Rockwell Automation 1771-QDC, D17716.5.85 User Manual

Plastic Molding Module

(Cat. No. 1771-QDC)

Inject Mode

Important User Information

Because of the variety of uses for the products described in this publication, those responsible for the application and use of this control equipment must satisfy themselves that all necessary steps have been taken to assure that each application and use meets all performance and safety requirements, including any applicable laws, regulations, codes and standards.

The illustrations, charts, sample programs and layout examples shown in this guide are intended solely for purposes of example. Since there are many variables and requirements associated with any particular installation, Allen-Bradley does not assume responsibility or liability (to include intellectual property liability) for actual use based upon the examples shown in this publication.

Allen-Bradley publication SGI-1.1, Safety Guidelines for the Application, Installation, and Maintenance of Solid State Control (available from your local Allen-Bradley office), describes some important differences between solid-state equipment and electromechanical devices that should be taken into consideration when applying products such as those described in this publication.

Reproduction of the contents of this copyrighted publication, in whole or in part,

without written permission of Allen-Bradley Company, Inc. is prohibited.

Throughout this manual we use ATTENTION and Important to alert you to the following:

ATTENTION: Tells readers where people may be hurt, machinery may be damaged, or economic loss may 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 that you frequently back up your application programs on an appropriate storage medium to avoid possible data loss.

PLC is a registered trademark of Allen-Bradley Company, Inc. PanelView, and PanelBuider are trademarks of Allen-Bradley Company, Inc

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(s)

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

Added the section, Record I/O Ranges.

Added the title Ground and Shield Your I/O Devices to better describe the task.

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).

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

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

Minor corrections as found

35, 310 A3, A4

21

29

Chapters 3 and 4

To Help You Find Changes

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

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

Use This Preface P1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Manual

Objectives Audience P2 Use Related

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of T

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

Publications

Overview of Inject Mode 11. . . . . . . . . . . . . . . . . . . . . . . . . .

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

P4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Chapter Inject Mode Operation 11

Objectives

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

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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 Use Worksheets to Select Module Parameters and I/O Ranges 31 Determine Initial Sensorconfiguration Values 34 Download Use SetOutput Operation to Move the Ram (Screw) 38 Complete Your Sensor Configuration 39 Select

Objectives

I/O Ranges

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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5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

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

36. . . . . . . . . . . . . . . . .

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) 57 Configure Jogs for the Clamp and Ejector 57 Write Ladder Logic to Assist with Clamp & Eject Jogs 59 Jog Your Clamp and Ejector 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

Load

Chapter Use These Worksheets 72 Procedure Determine

Select the T Set Values for Expert Response CompensationE (ERC) 715 Determine Unselected Valve Setoutput Values 715 Set Your Acceleration/Deceleration Ramp Rates 717 Determine Setoutput Values for End of Profiles 718 Set Pressure Control Limits 719 Set V Set Set

Enter and Download your Worksheet Values 726

Objectives

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Command and Status Bit T

Initial Configuration V

Objectives

to Determine and Enter Initial V

Bit Selections: Assign Module Outputs

for Your Control Valves 712. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ype of PID Algorithm

elocity Control Limits RPM Control Limits Profile T

and Watchdog Timer Preset 725

uning Constants, PressureAlarm Setpoints,

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

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

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alues 712. . . . . . . . . . . . . .

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

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

714. . . . . . . . . . . . . . . . . . . . . . . . .

722. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

723. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Load

Initial Profile V

Chapter Use These Worksheets 81 Determine and Record Setpoints for the Injection Profile (IPC) 82 Determine Bit Selections for Worksheet 8A 84 Determine Word Values for Worksheet 8A 85 Enter and Download your Worksheet Values 89 Determine and Record Setpoints for the Pack/Hold Profile (HPC) 89 Determine Bit Selections for Worksheet 8B 812

Objectives

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

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

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Table of Contents iii

Determine Word Values for Worksheet 8B 814. . . . . . . . . . . . . . . . . .

Enter and Download your Worksheet Values 815 Determine and Record Setpoints for Plastication Profile (PPC) 816 Determine Bit Selections for Worksheet 8C 818 Determine Word Values for Worksheet 8C 819 Enter and Download your Worksheet Values 822

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Span Your V

Chapter Referenced Worksheets 91 Span Your Injection Pressure Valve 92 Span Your Injection V Span Your Pack and Hold Pressure Valves 913 Span Your Plastication Pressure Valve 920 Span Y

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

Objectives

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elocity V

our Plastication RPM V

alve 97. . . . . . . . . . . . . . . . . . . . . . . .

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alve 925. . . . . . . . . . . . . . . . . . . . . . . .

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

Tune Your Machine for Producing Parts 101. . . . . . . . . . . . . . .

Chapter Closedloop Control 102 Tune Closedloop Pressure Control 102 Tune Closedloop V Tuning Considerations for Production Parts 108 Profile Requirements 108 Cushion, Shot Size, and T Unselected Valve Setoutput Values 1013 Logical Bridges and Endofprofile Setoutput Values 1015 Decompression Pullback 1016 Acceleration and Deceleration Ramp Rates 1016 Watchdog T Pressure Pressurelimited Expert Response Compensation 1021

Objectives

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elocity Control

imer and Profile Of

Alarm Setpoints

Injection V

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ransition Setpoints

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fsets 1018. . . . . . . . . . . . . . . . . . . . . . .

elocity vs. Position

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

105. . . . . . . . . . . . . . . . . . . . . . . .

1011. . . . . . . . . . . . . . . .

1018. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1019. . . . . . . . . . . . . . .

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2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Use This Preface

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 the minimum 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

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

Overview the inject process. This presents an overview on how the QDC module controls the inject phase of your injection molding system.

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

Configure the QDC module mode to match your specific application, and to communicate with inputs and outputs.

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

Jog the ram (screw). This task requires jog setpoints to be configured along with jog pressure alarm setpoints.

Set up communications between your PLC5 processor and the QDC module. Select command and status bits that you will use when writing your ladder logic.

Load your initial configuration values to the QDC module. This task requires you to determine and enter values into configuration blocks in preparation for chapter 9.

Load your initial machine profile setpoints to the QDC module. This is performed in preparation for chapter 9.

Span your machine's valves for inject mode. This is done using setoutput and openloop control.

Tune your machine for producing parts. Chapter 10

Troubleshoot problems that may occur with the QDC module. Chapter 11

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

chapter:

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

In order to apply the QDC module to a molding machine, we assume that you are an:

injection molding professional experienced programmer with Allen-Bradley PLC-5 processors hydraulics designer or technician

We use these abbreviations:

Abbreviated Name: Item

QDC module 1771QDC Plastic Molding Module

PLC processor

T45 or T47 T50 or T53 terminal

ProSet 600 Software

PanelView Terminal

PLC5 Processor

1784T45 or T47 1784T50 or T53 Industrial Terminal

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

2711KC1 PanelView Operator Interface Terminal

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 module's algorithms the selected valve.

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

module controls one valve and presets 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 Blocks

Status Blocks Data blocks used by the QDC module to relay information to the

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

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

Data blocks downloaded from the PLC5 data table to the QDC module to make configuration changes or to initiate machine actions.

PLC5 processor about the QDC module's current operating status.

with increasing signal input.

with decreasing signal input.

P-2

Preface

Command Blocks

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

Acronym: Description:

MCC Module Configuration Block

JGC Jog Configuration 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

DYC Dynamic Command Block

RLC

Inject ERC Values Command Block

Status Blocks

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

Acronym: Description:

SYS System Status Block

IPS Injection Profile Status Block

HPS Pack/Hold Profile Status Block

PPS Plastication Profile Status Block

RLS

Inject ERC Values Status Block

P-3

Preface

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)

Publications

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

Publication

17856.6.1 PLC5 Family Programmable

6200N8.001 6200 PLC5 Programming

17714.10 Application guide Select QDC module's mode of operation and

17716.5.86 17716.5.87 17716.5.93

17716.5.88 Plastic Molding Module

Use this documentation: To:

Controller Installation Manual

Software Documentation Set

Plastic Molding Module, 1771QDC, User Manuals

1771QDC, Reference Manual

Install the PLC processor and I/O modules.

