Otherwise, the procedure to
correct multiple errors becomes too complex.

7. Complete the procedure as follows:

a. If subject block has a required companion block, return to step 2

and repeat the procedure for the next block or companion block.

b. If the subject block is the companion block, download it.

Return to step 2 to download additional blocks if required.

8. The QDC module detected a programming error. Interpret the error

code returned by the QDC module in SYS62. The code identifies the
first detected programming error in the subject block whose ID is
reported in SYS61 (N40:213). Refer to Section 2 of the Plastic
Molding Module Reference Manual (publication 1771-6.5.88) for
how to interpret and correct the cause of programming errors.

9. Correct the error in the PLC-5 data table corresponding to the subject

block. Since you may have more than one programming error in the
subject block, return to step 4 and repeat the download procedure
until you have corrected all errors in this block. Then SYS62 = 0.

4-6

Jog Your Machine

Chapter

5

Chapter

Objectives

About Jogging

Use These W

orksheets

This chapter describes how to:

configure jog block values necessary to jog the ram (screw) and clamp
test jog values and make changes, if necessary
configure values which indirectly affect screw-rotate and ejector jogs

Jogging your machine is similar to operating it in set-output:
You apply percentage values to your QDC module’s outputs to obtain the
desired motion. The jog configuration block (JGC) lets you set up jog
parameters to control QDC module outputs to:

jog the ram (screw) forward and backward
jog the clamp open and closed

Although the QDC module (in inject and clamp mode) may not directly
control your machine’s screw-rotate or ejector jogs, your hydraulics may
require that valves connected to your QDC module outputs go to a certain
position to assure proper screw-rotate and ejector jog functions. The QDC
jog configuration block allows you to set up these indirect jog values.

The following table lists the command block and corresponding
worksheets for recording initial values to configure the QDC module for
jogging the ram (screw) and clamp.

To configure the QDC module
for jogging the:

ram (screw) and clamp JGC 5A 5-3
screwrotate and ejector (indirect control) JGC 5B 5-8

With this
block:

Use this
WorksheetOnPage

5-1

Chapter 5

Jog Your Machine

Determine

Initial Jog V

alues

Worksheet 5-A lists all words in which you must enter values to
successfully configure your QDC module for jogging the ram (screw) and
clamp forward and backward. Use it to record:

initial values

Enter initial values just sufficient to jog in the desired direction.
Keep this information in mind:

The numbers you enter are %-signal output.
For a range of –10 to +10 Vdc, zero output occurs @ 50%
(See Warning on next page.)

Later in this chapter you modify these values to obtain desired results.

pressure alarm setpoints for ram (screw) and clamp jogs

The QDC module sets an alarm any time ram (screw) and/or clamp
pressure equals or exceeds the corresponding alarm setpoints during a
jog. A zero entry inhibits alarm actuation.

Important:

High pressure alarms that you set in chapter 3 are also active

during jog functions.

Jog-specific high pressure alarms for eject jogs are NOT activated

in a QDC module configured for inject and clamp mode.

5-2

Worksheet 5. A
Ram (screw) and Clamp Jog Configuration V

Enter Your Initial Values Here

Chapter 5

Jog Your Machine

alues

Control Block

ProSet 600 Addr. Value Description Units

Word

Inject, Forward Jog

JGC17 N40:73 Set Output Values Output #1 % Signal Output

JGC18 N40:74 Output #2 % Signal Output

JGC19 N40:75 Output #3 % Signal Output

JGC20 N40:76 Output #4 % Signal Output

Inject, Reverse Jog

JGC25 N40:81 Set Output Values Output #1 % Signal Output

JGC26 N40:82 Output #2 % Signal Output

JGC27 N40:83 Output #3 % Signal Output

JGC28 N40:84 Output #4 % Signal Output

Clamp, Forward Jog

JGC33 N40:89 Set Output Values Output #1 % Signal Output

JGC34 N40:90 Output #2 % Signal Output

JGC35 N40:91 Output #3 % Signal Output

JGC36 N40:92 Output #4 % Signal Output

Clamp, Reverse Jog

JGC41 N40:97 Set Output Values Output #1 % Signal Output

JGC42 N40:98 Output #2 % Signal Output

JGC43 N40:99 Output #3 % Signal Output

JGC44 N40:100 Output #4 % Signal Output

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

Jog Pressure Alarms

JGC06 N40:62 Ram Jog Pressure, Alarm Setpoint Ram (screw) Pressure

JGC07 N40:63 Clamp Jog Pressure Alarm Setpoint Clamp Pressure

1

%

Signal Output

00.00 to 99.99 %

2

Pressure
0000 to 9999 PSI

000.0 to 999.9 Bar

2

2

5-3

Chapter 5

Jog Your Machine

ATTENTION: You can connect up to four different valves to
your QDC module. Although all four may not directly jog the
ram (screw) or clamp, consider their indirect effect when setting
jog set-output values. Indirectly, they could cause unexpected
machine motion with possible damage to equipment or injury to
personnel.

ATTENTION: A value of 0 entered in your data table does not
necessarily correspond to zero pressure or flow. For an output
configured +

10 Vdc, an output of 50% corresponds to zero

volts signal output (see graph). Amplifier electronics or spool
offsets may also be designed such that zero volts signal input
does not result in no flow or pressure. Please consult your valve
and amplifier specifications for more details.

10

5

0

Output Voltage

-5

-10

0 102030405060708090100

%

Output Requested

Enter and Download Initial Jog Values

Using the same procedure outlined in chapter 3, enter your initial jog
values in Worksheet 5-A.

Use the procedure in chapter 4 to download the jog configuration block
(JGC) to the QDC module. We repeat the JGC block download data.

5-4

To download Set B21/

JGC 1

Chapter 5

Jog Your Machine

Write Ladder Logic

Take time now to develop ladder logic (independent of Pro-Set 600
software) to jog the ram (screw) and clamp. You need to monitor switches
on your operator control panel, and set corresponding command bits.

Use word 1 in the dynamic command block (DYC01) to enable and disable
individual jogs. Use word 1 in the system status block (SYS01) to monitor
the QDC module’s reaction to jog commands. Tables 5.A and 5.B identify
command and status bits for jogging the ram (screw) and clamp.

Table 5.A

Bits for Ram (Screw) and Clamp Jogs

Enable

Control Block Word: ProSet 600 Address: Description:

DYC01B10 B34/394 Execute Ram (Screw) Jog Forward

DYC01B11 B34/395 Execute Ram (Screw) Jog Reverse

DYC01B12 B34/396 Execute Clamp Jog Forward

DYC01B13 B34/397 Execute Clamp Jog Reverse

Table 5.B

Bits for Ram (Screw) and Clamp Jogs

Status

Status Block Word: ProSet 600 Address: Description:

SYS01B10 B34/10 Ram (Screw) Jog Forward in Progress

SYS01B11 B34/11 Ram (Screw) Jog Reverse in Progress

SYS01B12 B34/12 Clamp Jog Forward in Progress

SYS01B13 B34/13 Clamp Jog Reverse in Progress

We provide a programming example (Figure 5.1) of jog control for
instructional purposes only. Your application-specific programming may
vary significantly from this example.

Important: You may also need to develop ladder logic that changes the
direction of ram (screw) and/or clamp travel hydraulically when you
command the QDC module to jog in reverse.

5-5

Chapter 5

Jog Your Machine

Figure 5.1
Example

Rung 6:1 DYC02-B15
| EMERGENCY ********* |

| STOP EXECUTE |
| CONDITION ALL STOP |
| EXISTS COMMAND |
| B3 B34 |
+––––] [–––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––( )–––––+
| 0 415 |
Rung 6:2
| CYCLE | MANUAL |DIRECTION DYC01-B10 |
| CONTROL | SCREW |SOLENOIDS ********** |
| SELECTOR | FORWARD |ALIGNED TO EXECUTE |
| (A/S/M) IN| JOG |MOVE SCREW SCREW |
| “MANUAL” | ALLOWED |FORWARD FWD JOG |
| I:003 B11 B11 B34 |
+––––] [––––––––] [––––––––] [–––––––––––––––––––––––––––––––––––––––––( )–––––+
| 05 1 8 394 |
Rung 6:3
| CYCLE | MANUAL |DIRECTION DYC01-B11 |
| CONTROL | SCREW |SOLENOIDS ********** |
| SELECTOR | REVERSE |ALIGNED TO EXECUTE |
| (A/S/M) IN| JOG |MOVE SCREW SCREW |
| “MANUAL” | ALLOWED |REVERSE REV JOG |
| I:003 B11 B11 B34 |
+––––] [––––––––] [––––––––] [–––––––––––––––––––––––––––––––––––––––––( )–––––+
| 05 2 9 395 |
Rung 6:4 |
| CYCLE | |DIRECTION DYC01-B12 |
| CONTROL | MANUAL |SOLENOIDS ********** |
| SELECTOR |CLAMP JOG |ALIGNED TO EXECUTE |
| (A/S/M) IN| FORWARD |MOVE CLAMP CLAMP FWD |
| “MANUAL” | ALLOWED |FORWARD JOG |
| I:003 B11 B11 B34 |
+––––] [––––––––] [––––––––] [–––––––––––––––––––––––––––––––––––––––––( )–––––+
| 05 4 11 396 |
Rung 6:5
| CYCLE | |DIRECTION DYC01-B13 |
| CONTROL | MANUAL |SOLENOIDS ********** |
| SELECTOR |CLAMP JOG |ALIGNED TO EXECUTE |
| (A/S/M) IN| REVERSE |MOVE CLAMP CLAMP REV |
| “MANUAL” | ALLOWED |REVERSE JOG |
| I:003 B11 B11 B34 |
+––––] [––––––––] [––––––––] [–––––––––––––––––––––––––––––––––––––––––( )–––––+
| 05 5 12 397 |

Programming for Ram (Screw) and Clamp Jogs

5-6

Chapter 5

Jog Your Machine

Jog Your Ram (Screw)
and Clamp

Configure Screwrotate and
Ejector Jogs
for Indirect Control

Jog your ram (screw) and clamp, one at a time, in forward and reverse
directions. Experiment with values you entered in the jog configuration
block (JGC) until you obtain the desired jog operation.