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

match it to your machine's hydraulics

Configure, program, install, and operate your QDC module in other QDC modes of operation

Program block transfers between PLC processor and QDC. Also, information on PLC5 data transfer logic.

P-4

Preface

Take time now to familiarize yourself with the Reference Manual, publication 1771-6.5.88. The five sections, in brief, include:

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, mechanical, electrical, and environmental specifications

about your module

instructions to help you calibrate your QDC module

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

Publication

65006.5.11 ProSet 600 Software

65006.5.12 ProSet 600 Software

65006.5.13 ProSet 600 Software

65006.5.14 ProSet 600 Software

65006.5.15 ProSet 600 Software

Use this documentation: To:

Designer's Guide

Assembly Manual

Overlay Installation Manual

Customization Manual

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 to your hard drive. Add overlays into your PLC5 and PanelView application files.

Install ProSet 600 overlays into your application files to obtain desired features.

Customize your ProSet 600 application to your machinecontrol requirements.

Support customizing your software control system.

P-5

Chapter

Overview of Inject Mode

Chapter

Objectives

Inject Mode Operation

Inject Phase Description

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

This chapter presents an overview of the 1771-QDC Plastic Molding Module in the Inject mode. We present a summary of Inject 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 as your QDC module’s mode of operation.

The Inject mode controls the following actions of your molding machine:

Shoots hot plastic into the mold Packs and holds the plastic until cured Reloads for the next shot

When you select the Inject mode, you can use the following phases:

Table 1.A

of Inject Mode

Phases

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)

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

Pre-decompression (optional)

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

Post-decompression (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.

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

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 referred to as sprue break.

action of the rotating ram (screw) grinds and melts the beads. The longer it grinds, the hotter it melts. You can vary the screw RPM or 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.

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

1-1

Chapter 1

Overview of Inject Mode

Figure 1.1

Operation of a T

Inject

ypical Machine Cycle

Clamp & Eject Operation

Injection Pack Hold

Post- PreDecompression Decompression

Transition to Pack or Hold

Plastication

(Reload)

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

1-2

11 10 9

Figure 1.2 Example

Injection Profile

87654321

Position or T

ime

Velocity or Pressure

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.

Chapter 1

Overview of Inject Mode

With this Profile

Velocity vs. Position Speed Length of the shot

Pressure-limited [1] Velocity vs. Position

Pressure vs. Position Pressure Length of the shot

Pressure vs. Time Pressure Time for a shot

You Control Injection With up to 11 Segments

Speed, with a maximum pressure

Distributed over the

Length of the shot

[1] Pressure-limited velocity vs. position profile differs from the velocity vs. position profile as follows: During any segment of a pressure-limited profile 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.

Example Benefits of Profiling an Injection Phase

The injection phase should force the melt through the mold as fast as possible without flashing 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 melt enters 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).

Figure 1.3 Velocity

Mold Cavity

Flow into mold

Example

Gate

Mold End

Injection

Sequence of execution

Profile

Position

Velocity

Back Point

1-3

Chapter 1

Overview of Inject 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 (part 2) 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. Segment pressures in part 4 are optimum for the velocity vs. position profile in part 3.

Figure 1.4

Prevention Example

Flash

1. Initial Velocity Profile

Velocity

2. Resulting Pressure Profile

Flash Point

Pressure

Position Position

3. Final Velocity Profile

Velocity

b ca

Position

4. Resulting Pressure Profile

Position

cbca

Flash Point

Pressure

As an option, you may select pressure-limited velocity vs. position injection control. With your pressure-limit setpoint below the flash point, the module switches to pressure control prior to flashing the mold.

1-4

Chapter 1

Overview of Inject 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 four events occurred:

Ram (screw) position exceeds a preset limit Ram (screw) pressure exceeds a preset limit Cavity 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 pressure transitions may or may not occur.

Pack Phase

The QDC module controls the pack phase with a pressure vs. time profile. You create the profile based on controlling hydraulic pressure against the ram (screw), or by controlling pressure within the mold cavity resulting from hydraulic pressure against the ram (screw). You can control either pressure with up to five time 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

Time

123

1-5

Chapter 1

Overview of Inject Mode

Lower density (last zone filled)

Example Benefits 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

Higher density (gate zone, greater pressure)

Pack Profile

Pressure

Gate

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

Time

Pack Profile

234

Time

Pressure

234

1-6

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

Chapter 1

Overview of Inject Mode

Hold Phase

The QDC module controls the hold phase with a pressure vs. time profile. You create the profile based on controlling hydraulic pressure against the ram (screw), or by controlling pressure within the mold cavity resulting from hydraulic pressure against the ram (screw). You can control either pressure with up to five time segments. You determine the pressure setpoints and time durations for the hold profile based on your 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 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 program to continue.

Plastication Phase

The plastication phase lets you achieve a melt temperature gradient in the barrel containing the ram (screw). To do this, you can create the plastication profile with up to 11 segments of position or time (figure 1.8).

You chose from four plastication profiles:

Backpressure vs. position Backpressure vs. time Screw RPM vs. position Screw RPM vs. time

1-7

Chapter 1

Overview of Inject Mode

Figure 1.8 Plastication

Backpressure or Screw RPM

12 345

Mold End

Phase Example

hotter

Position or Time

Temperature Gradient

Barrel Containing the Melt

7891011

cooler

Back Point

Affects of Profiling a Plastication Phase

Backpressure and/or screw RPM have these affects on plastication:

The higher the backpressure (or screw RPM) during plastication, the

higher the resultant temperature of the melt.

You can accelerate the backup rate by reducing backpressure

(or increasing screw RPM).

You can increase resultant melt temperature by increasing backpressure

(or increasing screw RPM).

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 Post-decompression pull-back 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.

Screw Speed

Beginning with the 1771-QDC/C revision of the module, you can control and monitor screw RPM only when you have configured the QDC module for the singular Inject mode. None of the other mode combinations allow for connecting a screw RPM sensor to the QDC module.

1-8

Chapter

Install the QDC Module

Chapter

Objectives

Record I/O Ranges

This chapter guides you through the following installation procedures:

record I/O ranges set module jumpers key your I/O chassis install your QDC module wire I/O devices to your 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 (Screw RPM) 0 to 10 Vdc 1 to 5 Vdc 4 to 20 mA

Input 4 (Cavity 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

s Circuit Board

RIGHT

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 (Appendix G) Calibrate = right

Run = left [1]

E5 I/O Density Standard = top [1]

Do not use bottom position

E6 E7 E8 E9

E10 E14 E13 E17

E11 E12 E15 E16

[1] factoryset defaults

Input 1 (Screw position) Input 2 (Screw pressure) Input 3 (Screw RPM) Input 4 (Cavity pressure)

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

Voltage = right [1] Current = left

Current = top Voltage = bottom [1]

-10 to +10VDC = top 0 to +10VDC or 4 to 20mA = bottom [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 to 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 stopped or when a system reset occurs and all outputs are forced to 0% (i.e. 0% output equals –10Vdc).

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:

Output Voltage (Vdc)

-10

0 102030405060708090100

%Output Requested

2-4

Chapter 2

Install the QDC Module

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

Install the QDC Module

1771QDC

12676

Install your QDC module in an I/O chassis with these steps:

1. First, 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.

2-5

Chapter 2

Install the QDC Module

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 tracks on the top and bottom of the

slot that guides the module into position.

Important: Be aware that Pro-Set 600 expects your QDC module to be placed in slot 0 of I/O rack 0 when operating in inject mode. 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 a firm

and even pressure on the module to seat it properly.

Wire the QDC Module

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

5. Connect the wiring arm to the module.

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 (Figure 2.3 and Table 2.B).

2-6

Figure 2.3

iring and Grounding

I/O

Chapter 2

Install the QDC Module

Customer PS

–

Screw Position Sensor

–

Screw Pressure Sensor

–

Screw RPM Sensor

–

Cavity Pressure Sensor

–

Input 3

Input 4

Input 1

Input 2

–

Customer PS

–

Amplifier Valve 1

–

To Valve 1

–

Amplifier Valve 2

Amplifier Valve 3

–

To Valve 2

–

17 16 15 14 13 12

10 9

8 7

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

erminal Designations

I/O

Transducer I/O Designation Terminal

Screw position Input 1 (+)

(-)

Screw pressure Input 2 (+)

(-)

Input common 14

Screw RPM Input 3 (+)

(-)

Cavity 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

+12vdc input (18 thru 10) any mode

+12vdc output (09 thru 02) voltage mode

+24vdc output (09 thru 02) current mode

2-8

Chapter 2

Install the QDC Module

Ground and Shield

our I/O Devices

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 (or equivalent). For cable distances over 50 ft, use 18-gage cable such as Belden 8760 (or equivalent)

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

amplifier end, 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

18v

+15V

22M

10G

–

22M

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

Do not connect. Test purposes, only.

-15V

109103

2-9

Chapter 2

Install the QDC Module

Figure 2.5 Shielding

QDC Module Output

Singleended Outputs

Customer Valve Amplifier

–

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 (terminals 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 (E-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, shall de-energize 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 power distribution circuit. For ungrounded systems or for more information on grounding and wiring guidelines, refer to Allen-Bradley publication 1770-4.1, Programmable Controller Wiring and Grounding Guidelines.

2-11

Chapter 2

Install the QDC Module

Disconnect

Figure 2.6

PLC Power Distribution with Interlocks

Typical

L2 L3

Incoming AC

Use any number of E-Stop switches in Series

CRM

Input Device

1FU 2FU

3FU

Step-down Transformer

FUSE

Start

CRM

I/O Chassis

Power Supply

GND

** See WARNING for Interlock Wiring Instructions **

Output

Input

Device

Module Wiring Arm

Output Module

Wiring Arm

CRM

L2 L3

Back-Panel Ground Bus

Equipment Grounding Conductors

CRM

To Motor Starters

Enclosure Wall

Grounding Electrode Conductor to Grounding Electrode System

Connect When Applicable

User DC

Supply

+–

To DC I/O Devices

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.

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.

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

output circuits.

Reference the current NEC code and ANSI B151.1-1984 for wiring guidelines.

•

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

•

2-12

10907I

Chapter

Configure the QDC Module's I/O

Chapter

Objectives

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

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

minimum and maximum pressures, positions, and RPM

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) 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.

Use W

orksheets to 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

ProSet 600 Address:

Module Parameters MCC02 B34/528 Worksheet 3-A Input Range MCC03 B34/544 Worksheet 3-B Output Range MCC04 B34/560 Worksheet 3-C

Use this Worksheet:

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

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

Code:

or 1

ord MCC02Bxx

Your value

Required initial value loaded by ProSet 600

15 14 13 12

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

11 10

09 08 07 06 05 04 03 02 01 00

System Operation:

Inject Mode 0 0

Select Units 0 = English 1 = metric

Example: If you select Inject operation with English units:

MCC02 = 00000000 00001000

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.

3-2

Worksheet 3B Select Input Ranges for your Sensors

Chapter 3

Configure the QDC Module's I/O

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 (Cavity Pressure) Range Select Input 3 (Screw RPM) Range Select Input 2 (Screw Pressure) Range Select Input 1 (Screw Position) Range

Code:

Your value

or 1

Required initial value loaded by ProSet 600

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

MCC03 = 11111111 10101010.

Worksheet 3C

Output Ranges for your V

Select

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

alves

Control W

ProSet 600 B34/bit

ord MCC04Bxx

15 14 13 12

11 10

09 08 07 06 05 04 03 02 01 00

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

Value 1 1 1 1 1 1 1 1

Select Output 4 Range

Select Output 3 Range Select Output 2 Range

Select Output 1 Range

Code:

Your value

or 1

Required initial value loaded by ProSet 600

Example: If you select 0-10 vdc for all four output ranges,

MCC04 = 11111111 01010101.

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

Output Range

-10 to +10 vdc 0 0 0 to +10 vdc 0 1 4 to 20 mA 1 0 Not connected 1 1

3-3

Chapter 3

Configure the QDC Module's I/O

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.

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 16mA 01600

0  010.00 vdc 5.6 vdc 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:

Table 3.A Determine

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

Minimum Position (Line 1)

Maximum Position

(Line 2)

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

(Line 3) sensor is reverseacting high end of your selected range

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

(Line 4) sensor is reverseacting low end of your selected range

Minimum Pressure (Lines 5 and 13)

Maximum Pressure (Lines 6 and 14)

Initial Sensorconfiguration V

N/A zero

ram (screw) is fully extended to the mold end (ram bottom)

N/A minimum range value specified by the

N/A maximum range value specified by the

alues for W

full travel of the sensor

manufacturer

orksheet 3D

3-4

Chapter 3

Configure the QDC Module's I/O

Category:

If your: Then Use a Value Equal to:

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

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

Minimum Screw RPM (Line 9) N/A zero

Maximum Screw RPM (Line 10)

N/A max range value specified by

the manufacturer

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

(Line 11) sensors are reverseacting high end of your selected range

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

(Line 12) sensors are reverseacting low end of your selected range

Worksheet 3D Determine

Initial Sensorconfiguration V

alues

Enter Your Initial Values Here

Input Line Control

Word

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

3 9 MCC51 N40:47 0 Minimum Screw RPM Rotational Speed

10 MCC52 N40:48 Maximum Screw RPM Rotational Speed

11 MCC53 N40:49 Analog Signal @ Min Screw RPM Input Signal Range

12 MCC54 N40.50 Analog Signal @ Max Screw RPM Input Signal Range

4 13 MCC57 N40:53 0 Minimum Cavity Pressure Cavity Pressure

14 MCC58 N40:54 Maximum Cavity Pressure Cavity Pressure

15 MCC59 N40:55 Analog Signal @ Min Cavity Pressure Input Signal Range

16 MCC60 N40:56 Analog Signal @ Max Cavity Pressure Input Signal Range

Incremental Distance

00.00

to 99.99in

000.0 to 999.9mm

Rotational Speed

000.0 to 999.9 RPM

ProSet 600 Address

Value Description Units

Input Signal Range

00.00 to 10.00VDC or

01.00 to 05.00VDC or

04.00 to 20.00MADC

Pressure

00000 to 20,000 PSI

0000.0 to 2000.0 Bar

Pressure

0000 to 9999 PSI

000.0 to 999.9 Bar

3-5

Chapter 3

Configure the QDC Module's I/O

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.

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.

3-6

Chapter 3

Configure the QDC Module's I/O

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.

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

3-7

Chapter 3

Configure the QDC Module's I/O

Use SetOutput Operation to Move the Ram (Screw)

To finish configuring the QDC module, you actuate the ram (screw) with the QDC module’s set-output operation that applies percentage values to your QDC module’s outputs to move the ram (screw) 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 configured jumper E11, E12, E15, and/or E16 for bi-directional valve operation, an output of 0% gives –10vdc, 50% gives 0vdc (see chart). Amplifier electronics or spool-null offsets may also allow pressure or flow at zero signal input. Consult your valve and amplifier specifications.