You must download the JGC to the QDC module each time you change a
value in the command block to implement the new value. Refer to the
download procedure outlined in chapter 4.

If You Observe This Condition: Then Make This Adjustment:

Rough jerky acceleration or deceleration
(hammering hydraulics)

Sluggish acceleration or deceleration 1) Boost jog pressure

1) Decrease jog pressure

2) Decrease jog flow

Although the QDC module (in inject and clamp mode) may not directly
control your machine’s screw-rotate and ejector jogs, your hydraulics may
require valves connected to this QDC module’s outputs to go to a certain
position to assure proper screw-rotate and/or ejector jog functions. The jog
configuration block lets you set up these indirect jog values.

If your hydraulics require it, take time now to set your valves connected to
the QDC module in inject and clamp mode to assist with screw-rotate
and/or eject jogs. Otherwise, omit the rest of this chapter.

Whenever the appropriate screw-rotate or ejector jog bit is set in dynamic
command block DYC01, the jog configuration block (JGC) values
corresponding to the respective jog are applied to QDC module outputs.

1. In Worksheet 5-B, enter values which must be applied to the QDC

module in inject and clamp mode to successfully execute screw-rotate
and/or ejector jogs.

Important: Jog-specific high pressure alarms are NOT activated in a QDC
module in inject and clamp mode during screw-rotate and ejector jogs.

2. Download the jog configuration block (JGC) using the download

procedure outlined in chapter 4.

5-7

Chapter 5

Jog Your Machine

Worksheet 5. B
Screwrotate & Eject Jog Configuration Values for Indirect Control

Enter Your Initial Values Here

Control Block
Word

Screw Rotate Jog

JGC09 N40:65 Set Output Values Output #1 % Signal Output

JGC10 N40:66 Output #2 % Signal Output

JGC11 N40:67 Output #3 % Signal Output

JGC12 N40:68 Output #4 % Signal Output

Ejector, Advance Jog

JGC49 N40:105 Set Output Values Output #1 % Signal Output

JGC50 N40:106 Output #2 % Signal Output

JGC51 N40:107 Output #3 % Signal Output

JGC52 N40:108 Output #4 % Signal Output

Ejector, Retract Jog

JGC57 N40:113 Set Output Values Output #1 % Signal Output

JGC58 N40:114 Output #2 % Signal Output

JGC59 N40:115 Output #3 % Signal Output

JGC60 N40:116 Output #4 % Signal Output

1

%

Signal Output

00.00 to 99.99 %

ProSet 600 Addr. Value Description Units

1

1

1

1

1

1

1

1

1

1

1

1

Write Ladder Logic to Assist
with Screwrotate and
Ejector Jogs

5-8

If your hydraulics require it, take time now to develop ladder logic
(independent of Pro-Set 600 software) so the QDC module (in inject and
clamp mode) can assist in screw-rotate and ejector jogs. Otherwise, omit
the rest of this chapter.

Use word 1 in the dynamic command block (DYC01) to enable and disable
individual jogs. Use word 1 in the system status block (SYS01) to monitor
the QDC module’s reaction to jog commands. Tables 5.C and 5.D identify
command and status bits for jogging screw rotation and/or the ejector.

Chapter 5

Jog Your Machine

Table 5.C

Bits for Screwrotate and Ejector Jogs

Enable

Command Block Word: ProSet 600 Address: Description:

DYC01B09 B34/393 Execute Screwrotate Jog

DYC01B14 B34/398 Execute Ejector Jog Advance

DYC01B15 B34/399 Execute Ejector Jog Retract

Table 5.D

Bits for Screwrotate and Ejector Jogs

Status

Status Block Word: ProSet 600

Address:

SYS01B09 B34/9 Screwrotate Jog in Progress

SYS01B14 B34/14 Ejector Jog Advance in Progress

SYS01B15 B34/15 Ejector Jog Retract in Progress

Description:

We provide a programming example (Figure 5.2) of assisted jog control for
instructional purposes only. Your application-specific programming may
vary significantly from this example.

Important: You may also need to develop ladder logic that changes the
direction of ejector travel hydraulically when you command the QDC
module to retract the ejector.

5-9

Chapter 5

Jog Your Machine

Figure 5.2
Example

Rung 6:6
| CYCLE | MANUAL |DIRECTION DYC01-B09 |
| CONTROL | SCREW |SOLENOIDS ********** |
| SELECTOR | ROTATE |ALIGNED TO EXECUTE |
| (A/S/M) IN| JOG | ROTATE UNASSIGNED |
| “MANUAL” | ALLOWED | SCREW #1 JOG |
| I:003 B11 B11 B34 |
+––––] [––––––––] [––––––––] [–––––––––––––––––––––––––––––––––––––––––( )–––––+
| 05 3 10 393 |
Rung 6:7 |
| CYCLE | MANUAL |DIRECTION DYC01-B14 |
| CONTROL | EJECTOR |SOLENOIDS ********** |
| SELECTOR | JOG |ALIGNED TO EXECUTE |
| (A/S/M) IN| ADVANCE |ADVANCE UNASSIGNED |
| “MANUAL” | ALLOWED |EJECTOR #6 JOG |
| I:003 B11 B11 B34 |
+––––] [––––––––] [––––––––] [–––––––––––––––––––––––––––––––––––––––––( )–––––+
| 05 6 13 398 |
Rung 6:8
| CYCLE | MANUAL |DIRECTION DYC01-B15 |
| CONTROL | EJECTOR |SOLENOIDS ********** |
| SELECTOR | JOG |ALIGNED TO EXECUTE |
| (A/S/M) IN| RETRACT |RETRACT UNASSIGNED |
| “MANUAL” | ALLOWED |EJECTOR #7 JOG |
| I:003 B11 B11 B34 |
+––––] [––––––––] [––––––––] [–––––––––––––––––––––––––––––––––––––––––( )–––––+
| 05 7 14 399 |

Programming for Assisting Screwrotate and/or Ejector Jogs

Jog the Ejector and
Rotate the Screw

Do this only after writing all direct and assisted ladder logic for controlling
screw-rotate and ejector jogs.

Jog your ejector in forward and retract directions. Rotate the ram (screw)
by jogging. Experiment with values you entered in the jog configuration
block (JGC) until you obtain the desired jog operation.

If You Observe This Condition: Then Make This Adjustment:

Rough jerky acceleration or deceleration
(hammering hydraulics)

Sluggish acceleration or deceleration 1) Boost jog pressure

1) Decrease jog pressure

2) Decrease jog flow

You must download the JGC block to the QDC module each time you
change a value in the command block to implement the new value. Refer
to the download procedure outlined in chapter 4.

5-10

Chapter

6

Select Command and Status Bits to Sequence
Machine Operation

Chapter

Assess Y

Objectives

our

Logic Requirements

In this chapter, we provide you with tables of command and status bits that
you use to write ladder logic to:

implement manual functions such as jog, set outputs, and stop
step your QDC module through machine cycles

We suggest how to assess your logic requirements and based on those
requirements how to use bit tables to write your machine’s sequential
ladder logic that depends on your machine’s hydraulic configuration.

You must add your own ladder logic according to your machine’s
sequencing requirements.

If you need to Refer to this table for required

Execute phases of the Inject mode
without interruption

Jog your machine in manual mode,
set outputs, or stop

Start the next profile or movement 6.B and 6.C

Interrupt ram (screw) and clamp
movement between profiles

Trigger new events 6.E

Review all available status bits 6.F

Review all available command
and configuration bits 6.G

command and/or status bits

no additional ladder logic required

6.A

6.D

Important: For a more thorough description of all command and status
bits presented in this chapter, refer to Section 3 of the Plastic Molding
Module Reference Manual (publication 1771-6.5.88).

6-1

Chapter 6

Select Command and Status Bits
to Sequence Machine Operation

Use Command and Status
Bit Tables

Use the following tables to select command and status bits when writing
ladder logic to control manual functions and machine sequencing.

Table 6.A
Command

To Initiate this action: Set this bit: The QDC module sets this

Direct Setoutput DYC01B08 SYS01B08

Unassigned #1 Jog DYC01B09 SYS01B09

Ram (screw) Forward Jog DYC01B10 SYS01B10

Ram (screw) Reverse Jog DYC01B11 SYS01B11

Clamp Forward Jog DYC01B12 SYS01B12

Clamp Reverse Jog DYC01B13 SYS01B13

Unassigned #6 Jog DYC01B14 SYS01B14

Unassigned #7 Jog DYC01B15 SYS01B15

Stop DYC02B15 SYS02B15

and Status Bits for Manual Control

bit during execution:

Table 6.B
Command

To initiate this
Profile/Movement:

1st Clamp Close DYC02B00 --- ---

2nd Clamp Close DYC02B01 1st Clamp Close CPC03B08

3rd Clamp Close DYC02B02 2nd Clamp Close CPC03B09

Low Pressure Close DYC02B03 3rd Clamp Close CPC03B10

Injection DYC02B04 --- ---

Pack DYC02B05 Injection

Hold DYC02B06 Pack

Predecompression DYC02B07 Hold HPC03B08

Plastication DYC02B08 Predecompression HPC03B09

Postdecompression DYC02B09 Plastication PPC03B08

1st Clamp Open DYC02B10 --- ---

2nd Clamp Open DYC02B11 1st Clamp Open OPC03B08

3rd Clamp Open DYC02B12 2nd Clamp Open OPC03B09

Clamp Open Slow DYC02B13 3rd Clamp Open OPC03B10

1

Injection, Pack, and Hold are always linked as one profile.

Bits for Automatic Functions

Toggle this bit: Or the Profile/Movement

starts automatically after:

If this bit is
Reset:

1

1

6-2

Chapter 6

Select Command and Status Bits
to Sequence Machine Operation

Table 6.C

and Command Bit Interaction for Automatic Functions

Status

For this
Profile/Movement:

1st Clamp Close SYS21B00 SYS02B00 SYS02B00 SYS21B00 CPC03B08 SYS22B00

2nd Clamp Close SYS21B01 SYS02B01 SYS02B01 SYS21B01 CPC03B09 SYS22B01

3rd Clamp Close SYS21B02 SYS02B02 SYS02B02 SYS21B02 CPC03B10 SYS22B02

Low Pressure Close SYS21B03 SYS02B03 SYS02B03 SYS21B03 --- SYS22B03

Injection SYS21B04 SYS02B04 SYS02B04 SYS21B04 --- ---

Pack SYS21B05 SYS02B05 SYS02B05 SYS21B05 --- ---

Hold SYS21B06 SYS02B06 SYS02B06 SYS21B06 HPC03B08 SYS22B06

Predecompression SYS21B07 SYS02B07 SYS02B07 SYS21B07 HPC03B09 SYS22B07

Plastication SYS21B08 SYS02B08 SYS02B08 SYS21B08 PPC03B08 SYS22B08

Postdecompression SYS21B09 SYS02B09 SYS02B09 SYS21B09 --- SYS22B09

1st Clamp Open SYS21B10 SYS02B10 SYS02B10 SYS21B10 OPC03B08 SYS22B10

2nd Clamp Open SYS21B11 SYS02B11 SYS02B11 SYS21B11 OPC03B09 SYS22B11

3rd Clamp Open SYS21B12 SYS02B12 SYS02B12 SYS21B12 OPC03B10 SYS22B12

During Execution
this bit in B34 is:

SET RESET SET RESET also SET also SET

At Completion
this bit in B34 is:

At completion
If this Then this
command bit is: status bit is:

Clamp Open Slow SYS21B13 SYS02B13 SYS02B13 SYS21B13 --- SYS22B13

6-3

Chapter 6

Select Command and Status Bits
to Sequence Machine Operation

Table 6.D

Bits T

Command

Bit Description: QDC Block Addr.:

0 = start 2nd clamp close profile @ endof 1st
1 = stop and setoutput @ endof 1st

0 = start 3rd clamp close profile @ endof 2nd
1 = stop and setoutput @ endof 2nd

0 = start LP close profile @ endof 3rd
1 = stop and setoutput @ endof 3rd

0 = start 2nd clamp open profile @ endof 1st
1 = stop and setoutput @ endof 1st

0 = start 3rd clamp open profile @ endof 2nd
1 = stop and setoutput @ endof 2nd

0 = start clamp open slow profile @ endof 3rd
1 = stop and setoutput @ endof 3rd

0 = start predecompression movement @ endof hold
1 = stop and set output @ endof hold

0 = start plastication profile @ endof predecompression
1 = stop and set output @ endof predecompression

0 = start postdecompression movement @ endof plastication
1 = stop and set output @ endof plastication

o Interrupt Inject and Clamp Movement Between Profiles

CPC03B08

CPC03B09

CPC03B10

OPC03B08

OPC03B09

OPC03B10

HPC03B08

HPC03B09

PPC03B08

6-4

Chapter 6

Select Command and Status Bits
to Sequence Machine Operation

Table 6.E
Miscellaneous

Reason for Using: Bit Description: QDC Block

To drop pump adders, or shift solenoids before
starting pack/hold profile

To inhibit clamp from opening in auto mode Cure timer timing SYS03B03

To start clampopen phase Ram (screw) retracted, and

To idle the machine and activate an alarm
because the hopper is running out of plastic

To shift solenoids for predecompression Setoutput in progress @ end

To shift solenoids for plastication Setoutput in progress @ end

To shift solenoids for postdecompression Setoutput in progress @ end

To idle the machine until starting next action Setoutput in progress @ end

Status Bits T

o T

rigger New Inject and Clamp Action

Injection complete SYS02B04

Cure time complete

Watchdog for plastication
phase

of hold

of predecompression

of plastication

of postdecompression

Addr.:

SYS03B04,
and
SYS03B05

SYS04B08

SYS22B06

SYS22B07

SYS22B08

SYS22B09

To drop pump adders, or shift solenoids Clamp in moldprotect zone SYS03B00

To add pump adders, or shift solenoids for
tonnage build or lockup

To start inject cycle Tonnage complete SYS03B02

To drop pump adders, or shift solenoids Clamp in openslow zone SYS03B06

To idle the machine until starting next action Mold fully open SYS03B07

To prevent starting next cycle when machine is
in auto mode

To start next cycle with machine in auto mode Cycle complete SYS03B11

To reopen the clamp when the part is stuck LP close watchdog timeout SYS04B03

Mold safe SYS03B01

Opendwell timer is timing SYS03B09

6-5

Chapter 6

Select Command and Status Bits
to Sequence Machine Operation

Table 6.F

Bits

Status

Category: Bit Status

(when = 1):

Jog Status executing unassigned #1 jog 09 SYS01B09

executing ram (screw) forward jog 10 SYS01B10

executing ram (screw) reverse jog 11 SYS01B11

executing clamp forward jog 12 SYS01B12

executing clamp reverse jog 13 SYS01B13

executing unassigned #6 jog 14 SYS01B14

executing unassigned #7 jog 15 SYS01B15

Profile Complete 1st clamp close profile complete 16 SYS02B00

2nd clamp close profile complete 17 SYS02B01

3rd clamp close profile complete 18 SYS02B02

LP close profile complete 19 SYS02B03

injection profile complete 20 SYS02B04

pack profile complete 21 SYS02B05

hold profile complete 22 SYS02B06

predecompress movement complete 23 SYS02B07

plastication profile complete 24 SYS02B08

ProSet
B34/xx:

QDC Block
Addr.:

postdecompress movement complete 25 SYS02B09

1st clamp open profile complete 26 SYS02B10

2nd clamp open profile complete 27 SYS02B11

3rd clamp open profile complete 28 SYS02B12

clamp open slow profile complete 29 SYS02B13

Busy Status no action (outputs at zero) 31 SYS02B15

Miscellaneous Status clamp in mold protection zone 32 SYS03B00

mold safe 33 SYS03B01

tonnage complete 34 SYS03B02

cure timer timing 35 SYS03B03

ram (screw) retracted 36 SYS03B04

cure time complete 37 SYS03B05

clamp in openslow zone 38 SYS03B06

mold open 39 SYS03B07

mold opendwell timer is timing 41 SYS03B09

cycle complete 43 SYS03B11

6-6

Chapter 6

Select Command and Status Bits
to Sequence Machine Operation

Table 6.F

(continued)

Status Bits

Category: Bit Status

(when = 1):

Watchdog Status 1st clamp close watchdog timed out 48 SYS04B00

2nd clamp close watchdog timed out 49 SYS04B01

3rd clamp close watchdog timed out 50 SYS04B02

LP close watchdog timed out 51 SYS04B03

predecompress watchdog timed out 55 SYS04B07

plastication watchdog timed out 56 SYS04B08

postdecompress watchdog timed out 57 SYS04B09

1st clamp open watchdog timed out 58 SYS04B10

2nd clamp open watchdog timed out 59 SYS04B11

3rd clamp open watchdog timed out 60 SYS04B12

clamp open slow watchdog timed out 61 SYS04B13

tonnage watchdog timed out 63 SYS04B15

Profile Status executing 1st close profile 320 SYS21B00

executing 2nd close profile 321 SYS21B01

executing 3rd close profile 322 SYS21B02

executing LP close profile 323 SYS21B03

ProSet
B34/xx:

QDC Block
Addr.:

executing injection profile 324 SYS21B04

executing pack profile 325 SYS21B05

executing hold profile 326 SYS21B06

executing predecompress movement 327 SYS21B07

executing plastication profile 328 SYS21B08

executing postdecompress movement 329 SYS21B09

executing 1st clamp open profile 330 SYS21B10

executing 2nd clamp open profile 331 SYS21B11

executing 3rd clamp open profile 332 SYS21B12

executing clamp open slow profile 333 SYS21B13

6-7

Chapter 6

Select Command and Status Bits
to Sequence Machine Operation

Table 6.F

(continued)

Status Bits

Category: Bit Status

Endof Profile
Setoutput Status

(when = 1):

executing endof 1st clamp close
setoutput

executing endof 2nd clamp close
setoutput

executing endof 3rd clamp close
setoutput

executing endof LP close setoutput 339 SYS22B03

executing end of hold setoutput 342 SYS22B06

executing end of predecompression
setoutput

executing end of plastication
setoutput

executing end of postdecompression
setoutput

executing endof 1st clamp open
setoutput

executing endof 2nd clamp open
setoutput

executing endof 3rd clamp open
setoutput

executing endof clamp open slow
setoutput

ProSet
B34/xx:

336 SYS22B00

337 SYS22B01

338 SYS22B02

343 SYS22B07

344 SYS22B08

345 SYS22B09

346 SYS22B10

347 SYS22B11

348 SYS22B12

349 SYS22B13

QDC Block
Addr.:

6-8

Chapter 6

Select Command and Status Bits
to Sequence Machine Operation

Table 6.G
Command

Operation: Function Enabled

Nonprofiled execute setoutput 392 DYC01B08

Action Commands execute ram (screw) forward jog 393 DYC01B09

execute ram (screw) reverse jog 394 DYC01B10

execute unassigned # 3 jog 395 DYC01B11

execute clamp forward jog 396 DYC01B12

execute clamp reverse jog 397 DYC01B13

Stop Command execute all stop (outputs = zero) 415 DYC02B15

Miscellaneous reset tonnage watchdog timer 416 DYC03B00

Commands reset cure timer 417 DYC03B01

Profile Action execute 1st clamp close profile 400 DYC02B00

Commands execute 2nd clamp close profile 401 DYC02B01

execute 3rd clamp close profile 402 DYC02B02

execute LP clamp close profile 403 DYC02B03

and Configuration Bits

(when = 1):

execute unassigned #6 jog 398 DYC01B14

execute unassigned #7 jog 399 DYC01B15

reset SYS01B08 424 DYC03B08

reset latched alarms 425 DYC03B09

reset complete bits 426 DYC03B10

ProSet
B34/xx:

QDC Block
Addr.:

execute injection profile 404 DYC02B04

execute pack profile 405 DYC02B05

execute hold profile 406 DYC02B06

execute predecompression movement 407 DYC02B07

execute plastication profile 408 DYC02B08

execute postdecompression movement 409 DYC02B09

execute 1st clamp open profile 410 DYC02B10

execute 2nd clamp open profile 411 DYC02B11

execute 3rd clamp open profile 412 DYC02B12

execute clamp open slow profile 413 DYC02B13

6-9

Chapter 6

Select Command and Status Bits
to Sequence Machine Operation

Table 6.G

(continued)

Command and Configuration Bits

Operation: Function Enabled

Logical Bridge set output @ end of 1st clamp close profile

Configured
Protection from
Clampzone
Overrun

(when = 1):

(0 = start 2nd clamp close profile)

set output @ end of 2nd clamp close profile
(0 = start 3rd clamp close profile)

set output @ end of 3rd clamp close profile
(0 = start clamp LP close profile)

set output @ end of hold profile
(0 = start predecompress movement @ end of hold)

set output @ end of predecompress movement
(0 = start plastication profile @ end of predecompress)

set output at end of plastication profile
(0 = start postdecompression at end of plastication)

set output @ end of 1st clamp open profile
(0 = start 2nd clamp open profile)

set output @ end of 2nd clamp open profile
(0 = start 3rd clamp open profile)

set output @ end of 3rd clamp open profile
(0 = start clamp open slow profile)

If a clamp close profile overruns the
mold protection zone:
0 = start LPclose profile
1 = stop and zero outputs

If a clamp open profile overruns the
clamp open slow zone
0 = start open slow profile
1 = stop and zero outputs

ProSet
Address:

B37/296 CPC03B08

B37/297 CPC03B09

B37/298 CPC03B10

B38/296 HPC03B08

B38/297 HPC03B09

B38/488 PPC03B08

B37/616 OPC03B08

B37/617 OPC03B09

B37/618 OPC03B10

B37/299 CPC03B11

B37/619 OPC03B11

QDC Block
Addr.:

6-10

Chapter

7

Load Initial Configuration Values

Chapter

Objectives

This chapter helps you determine, enter, and download configuration
setpoints required to tune the QDC module. You will refer to this chapter
frequently when tuning the QDC module in chapter 9.

We give you information to:

assign outputs for control valves
select the type of PID algorithm
set values for Expert Response Compensation
determine set-output values for profiles
set accel/decel ramp rates
determine set-output values for end of profiles
set pressure control limits
set velocity control limits
set profile tuning constants and pressure alarm setpoints

Then you:

determine initial values
record values on worksheets
enter them in your PLC-5 data table
download them to the QDC module

Important: We already entered on the worksheets most initial values
required for chapter 9. Your objective is to become familiar with how to:

determine setpoint values as described in text
enter and download values in preparation for tuning the machine in

chapter 9

Important: Before starting this chapter, you should have previously:

spanned your sensors and moved the ram (screw) and clamp (chapter 3)
jogged the ram (screw) and clamp (chapter 5)

7-1

Chapter 7

Load Initial Configuration Values

Use

These W

orksheets

The following table lists command blocks and corresponding worksheets
for recording your initial values that you use to configure the QDC
module.

To configure the QDC module with this configuration
block:

First Clamp Close Configuration Command Block (FCC) Worksheet 7-A 7-4
Second Clamp Close Configuration Command Block (SCC) Worksheet 7-B 7-6
Third Clamp Close Configuration Command Block (TCC) Worksheet 7-C 7-8
Low Pressure Close Configuration Command Block (LPC) Worksheet 7-D 7-10
Injection Configuration Command Block (INC) Worksheet 7-E 7-12

Pack Configuration Command Block (PKC) Worksheet 7-F 7-14
Hold Configuration Command Block (HDC) Worksheet 7-G 7-16
Plastication Configuration Command Block (PLC) Worksheet 7-H 7-18

First Clamp Open Configuration Command Block (FOC) Worksheet 7-I 7-20
Second Clamp Open Configuration Command Block (SOC) Worksheet 7-J 7-22
Third Clamp Open Configuration Command Block (TOC) Worksheet 7-K 7-24
Clamp Open Slow Configuration Command Block (OSC) Worksheet 7-L 7-26

Use this Worksheet: On page:

Important: We omitted pre- and post-decompression blocks because you
do not use them when spanning valves in chapter 9. We discuss their
application in chapter 10.

Take a moment now to browse through the worksheets.

Notice that each worksheet contains two parts:

control words for selecting parameters by setting bits
a configuration block of data words for recording initial values

Also notice that many parameters repeat from one block to the next. For
example:

control bits for selecting an output
block parameters such as decel ramp rate during profile

Because of this, we describe how you determine an initial value once for
all configuration blocks that require it. Then you enter that parameter in
all applicable configuration blocks. That is why we grouped all
worksheets together, followed by all text.

7-2

Chapter 7

Load Initial Configuration Values

This page is purposely blank so that the following 2-page worksheets will
be on facing pages.