8 6 4 2 0

-2

Output Voltage

-4

-6

-8

-10

0 102030405060708090100

3-8

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 - DYC12 (Pro-Set 600 words N40:121 - N40:124). 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.

Chapter 3

Configure the QDC Module's I/O

Actuate the Ram (screw) 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 (Pro-Set

600 address B34/392). The QDC module sets outputs 1 - 4 to percentage values that you entered in DYC09 - DYC12 respectively.

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

of one output as you observe the corresponding movement.

Complete Your Sensor Configuration

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:

screw position sensor values screw pressure sensor values cavity pressure sensor values screw RPM sensor values

In the procedures that follow, measure and record:

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

After determining these values from the procedures, write them down on Worksheet 4-E.

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

3-9

Chapter 3

Configure the QDC Module's I/O

Worksheet 3E Final Sensorconfiguration V

alues

Enter Your Final V

Input Line Control

Word

alues Here

ProSet 600 Address

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

3 9 MCC51 N40:47 0 Minimum Screw RPM Rotational Speed

10 MCC52 N40:48 Maximum Screw RPM Rotational Speed

11 MCC53 N40:49 Analog Signal @ Min Screw RPM Input Signal Range

12 MCC54 N40.50 Analog Signal @ Max Screw RPM Input Signal Range

4 13 MCC57 N40:53 0 Minimum Cavity Pressure Cavity Pressure

14 MCC58 N40:54 Maximum Cavity Pressure Cavity Pressure

15 MCC59 N40:55 Analog Signal @ Min Cavity Pressure Input Signal Range

16 MCC60 N40:56 Analog Signal @ Max Cavity Pressure Input Signal Range

Incremental Distance

00.00

to 99.99in

000.0 to 999.9mm

Rotational Speed

000.0 to 999.9 RPM

Input Signal Range

00.00 to 10.00VDC or

01.00 to 05.00VDC or

04.00 to 20.00MADC

Pressure

00000 to 20,000 PSI

0000.0 to 2000.0 Bar

Pressure

0000 to 9999 PSI

000.0 to 999.9 Bar

3-10

Chapter 3

Configure the QDC Module's I/O

Determine Values for the Ram (Screw) Position Sensor

ATTENTION: Incorrect values entered in DYC09 through DYC12 may result in rapid ram (screw) motion and potential damage to your barrel or seals of your injection cylinder.

To complete the configuration for your ram (screw) position sensor, do the following and enter the results on Worksheet 4-E:

Important: If your position sensor has zero and span potentiometers for setting the zero reference and linear resolution, do so during 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. Record this position value (normally 0000) on line 1 for MCC09 on

Worksheet 4-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 position 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.

3-11

Chapter 3

Configure the QDC Module's I/O

Determine Values for the Ram (Screw) Pressure Sensor

To complete the configuration for your ram (screw) pressure sensor, enter on Worksheet 4-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 4-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.

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.

3-12

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.

Chapter 3

Configure the QDC Module's I/O

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 Cavity Pressure Sensor (if used)

To complete the configuration for your cavity pressure sensor, enter in Worksheet 4-E minimum and maximum pressures and corresponding signal levels from manufacturer’s specifications in MCC57-60. Most applications require no further spanning.

Determine Values for the Screw RPM Sensor

To complete the configuration for your screw RPM sensor, enter in Worksheet 4-E on lines 9-12 (MCC51-54) minimum and maximum RPM and corresponding signal levels from manufacturer’s specifications. Most applications require no further spanning.

If your application requires greater accuracy, follow the this procedure:

1. Confirm that the screw is at rest (not rotating).

2. Record 0000 as the minimum RPM on line 9 for MCC51 of

Worksheet 4-E.

3. With your programming terminal, read signal level returned in

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

4. Record this signal level on line 11 for MCC53.

ATTENTION: Be sure that any residual plastic in your barrel

is hot enough to be liquified before proceeding to step 5. Attempting to rotate the screw at maximum RPM with cool plastic in the barrel could damage your barrel/screw set.

5. Allow full hydraulic flow to your screw motor at rated hydraulic

pressure to obtain maximum RPM.

6. Determine the actual RPM using a calibrated, hand-held touch

tachometer (or similar device).

7. Record the observed maximum RPM on line 10 for MCC52.

3-13

Chapter 3

Configure the QDC Module's I/O

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

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

9. Record this signal level on line 12 for MCC54.

10. Release all flow and pressure from your screw motor and allow the

screw to return to rest.

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

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

RPM Alarm Time Delay to warn of excessive screw RPM without nuisance alarms

Configure Software Travel Limits

You may want to use the software restrictions to stop the travel of your ram (screw) before it reaches its maximum limits (configured earlier in this chapter).

Figure 4.1 Software

Restrictions

Physical Travel Range

Safe Zone

d = deadband

3-14

Min SWTL Max SWTL

Min Position Max Position

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

Chapter 3

Configure the QDC Module's I/O

ignores all profile commands (except set-outputs 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 the operator to jog the cylinder a set distance away from the software overtravel. 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.

Configure the QDC module for SWTL as follows:

1. Determine these SWTL values for ram (screw) 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 and 14), inhibits the QDC module from performing this safety function.

Worksheet 3F

Configuration V

SWTL

Enter Your SWTL Configuration Values Here

Control Word ProSet 600

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

Incremental Distance

00.00 to 99.99in

000.0 to 999.9mm

Addr

. Value Description Units

alues

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

3-15

Chapter 3

Configure the QDC Module's I/O

Set Up Maximum RPM and Pressure Alarms, and Time Delays

The QDC module continuously monitors screw RPM, ram (screw) pressure, and cavity 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 or RPM for an amount of time before setting the high alarm. A setpoint of zero disables this delay.

Configure the QDC module for pressure and RPM alarms as follows:

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

alarms:

pressure-alarm setpoint time-delay setpoint

2. Determine these values for screw RPM alarms:

RPM-alarm setpoint time-delay setpoint

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

RPM alarm, and time delays you want to use.

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

earlier in this chapter:

Worksheet 3G

and T

Alarm

Enter Your 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

MCC55 N40:51 HighRPM Alarm Setpoint Rotational Speed

MCC56 N40:52 Screw RPM Timedelay Setpoint Time

MCC61 N40:57 Cavity Pressurealarm Setpoint Cavity Pressure

MCC62 N40:58 Cavitypressure Timedelay Setpoint Time

Time

Measured in Seconds

00.00

to 00.99

Pressure 0000 to 9999 PSI

000.0 to 999.9 Bar 0000.0 to 2000.0 Bar

imedelay Setpoints

imedelay Values Here

Rotational Speed

000.0 to 999.9 RPM

Measured in Seconds

Pressure 00000 to 20,000 PSI

3-16

Chapter 3

Configure the QDC Module's I/O

Configure a Digital Filter for the Position Input from the Ram (Screw)

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

To determine if you need a digital filter, move the ram (screw) very slowly. With your programming terminal, look for erratic position numbers reported for ram (screw) position by examining SYS25 (N40:177).

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 and enter it into MCC16 (N40:12). A value of zero disables the filter.

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 ram (screw) linear velocity of 10”/sec, a 00.01 time constant allows 0.10” 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

Chapter

Objectives

Configuration Concepts

This chapter introduces you to the remaining procedure necessary to successfully configure your QDC module. You must follow the procedures in the order given. 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 - you download these blocks 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 in 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 PLC-5 data table containing machine commands, set-up, and operating information for the QDC module. You download command blocks from PLC-5 data table to the QDC module manually on command or automatically at power up.

4-1

Chapter 4

Overview of Remaining Configuration Procedures

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

Type 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 injection profile

Plastication 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 Which Contain Examples

Status Blocks Information about machine operation and

operating status of the QDC module.

The molding machine is currently performing a predecompression movement.