7-3

Chapter 7

Load Initial Configuration Values

Worksheet 7A
First Clamp Close Configuration Block (FCC)

Control W

ProSet 600 Addr. B37/bit

ord FCC01Bxx

15 14 13 12 11 10 09 08 07 06 05 04 03 02 01 00

15 14 13 12 11 10 09 08 07 06 05 04 03 02 01 00

Value 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1 1

FCC

Block Identifier

Control W

ProSet 600 Addr. B37/bit

ord FCC02Bxx

15 14 13 12 11 10 09 08 07 06 05 04 03 02 01 00

31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16

Value 0 0 0 0 0 0 0 0 1 0

Code:

0

or 1

Your

value

Required initial value
loaded by ProSet 600

Selected
Pressure Valve

000 = Output 1
001 = Output 2
010 = Output 3
011 = Output 4

Selected
Velocity Valve

000 = Output 1
001 = Output 2
010 = Output 3
011 = Output 4

7-4

PID Pressure Algorithm
0 = Dependent Gains

1 = Independent Gains

Chapter 7

Load Initial Configuration Values

Worksheet 7A

(continued)

First Clamp Close Configuration Block (FCC)

Enter Y

our V

alues Here

Control Word ProSet 600 Addr. Value Description Units

FCC05 N43:1 1000 Minimum ERC PercentageVelocity Percent

FCC06 N43:2 1000 Minimum ERC PercentagePressure Percent

FCC08 N43:4 0 Profile Watchdog Timer Preset Time

FCC09 N43:5 * Output #1 SetOutput Value during Profile Percent Signal Output

FCC10 N43:6 * Output #2 SetOutput Value during Profile Percent Signal Output

FCC11 N43:7 * Output #3 SetOutput Value during Profile Percent Signal Output

FCC12 N43:8 * Output #4 SetOutput Value during Profile Percent Signal Output

FCC17 N43:13 0 Output #1 Acceleration Ramp Rate during Profile Percent Signal Output per Second

FCC18 N43:14 0 Output #2 Acceleration Ramp Rate during Profile Percent Signal Output per Second

FCC19 N43:15 0 Output #3 Acceleration Ramp Rate during Profile Percent Signal Output per Second

FCC20 N43:16 0 Output #4 Acceleration Ramp Rate during Profile Percent Signal Output per Second

FCC25 N43:21 0 Output #1 Deceleration Ramp Rate during Profile Percent Signal Output per Second

FCC26 N43:22 0 Output #2 Deceleration Ramp Rate during Profile Percent Signal Output per Second

FCC27 N43:23 0 Output #3 Deceleration Ramp Rate during Profile Percent Signal Output per Second

FCC28 N43:24 0 Output #4 Deceleration Ramp Rate during Profile Percent Signal Output per Second

FCC33 N43:29 * Output #1 SetOutput Value at Endof Profile Percent Signal Output

FCC34 N43:30 * Output #2 SetOutput Value at Endof Profile Percent Signal Output

FCC35 N43:31 * Output #3 SetOutput Value at Endof Profile Percent Signal Output

FCC36 N43:32 * Output #4 SetOutput Value at Endof Profile Percent Signal Output

FCC41 N43:37 0 Pressure Minimum Control Limit Pressure

FCC42 N43:38 * Pressure Maximum Control Limit Pressure

FCC43 N43:39 * Selected Pressure Valve, Output for Minimum Percent Signal Output

FCC44 N43:40 * Selected Pressure Valve, Output for Maximum Percent Signal Output

FCC45 N43:41 0 Velocity Minimum Control Limit Velocity along Axis

FCC46 N43:42 * Velocity Maximum Control Limit Velocity along Axis

FCC47 N43:43 * Selected Velocity Valve, Output for Minimum Percent Signal Output

FCC48 N43:44 * Selected Velocity Valve, Output for Maximum Percent Signal Output

FCC49 N43:45 100 Proportional Gain for Pressure Control None

FCC50 N43:46 400 Integral Gain for Pressure Control Inverse Time (Algorithm)

FCC51 N43:47 0 Derivative Gain for Pressure Control Time (Algorithm)

FCC52 N43:48 200 Proportional Gain for Velocity Control Inverse Time (Algorithm)

FCC53 N43:49 0 Feed Forward Gain for Velocity Control None

FCC57 N43:53 0 Profile High Pressure Alarm Setpoint Pressure

1

Time

00.00 to 99.99 Seconds 00.00 to 99.99 Inches per Second 0000 to 9999 PSI

5

Percent Signal Output per Second
0000 to 9999 00.00 to 99.99 minutes (ISA) 00.00 to 99.99 minutes (ISA)

2

Velocity along Axis

000.0 to 999.9 Millimeters per Second

6

Inverse T

ime (Algorithm)

00.00 to 99.99 seconds (AB) 00.00 to 99.99 seconds (AB)

3

Pressure

000.0 to 999.9 Bar

7

T

ime (Algorithm)

8

8

1

4

4

4

4

4

4

4

4

3

3

4

4

2

2

4

4

6

7

6

3

4

Percent Signal Output

00.00 to 99.99

8

Percent

00.00 to 99.99

5

5

5

5

5

5

5

5

*

Refer to the appropriate section later in this chapter for information on this parameter

7-5

Chapter 7

Load Initial Configuration Values

Worksheet 7B
Second Clamp Close Configuration Block (SCC)

Control W

ProSet 600 Addr. B37/bit

ord SCC01Bxx

15 14 13 12 11 10 09 08 07 06 05 04 03 02 01 00

79 78 77 76 75 74 73 72 71 70 69 68 67 66 65 64

Value 0 0 0 0 0 0 0 0 0 0 0 0 0 1 0 0

SCC

Block Identifier

Control W

ProSet 600 Addr. B37/bit

ord SCC02Bxx

15 14 13 12 11 10 09 08 07 06 05 04 03 02 01 00

95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80

Value 0 0 0 0 0 0 0 0 1 0

Code:

0

or 1

Your

value

Required initial value
loaded by ProSet 600

Selected
Pressure Valve

000 = Output 1
001 = Output 2
010 = Output 3
011 = Output 4

Selected
Velocity Valve

000 = Output 1
001 = Output 2
010 = Output 3
011 = Output 4

7-6

PID Pressure Algorithm
0 = Dependent Gains

1 = Independent Gains

Chapter 7

Load Initial Configuration Values

Worksheet 7B

(continued)

Second Clamp Close Configuration Block (SCC)

Enter Y

our V

alues Here

Control Word ProSet 600 Addr. Value Description Units

SCC05 N43:61 1000 Minimum ERC PercentageVelocity Percent

SCC06 N43:62 1000 Minimum ERC PercentagePressure Percent

SCC08 N43:64 0 Profile Watchdog Timer Preset Time

SCC09 N43:65 * Output #1 SetOutput Value during Profile Percent Signal Output

SCC10 N43:66 * Output #2 SetOutput Value during Profile Percent Signal Output

SCC11 N43:67 * Output #3 SetOutput Value during Profile Percent Signal Output

SCC12 N43:68 * Output #4 SetOutput Value during Profile Percent Signal Output

SCC17 N43:73 0 Output #1 Acceleration Ramp Rate during Profile Percent Signal Output per Second

SCC18 N43:74 0 Output #2 Acceleration Ramp Rate during Profile Percent Signal Output per Second

SCC19 N43:75 0 Output #3 Acceleration Ramp Rate during Profile Percent Signal Output per Second

SCC20 N43:76 0 Output #4 Acceleration Ramp Rate during Profile Percent Signal Output per Second

SCC25 N43:81 0 Output #1 Deceleration Ramp Rate during Profile Percent Signal Output per Second

SCC26 N43:82 0 Output #2 Deceleration Ramp Rate during Profile Percent Signal Output per Second

SCC27 N43:83 0 Output #3 Deceleration Ramp Rate during Profile Percent Signal Output per Second

SCC28 N43:84 0 Output #4 Deceleration Ramp Rate during Profile Percent Signal Output per Second

SCC33 N43:89 * Output #1 SetOutput Value at Endof Profile Percent Signal Output

SCC34 N43:90 * Output #2 SetOutput Value at Endof Profile Percent Signal Output

SCC35 N43:91 * Output #3 SetOutput Value at Endof Profile Percent Signal Output

SCC36 N43:92 * Output #4 SetOutput Value at Endof Profile Percent Signal Output

SCC41 N43:97 0 Pressure Minimum Control Limit Pressure

SCC42 N43:98 * Pressure Maximum Control Limit Pressure

SCC43 N43:99 * Selected Pressure Valve, Output for Minimum Percent Signal Output

SCC44 N43:100 * Selected Pressure Valve, Output for Maximum Percent Signal Output

SCC45 N43:101 0 Velocity Minimum Control Limit Velocity along Axis

SCC46 N43:102 * Velocity Maximum Control Limit Velocity along Axis

SCC47 N43:103 * Selected Velocity Valve, Output for Minimum Percent Signal Output

SCC48 N43:104 * Selected Velocity Valve, Output for Maximum Percent Signal Output

SCC49 N43:105 100 Proportional Gain for Pressure Control None

SCC50 N43:106 400 Integral Gain for Pressure Control Inverse Time (Algorithm)

SCC51 N43:107 0 Derivative Gain for Pressure Control Time (Algorithm)

SCC52 N43:108 200 Proportional Gain for Velocity Control Inverse Time (Algorithm)

SCC53 N43:109 0 Feed Forward Gain for Velocity Control None

SCC57 N43:113 0 Profile High Pressure Alarm Setpoint Pressure

1

Time

00.00 to 99.99 Seconds 00.00 to 99.99 Inches per Second 0000 to 9999 PSI

5

Percent Signal Output per Second
0000 to 9999 00.00 to 99.99 Minutes (ISA) 00.00 to 99.99 Minutes (ISA)

2

Velocity along Axis

000.0 to 999.9 Millimeters per Second

6

Inverse T

ime (Algorithm)

00.00 to 99.99 Seconds (AB) 00.00 to 99.99 Seconds (AB)

3

Pressure

000.0 to 999.9 Bar

7

T

ime (Algorithm)

8

8

1

3

3

3

4

Percent Signal Output

00.00 to 99.99

8

Percent

00.00 to 99.99

4

4

4

4

4

4

4

4

4

4

2

2

4

4

6

7

6

5

5

5

5

5

5

5

5

*

Refer to the appropriate section later in this chapter for information on this parameter