Special Command and Status Blocks

4-2

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

Types 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 processor information relevant to common module parameters.

Sensor spanning information and global alarm setpoints

Command to start the Plastication phase

Actual voltages and engineering units read back at the four QDC inputs

Chapter 4

Overview of Remaining Configuration Procedures

Step Procedure Information that you enter: Refer to:

1 Jog Your Machine Machine jog pressure and flow setpoints are

2 Write a PLC Program to

3 Enter Initial

Configuration procedures detailed in 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 block (JGC).

You jog your ram (screw) with commands in the Dynamic Command block (DYC) to further refine your jog configuration.

Jogpressure and screwRPM alarm setpoints that you determine.

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

You must write PLC ladder logic to cycle the machine in the desired manner.

Output values to valves controlling pressure or flow, ramp rates, and valve span.

Chapter 5

Chapter 6

Chapter 7

(Used in Chapters 9 & 10)

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

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

5 Span Your Valves Configuration parameters necessary to accurately

span your hydraulic valves in open loop. You also set profile pressure alarms.

6 Tune Your Machine

for Producing Parts

Closedloop tuning parameters. We also discuss other setpoints for part tuning and machine tuning.

Chapter 8

(Used in Chapters 9 & 10)

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5 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

Subject Block

JGC 02 1

INC 08 7 IPC

IPC 09 8

PKC 10 9 HPC

HDC 11 10 HPC

HPC 12 11

PRC 13 12

PLC 14 13 PPC

PPC 15 14

PSC 16 15

ProSet 600 Block ID Number

ProSet 600 Command Bit in B21

Required 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:

This block has errors:

Fix them as follows:

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

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

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

When you have done all three: Then:

1. Corrected all errors in MCC and DYC blocks

2. Entered the ID of the subject block in DYC61

3. Downloaded the subject block

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

4-5

Chapter 4

Overview of Remaining Configuration Procedures

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 the 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

Objectives

About Jogging

This chapter describes how to:

configure all jog block values necessary to jog your ram (screw) test jog values and make changes, if necessary configure values which may indirectly affect clamp and eject jogs

Jogging your machine is similar to operating it in set-output operation: 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:

rotate the ram (screw) jog it forward and backward

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

Use These W

orksheets

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

To configure the QDC module for jogging the:

ram (screw) JGC 5A 5-3 clamp and ejector 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). 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 +10vdc, zero output occurs @ 50% (See Warning on next page.)

Later in this chapter you modify them to obtain desired jog results.

setpoints for jog-RPM and jog-pressure alarms

The QDC module sets an alarm any time ram (screw) RPM and/or pressure equals or exceeds the respective value during jogs. A zero entry inhibits alarm actuation.

Important:

High RPM and/or high pressure alarms that you set in chapter 3

are also active during jog functions.

Jog-specific high pressure alarms for clamp and eject jogs are

NOT activated in a QDC module configured for inject mode.

5-2

Worksheet 5. A Ram (screw) Jog Configuration V

Enter Your Initial Values Here

Chapter 5

Jog Your Machine

alues

Control Block Word

ProSet 600 Address

Value Description Units

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

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

Jog RPM and Pressure Alarms

JGC05 N40:61 Screwrotate Jog RPM, Alarm Setpoint Rotational Speed

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

Signal Output

00.00 to 99.99 %

Pressure 0000 to 9999 PSI

000.0 to 999.9 Bar

Rotational Speed

000.0 to 999.9 RPM

ATTENTION: You can connect up to four different valves to your QDC module. Although all four may not directly jog the ram (screw), 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.

5-3

Chapter 5

Jog Your Machine

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

10VDC, 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.

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. To download the jog configuration block (JGC), refer to the download procedure outlined in chapter 4.

5-4

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) with the QDC module. 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).

Table 5.A Ram

(Screw) Jog Enable Bits

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

DYC01B09 B34/393 Execute Screw Rotate Jog

DYC01B10 B34/394 Execute Inject Cylinder Jog Forward

DYC01B11 B34/395 Execute Inject Cylinder Jog Reverse

Table 5.B

(Screw) Jog Status Bits

Ram

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

SYS01B09 B34/9 Screw Rotate Jog in Progress

SYS01B10 B34/10 Inject Cylinder Jog Forward in

Progress

SYS01B11 B34/11 Inject Cylinder 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) travel hydraulically when you command the QDC module to jog the ram (screw) in reverse.

5-5

Chapter 5

Jog Your Machine

Figure 5.1 Example

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

Jog Programming

5-6

Chapter 5

Jog Your Machine

Jog Your Ram (Screw)

Configure Jogs for the Clamp and Ejector

Jog your ram (screw) 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 setpoint

Although the QDC module (in inject mode) may not be directly controlling your machine’s clamp and ejector jogs, your hydraulics may require valves connected to this QDC module’s outputs to go to a certain position to assure proper clamp 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 mode) to assist with clamp and/or eject jogs. Otherwise, omit the rest of this chapter.

Whenever the appropriate clamp 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 mode) to successfully execute clamp and ejector jogs.

Important: Jog-specific high pressure alarms are NOT activated in an inject-mode QDC module during clamp 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 Clamp & Eject Jog Configuration Values for QDC Module in Inject Mode

Enter Your Initial Values Here

Control Block

ProSet 600 Addr. Value Description Units

Word

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

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

Signal Output

00.00 to 99.99 %

5-8

Chapter 5

Jog Your Machine

Write Ladder Logic to Assist with Clamp & Eject Jogs

If your hydraulics require it, take time now to develop ladder logic (independent of Pro-Set 600 software) so the QDC module (in inject mode) can assist jogging the clamp and ejector. 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 the clamp and/or ejector.

Table 5.C Clamp

and Eject Jog Enable Bits

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

DYC01B12 B34/396 Execute Clamp Jog Forward

DYC01B13 B34/397 Execute Clamp Jog Reverse

DYC01B14 B34/398 Execute Ejector Jog Advance

DYC01B15 B34/399 Execute Ejector Jog Retract

Table 5.D

and Eject Jog Status Bits

Clamp

Status Block Word: ProSet 600

Address:

SYS01B12 B34/12 Clamp Jog Forward in Progress

SYS01B13 B34/13 Clamp Jog Reverse 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 clamp and/or ejector travel hydraulically when you command the QDC module to retract the clamp and/or ejector.

5-9

Chapter 5

Jog Your Machine

Figure 5.2 Example

Programming for Assisting Clamp and/or Ejector Jogs

Jog Your Clamp and Ejector

5-10

Do this only after writing all direct and assisted ladder logic for controlling clamp and eject jogs.

Jog your clamp and/or ejector in forward and retract directions. Experiment with values you entered in the jog configuration block (JGC) until you obtain the desired jog operation.

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.