7-7

Chapter 7

Load Initial Configuration Values

Worksheet 7C
Third Clamp Close Configuration Block (TCC)

Control W

ProSet 600 Addr. B37/bit

ord TCC01Bxx

15 14 13 12 11 10 09 08 07 06 05 04 03 02 01 00

143 142 141 140 139 138 137 136 135 134 133 132 131 130 129 128

Value 0 0 0 0 0 0 0 0 0 0 0 0 0 1 0 1

TCC

Block Identifier

Control W

ProSet 600 Addr. B37/bit

ord TCC02Bxx

15 14 13 12 11 10 09 08 07 06 05 04 03 02 01 00

159 158 157 156 155 154 153 152 151 150 149 148 147 146 145 144

Value 0 0 0 0 0 0 0 0 1 0

Code:

0

or 1

Your

value

Required initial value
loaded by ProSet 600

Selected
Pressure Valve

000 = Output 1
001 = Output 2
010 = Output 3
011 = Output 4

Selected
Velocity Valve

000 = Output 1
001 = Output 2
010 = Output 3
011 = Output 4

7-8

PID Pressure Algorithm
0 = Dependent Gains

1 = Independent Gains

Chapter 7

Load Initial Configuration Values

Worksheet 7C

(continued)

Third Clamp Close Configuration Block (TCC)

Enter Y

our V

alues Here

Control Word ProSet 600 Addr. Value Description Units

TCC05 N43:121 1000 Minimum ERC PercentageVelocity Percent

TCC06 N43:122 1000 Minimum ERC PercentagePressure Percent

TCC08 N43:124 0 Profile Watchdog Timer Preset Time

TCC09 N43:125 * Output #1 SetOutput Value during Profile Percent Signal Output

TCC10 N43:126 * Output #2 SetOutput Value during Profile Percent Signal Output

TCC11 N43:127 * Output #3 SetOutput Value during Profile Percent Signal Output

TCC12 N43:128 * Output #4 SetOutput Value during Profile Percent Signal Output

TCC17 N43:133 0 Output #1 Acceleration Ramp Rate during Profile Percent Signal Output per Second

TCC18 N43:134 0 Output #2 Acceleration Ramp Rate during Profile Percent Signal Output per Second

TCC19 N43:135 0 Output #3 Acceleration Ramp Rate during Profile Percent Signal Output per Second

TCC20 N43:136 0 Output #4 Acceleration Ramp Rate during Profile Percent Signal Output per Second

TCC25 N43:141 0 Output #1 Deceleration Ramp Rate during Profile Percent Signal Output per Second

TCC26 N43:142 0 Output #2 Deceleration Ramp Rate during Profile Percent Signal Output per Second

TCC27 N43:143 0 Output #3 Deceleration Ramp Rate during Profile Percent Signal Output per Second

TCC28 N43:144 0 Output #4 Deceleration Ramp Rate during Profile Percent Signal Output per Second

TCC33 N43:149 * Output #1 SetOutput Value at Endof Profile Percent Signal Output

TCC34 N43:150 * Output #2 SetOutput Value at Endof Profile Percent Signal Output

TCC35 N43:151 * Output #3 SetOutput Value at Endof Profile Percent Signal Output

TCC36 N43:152 * Output #4 SetOutput Value at Endof Profile Percent Signal Output

TCC41 N43:157 0 Pressure Minimum Control Limit Pressure

TCC42 N43:158 * Pressure Maximum Control Limit Pressure

TCC43 N43:159 * Selected Pressure Valve, Output for Minimum Percent Signal Output

TCC44 N43:160 * Selected Pressure Valve, Output for Maximum Percent Signal Output

TCC45 N43:161 0 Velocity Minimum Control Limit Velocity along Axis

TCC46 N43:162 * Velocity Maximum Control Limit Velocity along Axis

TCC47 N43:163 * Selected Velocity Valve, Output for Minimum Percent Signal Output

TCC48 N43:164 * Selected Velocity Valve, Output for Maximum Percent Signal Output

TCC49 N43:165 100 Proportional Gain for Pressure Control None

TCC50 N43:166 400 Integral Gain for Pressure Control Inverse Time (Algorithm)

TCC51 N43:167 0 Derivative Gain for Pressure Control Time (Algorithm)

TCC52 N43:168 200 Proportional Gain for Velocity Control Inverse Time (Algorithm)

TCC53 N43:169 0 Feed Forward Gain for Velocity Control None

TCC57 N43:173 0 Profile High Pressure Alarm Setpoint Pressure

1

Time

00.00 to 99.99 Seconds 00.00 to 99.99 Inches per Second 0000 to 9999 PSI

5

Percent Signal Output per Second
0000 to 9999 00.00 to 99.99 Minutes (ISA) 00.00 to 99.99 Minutes (ISA)

2

Velocity along Axis

000.0 to 999.9 Millimeters per Second

6

Inverse T

ime (Algorithm)

00.00 to 99.99 Seconds (AB) 00.00 to 99.99 Seconds (AB)

3

Pressure

000.0 to 999.9 Bar

7

T

ime (Algorithm)

8

8

1

3

3

3

4

Percent Signal Output

00.00 to 99.99

8

Percent

00.00 to 99.99

4

4

4

4

4

4

4

4

4

4

2

2

4

4

6

7

6

5

5

5

5

5

5

5

5

*

Refer to the appropriate section later in this chapter for information on this parameter

7-9

Chapter 7

Load Initial Configuration Values

Worksheet 7D
Clamp Low Pressure Close Configuration Block (LPC)

Control Word LPC01Bxx

ProSet 600 Addr. B37/bit

15 14 13 12 11 10 09 08 07 06 05 04 03 02 01 00

207 206 205 204 203 202 201 200 199 198 197 196 195 194 193 192

Value 0 0 0 0 0 0 0 0 0 0 0 0 0 1 1 0

LPC

Block Identifier

Control Word LPC02Bxx

ProSet 600 Addr. B37/bit

15 14 13 12 11 10 09 08 07 06 05 04 03 02 01 00

223 222 221 220 219 218 217 216 215 214 213 212 211 210 209 208

Value 0 0 0 0 0 0 0 0 1 0 0 0 0

Code:

0

or 1

Your

value

Required initial value
loaded by ProSet 600

Selected
Pressure Valve

000 = Output 1
001 = Output 2
010 = Output 3
011 = Output 4

7-10

PID Pressure Algorithm
0 = Dependent Gains

1 = Independent Gains

Chapter 7

Load Initial Configuration Values

Worksheet 7D

(continued)

Clamp Low Pressure Close Configuration Block (LPC)

Enter Y

our V

alues Here

Control Word ProSet 600 Addr. Value Description Units

LPC06 N43:182 1000 Minimum ERC PercentagePressure Percent

LPC07 N43:183 0 Tonnage Watchdog Timer Preset Time

LPC08 N43:184 0 Profile Watchdog Timer Preset Time

LPC09 N43:185 * Output #1 SetOutput Value during Profile Percent Signal Output

LPC10 N43:186 * Output #2 SetOutput Value during Profile Percent Signal Output

LPC11 N43:187 * Output #3 SetOutput Value during Profile Percent Signal Output

LPC12 N43:188 * Output #4 SetOutput Value during Profile Percent Signal Output

LPC17 N43:193 0 Output #1 Acceleration Ramp Rate during Profile Percent Signal Output per Second

LPC18 N43:194 0 Output #2 Acceleration Ramp Rate during Profile Percent Signal Output per Second

LPC19 N43:195 0 Output #3 Acceleration Ramp Rate during Profile Percent Signal Output per Second

LPC20 N43:196 0 Output #4 Acceleration Ramp Rate during Profile Percent Signal Output per Second

LPC25 N43:201 0 Output #1 Deceleration Ramp Rate during Profile Percent Signal Output per Second

LPC26 N43:202 0 Output #2 Deceleration Ramp Rate during Profile Percent Signal Output per Second

LPC27 N43:203 0 Output #3 Deceleration Ramp Rate during Profile Percent Signal Output per Second

LPC28 N43:204 0 Output #4 Deceleration Ramp Rate during Profile Percent Signal Output per Second

LPC33 N43:209 * Output #1 SetOutput Value at Endof Profile Percent Signal Output

LPC34 N43:210 * Output #2 SetOutput Value at Endof Profile Percent Signal Output

LPC35 N43:211 * Output #3 SetOutput Value at Endof Profile Percent Signal Output

LPC36 N43:212 * Output #4 SetOutput Value at Endof Profile Percent Signal Output

LPC41 N43:217 0 Pressure Minimum Control Limit Pressure

LPC42 N43:218 * Pressure Maximum Control Limit Pressure

LPC43 N43:219 * Selected Pressure Valve, Output for Minimum Percent Signal Output

LPC44 N43:220 * Selected Pressure Valve, Output for Maximum Percent Signal Output

LPC49 N43:225 100 Proportional Gain for Pressure Control None

LPC50 N43:226 400 Integral Gain for Pressure Control Inverse Time (Algorithm)