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 setpoint

Chapter

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) movement between profiles

Trigger new events 6.E

Review all available status bits 6.F

Review all available command and configuration bits

command and/or status bits

no additional ladder logic required

6.A

6.D

6.G

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 sets this bit

Direct Setoutput DYC01B08 SYS01B08

Screw Rotate Jog DYC01B09 SYS01B09

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

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

Unassigned # 4 Jog DYC01B12 SYS01B12

Unassigned # 5 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

during execution

Table 6.B Command

To initiate this profile/movement

Injection DYC02B04 - -

Pack DYC02B05 Injection Note 1

Hold DYC02B06 Pack Note 1

Predecompression DYC02B07 Hold HPC03B08

Plastication DYC02B08 Predecompression HPC03B09

Postdecompression DYC02B09 Plastication PPC03B08

Note 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

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

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

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 command bit is This status bit is

Table 6.D

Bits T

Command

Bit Description QDC Block Address

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

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

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

o Interrupt Ram (screw) Movement Between Profiles

HPC03B08

HPC03B09

PPC03B08

Table 6.E Miscellaneous

Reason for Using Bit Description QDC Block Address

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 of hold SYS22B06

To shift solenoids for plastication Setoutput in progress @ end of predecompression SYS22B07

To shift solenoids for postdecompression Setoutput in progress @ end of plastication SYS22B08

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

Status Bits T

Injection complete SYS02B04

Cure time complete

Watchdog for plastication phase SYS04B08

postdecompression

o T

rigger New Events in Inject Mode

SYS03B04, and SYS03B05

SYS22B09

6-3

Chapter 6

Select Command and Status Bits To Sequence Machine Operation

Table 6.F

Bits

Status

Category Bit Status

(when = 1)

Jog Status executing screw rotate jog 9 SYS01B09

executing inject cylinder forward jog 10 SYS01B10

executing inject cylinder reverse jog 11 SYS01B11

executing unassigned #4 jog 12 SYS01B12

executing unassigned #5 jog 13 SYS01B13

executing unassigned #6 jog 14 SYS01B14

executing unassigned #7 jog 15 SYS01B15

Profile Complete injection profile complete 20 SYS02B04

pack profile complete 21 SYS02B05

hold profile complete 22 SYS02B06

predecompression movement complete 23 SYS02B07

plastication profile complete 24 SYS02B08

postdecompression movement complete 25 SYS02B09

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

Miscellaneous Status cure timer timing 35 SYS03B03

ProSet B34/___

QDC Block Address

ram (screw) retracted 36 SYS03B04

cure time complete 37 SYS03B05

Watchdog Status predecompression watchdog timed out 55 SYS04B07

plastication watchdog timed out 56 SYS04B08

postdecompression watchdog timed out 57 SYS04B09

Profile Status executing injection profile 324 SYS21B04

executing pack profile 325 SYS21B05

executing hold profile 326 SYS21B06

executing predecompression movement 327 SYS21B07

executing plastication profile 328 SYS21B08

executing postdecompression movement 329 SYS21B09

End of Profile executing end of hold setoutput 342 SYS22B06

Setoutput Status executing end of predecompression setoutput 343 SYS22B07

executing end of plastication setoutput 344 SYS22B08

executing end of postdecompression setoutput 345 SYS22B09

6-4

Chapter 6

Select Command and Status Bits To Sequence Machine Operation

Table 6.G Command

Category Function Enabled

Nonprofiled execute setoutput 392 DYC01B08

Action Commands execute screw rotate jog 393 DYC01B09

Profiled execute injection profile 404 DYC02B04

Action Commands execute pack profile 405 DYC02B05

and Configuration Bits

(when = 1)

execute inject cylinder forward jog 394 DYC01B10

execute inject cylinder reverse jog 395 DYC01B11

execute unassigned #4 jog 396 DYC01B12

execute unassigned #5 jog 397 DYC01B13

execute unassigned #6 jog 398 DYC01B14

execute unassigned #7 jog 399 DYC01B15

execute hold profile 406 DYC02B06

execute predecompression movement 407 DYC02B07

ProSet B34/___

QDC Block Address

execute plastication profile 408 DYC02B08

execute postdecompression movement 409 DYC02B09

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

Miscellaneous reset cure timer 417 DYC03B01

Commands reset SYS01B08 424 DYC03B08

reset latched alarms 425 DYC03B09

reset complete bits (SYS02) 426 DYC03B10

Logical Bridge Configuration

set output at end of hold profile (0 = start predecompression movement at end of hold)

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

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

B38/296 HPC03B08

B38/297 HPC03B09

B38/488 PPC03B08

6-5

Chapter

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 screw RPM 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) in chapter 3 jogged the ram (screw) in 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

Injection Configuration Command Block (INC) 7A 7-3 Pack Configuration Command Block (PKC) 7B 7-5 Hold Configuration Command Block (HDC) 7C 7-7 Plastication Configuration Command Block (PLC) 7D 7-9

Use this WorksheetOnPage

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 Injection Configuration Command 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

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:

Selected Ram Velocity Valve

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

or 1

Your value

Required initial value loaded by ProSet 600

Ram PID Pressure Algorithm

0 = Dependent Gains 1 = Independent Gains

Selected Ram Pressure Valve

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

7-4

Chapter 7

Load Initial Configuration Values

orksheet 7A (continued)

Injection Configuration Command Block (INC)

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 Ram (screw) Pressure Alarm Setpoint Pressure

INC58 N44:54 0 Profile High Cavity Pressure Alarm Setpoint Pressure

Pressure 00000 to 20000 PSI

0000.0 to 2000.0 Bar

Percent Signal Output per Second 0000 to 9999

Velocity along Axis

00.00 to 99.99 inches per second

000.0 to 999.9 millimeters per second

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)

Pressure 0000 to 9999 PSI

000.0 to 999.9 Bar

ime (Algorithm)

Percent Signal Output

00.00 to 99.99

Percent

00.00 to 99.99

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 Pack Configuration Command 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 1

Selected Cavity Pressure Valve

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

Code:

Selected Ram Pressure Valve

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

Your value

7-6

or 1

Required initial value loaded by ProSet 600

Ram PID Pressure Algorithm

0 = Dependent Gains 1 = Independent Gains

Cavity PID Pressure Algorithm

0 = Dependent Gains 1 = Independent Gains

Chapter 7

Load Initial Configuration Values

orksheet 7B (continued)

Pack Configuration Command Block (PKC)

Enter Y

our V

alues Here

Control Word ProSet 600 Addr. Value Description Units

PKC05 N44:121 1000 Minimum ERC PercentageCavity Pressure Percent

PKC06 N44:122 1000 Minimum ERC PercentageRam (Screw) 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 Accel Ramp Rate During Profile Percent Signal Output per Second

PKC18 N44:134 0 Output #2 Accel Ramp Rate During Profile Percent Signal Output per Second

PKC19 N44:135 0 Output #3 Accel Ramp Rate During Profile Percent Signal Output per Second

PKC20 N44:136 0 Output #4 Accel Ramp Rate During Profile Percent Signal Output per Second

PKC25 N44:141 0 Output #1 Decel Ramp Rate During Profile Percent Signal Output per Second

PKC26 N44:142 0 Output #2 Decel Ramp Rate During Profile Percent Signal Output per Second

PKC27 N44:143 0 Output #3 Decel Ramp Rate During Profile Percent Signal Output per Second

PKC28 N44:144 0 Output #4 Decel Ramp Rate During Profile Percent Signal Output per Second

PKC41 N44:157 0 Ram (screw) Pressure Minimum Control Limit Pressure

PKC42 N44:158 * Ram (screw) Pressure Maximum Control Limit Pressure

PKC43 N44:159 * Selected Ram (screw) Pressure Valve, Output for Minimum Percent Signal Output

PKC44 N44:160 * Selected Ram (screw) Pressure Valve, Output for Maximum Percent Signal Output

PKC45 N44:161 0 Cavity Pressure Minimum Control Limit Pressure

PKC46 N44:162 * Cavity Pressure Maximum Control Limit Pressure

PKC47 N44:163 * Selected Cavity Pressure Valve, Output for Minimum Percent Signal Output

PKC48 N44:164 * Selected Cavity Pressure Valve, Output for Maximum Percent Signal Output

PKC49 N44:165 100 Proportional Gain for Ram (screw) Pressure Control None

PKC50 N44:166 400 Integral Gain for Ram (screw) Pressure Control Inverse Time (Algorithm)

PKC51 N44:167 0 Derivative Gain for Ram (screw) Pressure Control Time (Algorithm)

PKC52 N44:168 100 Proportional Gain for Cavity Pressure Control None

PKC53 N44:169 400 Integral Gain for Cavity Pressure Control Inverse Time (Algorithm)

PKC54 N44:170 0 Derivative Gain for Cavity Pressure Control Time (Algorithm)