LPC51 N43:227 0 Derivative Gain for Pressure Control Time (Algorithm)

LPC57 N43:233 0 Profile High Pressure Alarm Setpoint Pressure

1

Time

00.00 to 99.99 Seconds

5

Inverse T

ime (Algorithm)

00.00 to 99.99 Minutes (ISA) 00.00 to 99.99 Minutes (ISA)

00.00 to 99.99 Seconds (AB) 00.00 to 99.99 Seconds (AB)

2

Pressure
0000 to 9999 PSI

000.0 to 999.9 Bar

6

T

ime (Algorithm)

3

Percent

Signal Output

00.00 to 99.99

7

Percent

00.00 to 99.99

7

1

1

3

3

3

3

3

3

3

3

2

2

3

3

5

6

2

4

Percent Signal Output per Second
0000 to 9999

4

4

4

4

4

4

4

4

*

Refer to the appropriate section later in this chapter for information on this parameter

7-11

Chapter 7

Load Initial Configuration Values

Worksheet 7E
Injection Configuration Block (INC)

Control W

ProSet 600 Addr. B38/bit

ord INC01Bxx

15 14 13 12 11 10 09 08 07 06 05 04 03 02 01 00

15 14 13 12 11 10 09 08 07 06 05 04 03 02 01 00

Value 0 0 0 0 0 0 0 0 0 0 0 0 1 0 0 0

INC

Block Identifier

Control W

ProSet 600 Addr. B38/bit

ord INC02Bxx

15 14 13 12 11 10 09 08 07 06 05 04 03 02 01 00

31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16

Value 0 0 0 0 0 0 0 0 1 0

Code:

0

or 1

Your

value

Required initial value
loaded by ProSet 600

Selected
Pressure Valve

000 = Output 1
001 = Output 2
010 = Output 3
011 = Output 4

Selected
Velocity Valve

000 = Output 1
001 = Output 2
010 = Output 3
011 = Output 4

7-12

PID Pressure Algorithm

0 = Dependent Gains
1 = Independent Gains

Chapter 7

Load Initial Configuration Values

Worksheet 7E(continued)

Enter Y

our V

alues Here

Control Word ProSet 600 Addr. Value Description Units

INC05 N44:1 1000 Minimum ERC PercentageVelocity Percent

INC06 N44:2 1000 Minimum ERC PercentagePressure Percent

INC09 N44:5 * Output #1 Setoutput Value During Profile Percent Signal Output

INC10 N44:6 * Output #2 Setoutput Value During Profile Percent Signal Output

INC11 N44:7 * Output #3 Setoutput Value During Profile Percent Signal Output

INC12 N44:8 * Output #4 Setoutput Value During Profile Percent Signal Output

INC17 N44:13 0 Output #1 Acceleration Ramp Rate During Profile Percent Signal Output per Second

INC18 N44:14 0 Output #2 Acceleration Ramp Rate During Profile Percent Signal Output per Second

INC19 N44:15 0 Output #3 Acceleration Ramp Rate During Profile Percent Signal Output per Second

INC20 N44:16 0 Output #4 Acceleration Ramp Rate During Profile Percent Signal Output per Second

INC25 N44:21 0 Output #1 Deceleration Ramp Rate During Profile Percent Signal Output per Second

INC26 N44:22 0 Output #2 Deceleration Ramp Rate During Profile Percent Signal Output per Second

INC27 N44:23 0 Output #3 Deceleration Ramp Rate During Profile Percent Signal Output per Second

INC28 N44:24 0 Output #4 Deceleration Ramp Rate During Profile Percent Signal Output per Second

INC41 N44:37 0 Pressure Minimum Control Limit Pressure

INC42 N44:38 * Pressure Maximum Control Limit Pressure

INC43 N44:39 * Selected Pressure Valve, Output for Minimum Percent Signal Output

INC44 N44:40 * Selected Pressure Valve, Output for Maximum Percent Signal Output

INC45 N44:41 0 Velocity Minimum Control Limit Velocity along Axis

INC46 N44:42 * Velocity Maximum Control Limit Velocity along Axis

INC47 N44:43 * Selected Velocity Valve, Output for Minimum Percent Signal Output

INC48 N44:44 * Selected Velocity Valve, Output for Maximum Percent Signal Output

INC49 N44:45 100 Proportional Gain for Pressure Control None

INC50 N44:46 400 Integral Gain for Pressure Control Inverse Time (Algorithm)

INC51 N44:47 0 Derivative Gain for Pressure Control Time (Algorithm)

INC52 N44:48 200 Proportional Gain for Velocity Control Inverse Time (Algorithm)

INC53 N44:49 0 Feed Forward Gain for Velocity Control None

INC57 N44:53 0 Profile High Pressure Alarm Setpoint Pressure

2

Velocity along Axis

00.00 to 99.99 inches per second

000.0 to 999.9 millimeters per second

5

Percent Signal Output per Second
0000 to 9999

Injection Configuration Block (INC)

3

Pressure
0000 to 9999 PSI

000.0 to 999.9 Bar

6

Inverse T

ime (Algorithm)

00.00 to 99.99 Minutes (ISA) 00.00 to 99.99 Minutes (ISA)

00.00 to 99.99 Seconds (AB) 00.00 to 99.99 Seconds (AB)

4

Percent Signal Output

00.00 to 99.99

7

T

ime (Algorithm)

8

8

3

3

3

8

4

4

4

4

4

4

2

2

4

4

6

7

6

Percent

00.00 to 99.99

5

5

5

5

5

5

5

5

*

Refer to the appropriate section later in this chapter for information on this parameter

7-13

Chapter 7

Load Initial Configuration Values

Worksheet 7F
Pack Configuration Block (PKC)

Control W

ProSet 600 Addr. B38/bit

ord PKC01Bxx

15 14 13 12 11 10 09 08 07 06 05 04 03 02 01 00

143 142 141 140 139 138 137 136 135 134 133 132 131 130 129 128

Value 0 0 0 0 0 0 0 0 0 0 0 0 1 0 1 0

PKC

Block Identifier

Control Word PKC02Bxx

ProSet 600 Addr. B38/bit

15 14 13 12 11 10 09 08 07 06 05 04 03 02 01 00

159 158 157 156 155 154 153 152 151 150 149 148 147 146 145 144

Value 0 0 0 0 0 0 0 0 1 0 0 0 0

Code:

0

or 1

Your

value

Required initial value
loaded by ProSet 600

PID Pressure Algorithm

0 = Dependent Gains
1 = Independent Gains

Selected
Pressure Valve

000 = Output 1
001 = Output 2
010 = Output 3
011 = Output 4

7-14

Chapter 7

Load Initial Configuration Values

Worksheet 7F

(continued)

Pack Configuration Block (PKC)

Enter Y

our V

alues Here

Control Word ProSet 600 Addr. Value Description Units

PKC06 N44:122 1000 Minimum ERC PercentagePressure Percent

PKC09 N44:125 * Output #1 Setoutput Value During Profile Percent Signal Output

PKC10 N44:126 * Output #2 Setoutput Value During Profile Percent Signal Output

PKC11 N44:127 * Output #3 Setoutput Value During Profile Percent Signal Output

PKC12 N44:128 * Output #4 Setoutput Value During Profile Percent Signal Output

PKC17 N44:133 0 Output #1 Acceleration Ramp Rate During Profile Percent Signal Output per Second

PKC18 N44:134 0 Output #2 Acceleration Ramp Rate During Profile Percent Signal Output per Second

PKC19 N44:135 0 Output #3 Acceleration Ramp Rate During Profile Percent Signal Output per Second

PKC20 N44:136 0 Output #4 Acceleration Ramp Rate During Profile Percent Signal Output per Second

PKC25 N44:141 0 Output #1 Deceleration Ramp Rate During Profile Percent Signal Output per Second

PKC26 N44:142 0 Output #2 Deceleration Ramp Rate During Profile Percent Signal Output per Second

8

4

4

4

4

5

5

5

5

5

5

PKC27 N44:143 0 Output #3 Deceleration Ramp Rate During Profile Percent Signal Output per Second

PKC28 N44:144 0 Output #4 Deceleration Ramp Rate During Profile Percent Signal Output per Second

PKC41 N44:157 0 Pressure Minimum Control Limit Pressure

PKC42 N44:158 * Pressure Maximum Control Limit Pressure

PKC43 N44:159 * Selected Pressure Valve, Output for Minimum Percent Signal Output

PKC44 N44:160 * Selected Pressure Valve, Output for Maximum Percent Signal Output

5

5

3

3

4

4

PKC49 N44:165 100 Proportional Gain for Pressure Control None

PKC50 N44:166 400 Integral Gain for Pressure Control Inverse Time (Algorithm)

PKC51 N44:167 0 Derivative Gain for Pressure Control Time (Algorithm)

PKC57 N44:173 0 Profile High Pressure Alarm Setpoint Pressure

3

Pressure
0000 to 9999 PSI

000.0 to 999.9 Bar

5

Percent Signal Output per Second
0000 to 9999

*

Refer to the appropriate section later in this chapter for information on this parameter

4

Percent

Signal Output

00.00 to 99.99

6

Inverse T

ime (Algorithm)