PKC57 N44:173 0 Profile High Ram (screw) Pressure Alarm Setpoint Pressure

PKC58 N44:174 0 Profile High Cavity Pressure Alarm Setpoint Pressure

Pressure 00000 to 20000 PSI

0000.0 to 2000.0 Bar

Percent Signal Output per Second 0000 to 9999

Velocity along Axis

00.00 to 99.99 inches per second

000.0 to 999.9 millimeters per second

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)

Pressure 0000 to 9999 PSI

000.0 to 999.9 Bar

ime (Algorithm)

00.00 to 99.99 minutes (ISA)

Percent Signal Output

00.00 to 99.99

Percent

00.00 to 99.99

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 Hold Configuration Command 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 1

Selected Cavity Pressure Valve

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

Code:

Your value

Selected Ram Pressure Valve

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

7-8

or 1

Required initial value loaded by ProSet 600

Ram PID Pressure Algorithm

0 = Dependent Gains 1 = Independent Gains

Cavity PID Pressure Algorithm

0 = Dependent Gains 1 = Independent Gains

Chapter 7

Load Initial Configuration Values

orksheet 7C (continued)

Hold Configuration Command Block (HDC)

Enter Y

our V

alues Here

Control Word ProSet 600 Addr. Value Description Units

HDC05 N44:181 1000 Minimum ERC PercentageCavity Pressure Percent

HDC06 N44:182 1000 Minimum ERC PercentageRam (Screw) 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 Accel Ramp Rate During Profile Percent Signal Output per Second

HDC18 N44:194 0 Output #2 Accel Ramp Rate During Profile Percent Signal Output per Second

HDC19 N44:195 0 Output #3 Accel Ramp Rate During Profile Percent Signal Output per Second

HDC20 N44:196 0 Output #4 Accel Ramp Rate During Profile Percent Signal Output per Second

HDC25 N44:201 0 Output #1 Decel Ramp Rate During Profile Percent Signal Output per Second

HDC26 N44:202 0 Output #2 Decel Ramp Rate During Profile Percent Signal Output per Second

HDC27 N44:203 0 Output #3 Decel Ramp Rate During Profile Percent Signal Output per Second

HDC28 N44:204 0 Output #4 Decel 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 Ram (screw) Pressure Minimum Control Limit Pressure

HDC42 N44:218 * Ram (screw) Pressure Maximum Control Limit Pressure

HDC43 N44:219 * Selected Ram (screw) Pressure Valve, Output for Minimum Percent Signal Output

HDC44 N44:220 * Selected Ram (screw) Pressure Valve, Output for Maximum Percent Signal Output

HDC45 N44:221 0 Cavity Pressure Minimum Control Limit Pressure

HDC46 N44:222 * Cavity Pressure Maximum Control Limit Pressure

HDC47 N44:223 * Selected Cavity Pressure Valve, Output for Minimum Percent Signal Output

HDC48 N44:224 * Selected Cavity Pressure Valve, Output for Maximum Percent Signal Output

HDC49 N44:225 100 Proportional Gain for Ram (screw) Pressure Control None

HDC50 N44:226 400 Integral Gain for Ram (screw) Pressure Control Inverse Time (algorithm)

HDC51 N44:227 0 Derivative Gain for Ram (screw) Pressure Control Time (algorithm)

HDC52 N44:228 100 Proportional Gain for Cavity Pressure Control None

HDC53 N44:229 400 Integral Gain for Cavity Pressure Control Inverse Time (algorithm)

HDC54 N44:230 0 Derivative Gain for Cavity Pressure Control Time (algorithm)

HDC57 N44:233 0 Profile High Ram (screw) Pressure Alarm Setpoint Pressure

HDC58 N44:234 0 Profile High Cavity Pressure Alarm Setpoint Pressure

Pressure 00000 to 20000 PSI

0000.0 to 2000.0 Bar

Percent Signal Output per Second 0000 to 9999

Velocity along Axis

00.00 to 99.99 inches per second

000.0 to 999.9 millimeters per second

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)

Pressure 0000 to 9999 PSI

000.0 to 999.9 Bar

ime (Algorithm)

Percent Signal Output

00.00 to 99.99

Percent

00.00 to 99.99

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

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 1

Code:

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

Selected RPM Valve

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

PID RPM Algorithm 0 = Dependent Gains

1 = Independent Gains

7-10

Chapter 7

Load Initial Configuration Values

orksheet 7D (continued)

Plastication Configuration Block (PLC)

Enter Y

our V

alues Here

Control Word ProSet 600 Addr. Value Description Units

PLC05 N44:361 1000 Minimum RPM Control ERC Percentage Percent

PLC06 N44:362 1000 Minimum Pressure Control ERC Percentage 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

PLC45 N44:401 0 RPM Minimum Control Limit RPM

PLC46 N44:402 * RPM Maximum Control Limit RPM

PLC47 N44:403 * Selected RPM Valve, Output for Minimum Percent Signal Output

PLC48 N44:404 * Selected RPM 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)

PLC52 N44:405 100 Proportional Gain for RPM Control None

PLC53 N44:406 400 Integral Gain for RPM Control Inverse Time (Algorithm)

PLC54 N44:407 0 Derivative Gain for RPM Control Time (Algorithm)

PLC57 N44:413 0 Profile High Pressure Alarm Setpoint Pressure

Time

00.00 to 99.99 seconds

Percent Signal Output per Second 0000 to 9999

Screw

Speed

000.0 to 999.9 RPM

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)

Pressure 0000 to 9999 PSI

000.0 to 999.9 Bar

ime (Algorithm)

Percent Signal Output

00.00 to 99.99

Percent

00.00 to 99.99

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

7-11

Chapter 7

Load Initial Configuration Values

Procedure to Determine and Enter Initial Values

Determine Bit Selections: Assign Module Outputs for Your Control Valves

Follow this procedure to complete each worksheet:

1. Read the text for the subject parameter.

2. Determine your initial value.

Important: If you need additional information when determining your

initial values, refer to the same configuration blocks in Section 3 of the Plastic Molding Module Reference Manual, publication 1771-6.5.88.

3. Observe the list of configuration words that require the subject

parameter. The list is located under the title of each subject parameter.

4. Locate each worksheet that requires the subject parameter.

5. Record the value on the corresponding line(s) in the worksheet.

Important: Block identifier codes are already recorded for you.

Selected Control Valve for Injection Velocity

(INC02)

The QDC module can control ram (screw) movement using a velocity vs. position algorithm. Since you can connect up to four valves to your QDC module, you must tell it which valve to use for velocity (flow) control.

B02 B01 B00 Selects:

0 0 0 Output #1 Used for Velocity Control

0 0 1 Output #2 Used for Velocity Control

0 1 0 Output #3 Used for Velocity Control

0 1 1 Output #4 Used for Velocity Control

Record the appropriate bit selections for your valve configuration in the control word of worksheet 7-A.

Selected Control Valve for Screw RPM

(PLC02)

The QDC module can control screw RPM using an RPM vs. position or time algorithm. Since you can connect up to four valves to your QDC module, you must tell it which valve to use for RPM control.

7-12

Chapter 7

Load Initial Configuration Values

B02

0 0 0 Output #1 Used for RPM Control

0 0 1 Output #2 Used for RPM Control

0 1 0 Output #3 Used for RPM Control

0 1 1 Output #4 Used for RPM Control

B01 B00 Selects:

Record the appropriate bit selections for your valve configurations in the control word of worksheet 7-D.

Selected Control Valve for Ram (Screw) Pressure

(INC02, PKC02, HDC02, and PLC02)

The QDC module can control ram (screw) movement using pressure vs. position or time algorithms. For the plastication algorithm, the pressure component is backpressure. You must tell the QDC module which valve to use for controlling pressure with these algorithms.