00.00 to 99.99 Minutes (ISA)

00.00 to 99.99 Seconds (AB) 00.00 to 99.99 Seconds (AB)

7

T

ime (Algorithm)

00.00 to 99.99 Minutes (ISA)

3

8

Percent

00.00 to 99.99

6

7

7-15

Chapter 7

Load Initial Configuration Values

Worksheet 7G
Hold Configuration Block (HDC)

Control W

ProSet 600 Addr. B38/bit

ord HDC01Bxx

15 14 13 12 11 10 09 08 07 06 05 04 03 02 01 00

207 206 205 204 203 202 201 200 199 198 197 196 195 194 193 192

Value 0 0 0 0 0 0 0 0 0 0 0 0 1 0 1 1

HDC

Block Identifier

Control W

ProSet 600 Addr. B38/bit

ord HDC02Bxx

15 14 13 12 11 10 09 08 07 06 05 04 03 02 01 00

223 222 221 220 219 218 217 216 215 214 213 212 211 210 209 208

Value 0 0 0 0 0 0 0 0 1 0 0 0 0

Code:

0

or 1

Your

value

Required initial value
loaded by ProSet 600

Selected
Pressure Valve

000 = Output 1
001 = Output 2
010 = Output 3
011 = Output 4

PID Pressure Algorithm
0 = Dependent Gains

1 = Independent Gains

7-16

Chapter 7

Load Initial Configuration Values

Worksheet 7G

(continued)

Hold Configuration Block (HDC)

Enter Y

our V

alues Here

Control Word ProSet 600 Addr. Value Description Units

HDC06 N44:182 1000 Minimum ERC PercentagePressure Percent

HDC09 N44:185 * Output #1 Setoutput Value During Profile Percent Signal Output

HDC10 N44:186 * Output #2 Setoutput Value During Profile Percent Signal Output

HDC11 N44:187 * Output #3 Setoutput Value During Profile Percent Signal Output

HDC12 N44:188 * Output #4 Setoutput Value During Profile Percent Signal Output

HDC17 N44:193 0 Output #1 Acceleration Ramp Rate During Profile Percent Signal Output per Second

HDC18 N44:194 0 Output #2 Acceleration Ramp Rate During Profile Percent Signal Output per Second

HDC19 N44:195 0 Output #3 Acceleration Ramp Rate During Profile Percent Signal Output per Second

HDC20 N44:196 0 Output #4 Acceleration Ramp Rate During Profile Percent Signal Output per Second

HDC25 N44:201 0 Output #1 Deceleration Ramp Rate During Profile Percent Signal Output per Second

HDC26 N44:202 0 Output #2 Deceleration Ramp Rate During Profile Percent Signal Output per Second

HDC27 N44:203 0 Output #3 Deceleration Ramp Rate During Profile Percent Signal Output per Second

HDC28 N44:204 0 Output #4 Deceleration Ramp Rate During Profile Percent Signal Output per Second

HDC33 N44:209 * Output #1 Setoutput Value at Endof Profile Percent Signal Output

HDC34 N44:210 * Output #2 Setoutput Value at Endof Profile Percent Signal Output

HDC35 N44:211 * Output #3 Setoutput Value at Endof Profile Percent Signal Output

HDC36 N44:212 * Output #4 Setoutput Value at Endof Profile Percent Signal Output

HDC41 N44:217 0 Pressure Minimum Control Limit Pressure

HDC42 N44:218 * Pressure Maximum Control Limit Pressure

HDC43 N44:219 * Selected Pressure Valve, Output for Minimum Percent Signal Output

HDC44 N44:220 * Selected Pressure Valve, Output for Maximum Percent Signal Output

HDC49 N44:225 100 Proportional Gain for Pressure Control None

HDC50 N44:226 400 Integral Gain for Pressure Control Inverse Time (algorithm)

HDC51 N44:227 0 Derivative Gain for Pressure Control Time (algorithm)

HDC57 N44:233 0 Profile High Pressure Alarm Setpoint Pressure

3

Pressure
0000 to 9999 PSI

000.0 to 999.9 Bar

5

Percent Signal Output per Second
0000 to 9999

4

Percent

Signal Output

00.00 to 99.99

6

Inverse T

ime (Algorithm)

00.00 to 99.99 Minutes (ISA) 00.00 to 99.99 Minutes (ISA)

00.00 to 99.99 Seconds (AB) 00.00 to 99.99 Seconds (AB)

7

T

ime (Algorithm)

8

4

4

4

4

5

5

5

5

5

5

5

5

4

4

4

4

3

3

4

4

6

7

3

8

Percent

00.00 to 99.99

*

Refer to the appropriate section later in this chapter for information on this parameter

7-17

Chapter 7

Load Initial Configuration Values

Worksheet 7H
Plastication Configuration Block (PLC)

Control Word PLC01Bxx

ProSet 600 Addr. B38/bit

15 14 13 12 11 10 09 08 07 06 05 04 03 02 01 00

399 398 397 396 395 394 393 392 391 390 389 388 387 386 385 384

Value 0 0 0 0 0 0 0 0 0 0 0 0 1 1 1 0

PLC

Block Identifier

Control Word PLC02Bxx

ProSet 600 Addr. B38/bit

15 14 13 12 11 10 09 08 07 06 05 04 03 02 01 00

415 414 413 412 411 410 409 408 407 406 405 404 403 402 401 400

Value 0 0 0 0 0 0 0 0 1 0 0 0 0

Code:

0

or 1

Your

value

Required initial value
loaded by ProSet 600

Selected
Pressure Valve

000 = Output 1
001 = Output 2
010 = Output 3
011 = Output 4

7-18

PID Pressure Algorithm
0 = Dependent Gains

1 = Independent Gains

Chapter 7

Load Initial Configuration Values

Worksheet 7H

(continued)

Plastication Configuration Block (PLC)

Enter Y

our V

alues Here

Control Word ProSet 600 Addr. Value Description Units

PLC06 N44:362 1000 Minimum ERC PercentagePressure Percent

PLC08 N44:364 0 Profile Watchdog Timer Preset Time

PLC09 N44:365 * Output #1 Setoutput Value During Profile Percent Signal Output

PLC10 N44:366 * Output #2 Setoutput Value During Profile Percent Signal Output

PLC11 N44:367 * Output #3 Setoutput Value During Profile Percent Signal Output

PLC12 N44:368 * Output #4 Setoutput Value During Profile Percent Signal Output

PLC17 N44:373 0 Output #1 Acceleration Ramp Rate During Profile Percent Signal Output per Second

PLC18 N44:374 0 Output #2 Acceleration Ramp Rate During Profile Percent Signal Output per Second

PLC19 N44:375 0 Output #3 Acceleration Ramp Rate During Profile Percent Signal Output per Second

PLC20 N44:376 0 Output #4 Acceleration Ramp Rate During Profile Percent Signal Output per Second

PLC25 N44:381 0 Output #1 Deceleration Ramp Rate During Profile Percent Signal Output per Second

PLC26 N44:382 0 Output #2 Deceleration Ramp Rate During Profile Percent Signal Output per Second

PLC27 N44:383 0 Output #3 Deceleration Ramp Rate During Profile Percent Signal Output per Second

PLC28 N44:384 0 Output #4 Deceleration Ramp Rate During Profile Percent Signal Output per Second

PLC33 N44:389 * Output #1 Setoutput Value at Endof Profile Percent Signal Output

PLC34 N44:390 * Output #2 Setoutput Value at Endof Profile Percent Signal Output

PLC35 N44:391 * Output #3 Setoutput Value at Endof Profile Percent Signal Output

PLC36 N44:392 * Output #4 Setoutput Value at Endof Profile Percent Signal Output

PLC41 N44:397 0 Pressure Minimum Control Limit Pressure

PLC42 N44:398 * Pressure Maximum Control Limit Pressure

PLC43 N44:399 * Selected Pressure Valve, Output for Minimum Percent Signal Output

PLC44 N44:400 * Selected Pressure Valve, Output for Maximum Percent Signal Output

PLC49 N44:405 100 Proportional Gain for Pressure Control None

PLC50 N44:406 400 Integral Gain for Pressure Control Inverse Time (Algorithm)

PLC51 N44:407 0 Derivative Gain for Pressure Control Time (Algorithm)

PLC57 N44:413 0 Profile High Pressure Alarm Setpoint Pressure

1

Time

00.00 to 99.99 seconds

5

Percent Signal Output per Second
0000 to 9999

3

Pressure
0000 to 9999 PSI

000.0 to 999.9 Bar

6

Inverse T

ime (Algorithm)

00.00 to 99.99 Minutes (ISA) 00.00 to 99.99 Minutes (ISA)

00.00 to 99.99 Seconds (AB) 00.00 to 99.99 Seconds (AB)

4

Percent

00.00 to 99.99

7

T

ime (Algorithm)

Signal Output

8

1

3

3

3

8

Percent

00.00 to 99.99

4

4

4

4

4

4

4

4

4

4

6

7

5

5

5

5

5

5

5

5

*

Refer to the appropriate section later in this chapter for information on this parameter

7-19