B06 B05 B04 Selects:

0 0 0 Output #1 Used for Pressure Control

0 0 1 Output #2 Used for Pressure Control

0 1 0 Output #3 Used for Pressure Control

0 1 1 Output #4 Used for Pressure Control

Record the appropriate bit selections for your valve configurations in the control word of applicable worksheets.

Selected Control Valve for Cavity Pressure

(PKC02 and HDC02)

The QDC module can control cavity pressure using a pressure vs. time algorithm during pack and hold. You must tell the QDC module which valve to use for controlling pressure with this algorithm.

B02 B01 B00 Selects:

0 0 0 Output #1 Used for Pressure Control

0 0 1 Output #2 Used for Pressure Control

0 1 0 Output #3 Used for Pressure Control

0 1 1 Output #4 Used for Pressure Control

Record the appropriate bit selections for your valve configurations in the control word of applicable worksheets.

7-13

Chapter 7

Load Initial Configuration Values

Select the Type of PID Algorithm

Type of PID Algorithm

(INC02, PKC02, HDC02, and PLC02)

When executing pressure or screw RPM versus position or time profiles, the QDC module can use one of two types of PID algorithms: dependent gains (ISA) or independent gains (Allen-Bradley).

If B07(B03) = : Then it uses:

0 Dependent Gains (ISA)

1 Independent Gains (AB)

Dependent gains (ISA): Output = Kc[(E) + 1/Ti

∫

(E)dt + Td*d(E)/dt]

Independent gains (AB): Output = Kp(E) + Ki

∫

(E)dt + Kd*d(E)/dt

Comparison of Gain Constants

Compare dependent and independent gains constants as follows:

Dependent Gains Constants: Independent Gains Constants:

Controller Gain Kc (dimensionless) Proportional Gain Kp (dimensionless)

Reset Term 1/Ti (minutes per repeat) Integral Gain Ki (inverse seconds)

Rate Term Td (minutes) Derivative Term Kd (seconds)

Other variables used in any algorithm choice include:

Output = Percentage of full scale E = Error (scaled) SP-PV (Setpoint-Process Variable) PV = Process Variable (scaled)

Convert from dependent to independent gain constants by substituting controller gain (Kc), reset (1/Ti), and rate (Td) values in these formulas:

= Kc unitless

Ki =

inverse seconds

60 T

Kd = Kc(Td)60 seconds

We recorded bit B07 (B03) = 1 for A-B independent gains on all corresponding worksheets.

7-14

Chapter 7

Load Initial Configuration Values

Important: These recorded PID gain constants and closed-loop tuning procedures in chapter 10 assume the selection of independent (A-B) gains. If, after attempting to tune your pressure loops in chapter 10, you believe you must use dependent (ISA) gain constants, refer to section 3 of the Reference Manual (1771-6.5.88) for information on this option.

Set Values for Expert Response Compensation



(ERC)

Determine Unselected Valve Setoutput Values

Expert Response Compensation Minimum Percentages

(INC0506,

The QDC module uses a proprietary control scheme called Expert Response Compensation machine hydraulics, raw materials, and other process variables. It compensates for abrupt upsets and long term deviations to your process.

We already recorded an initial value of 10% (1000) on all worksheets.

We help you select final values required for your application in chapter 10. For additional information, refer to section 3 of the Plastic Molding Module Reference Manual (publication 1771-6.5.88).

Unselected Valve Setoutput Values

(INC0912,

Earlier in this chapter, you told the QDC module which of its four outputs was being used to control pressure and flow profiles. Your machine hydraulics probably require that the remaining unselected valves connected to your QDC module assume a set-output condition during the profile.

PKC0506, HDC0506, PLC0506)

. It accounts for changes in your machine,

PKC0912, HDC0912, and PLC0912)

Words 09 through 12 define set-output values for your unselected valves. The QDC module sets its four outputs to the values in these words each time it starts the appropriate profile with this exception:

Important: The QDC module ignores the set-output value associated with the selected valve, and drives that output independently.

To assist you when determining unselected valve set-output values, refer to Table 7.A. We present this table for reference, only. Your application will dictate your setpoints.

7-15

Chapter 7

Load Initial Configuration Values

Table 7.A Setoutput

If the unselected valve controls

Pressure Unidirectional Direct acting Maximum pressure 9999

Pressure Unidirectional Direct acting Medium pressure 7500 to 5000

Pressure Unidirectional Direct acting Low pressure 5000 to 2500

Pressure Unidirectional Direct acting Minimum pressure 0

Pressure Unidirectional Reverse acting Maximum pressure 0

Pressure Unidirectional Reverse acting Medium pressure 2500 to 5000

Pressure Unidirectional Reverse acting Low pressure 5000 to 7500

Flow Unidirectional Reverse acting Minimum pressure 9999

Flow Unidirectional Direct acting Maximum flow 9999

Flow Unidirectional Direct acting Medium flow 7500 to 5000

Flow Unidirectional Direct acting Low flow 5000 to 2500

Flow Unidirectional Direct acting Minimum flow 0

and the unselected valve type is

Setpoints for Unselected V

and during profile, valve action is

alves

and during profile, you require

Then enter

Flow Unidirectional Reverse acting Maximum flow 0

Flow Unidirectional Reverse acting Medium flow 2500 to 5000

Flow Unidirectional Reverse acting Low flow 5000 to 7500

Flow Unidirectional Reverse acting Minimum flow 9999

Flow Bidirectional Direct acting Maximum flow 9999

Flow Bidirectional Direct acting Medium flow 8750 to 7500

Flow Bidirectional Direct acting Low flow 7500 to 6250

Flow Bidirectional Direct acting Minimum flow 5000

Flow Bidirectional Reverse acting Maximum flow 0

Flow Bidirectional Reverse acting Medium flow 1250 to 2500

Flow Bidirectional Reverse acting Low flow 2500 to 3750

Flow Bidirectional Reverse acting Minimum flow 5000

Important: Valve spanning procedures in chapter 9 require unselected valves be driven at signal levels representative of a normal production run. We discuss process considerations that impend changing these values in chapter 10. Changing these values may require you to re-span your valves.

7-16

Record all set-output values for unselected valves in worksheets 7.A – 7.D.

Chapter 7

Load Initial Configuration Values

ATTENTION: A value of 0 entered in your set-output words does not necessarily correspond to zero pressure or flow. If you configured for bi-directional valve operation (–10 to + 10VDC), an output value of 50% gives a zero volts signal output (see graph) while an output value of 0% or 100% gives a maximum signal output . Amplifier electronics or spool offsets may also allow pressure or flow at zero volts signal input. Consult your valve and amplifier specifications for more details.

8 6 4 2 0

-2

Output Voltage

-4

-6

-8

-10

0 102030405060708090100

Set Your Acceleration/Deceleration Ramp Rates

Output Requested

For additional information, refer to section 3 of the Plastic Molding Module Reference Manual (publication 1771-6.5.88).

You may need ramp rates for smooth actuator motion. The QDC module gives you multi-stepped profiles to reduce the need for ramp rates, so we recommend starting with zero ramp rates. If you observe rough, jerky motion during profile tuning in chapter 10, enter other values at that time.

ATTENTION: Using ramp rates may degrade closed-loop control, ERC calculations, and QDC control capability. Use ramp rates only if machine operation mandates them.

7-17

Chapter 7

Load Initial Configuration Values

Acceleration Ramp Rates

(INC1720,

The QDC module uses acceleration ramp rates when moving its outputs to a higher setpoint during execution of a profile. They affect both selected and unselected valves. A ramp rate of zero disables ramping, and the QDC module steps directly from setpoint to setpoint.

We recorded zero on corresponding worksheets.

PKC1720, HDC1720, and PLC1720

)

Deceleration Ramp Rates

(INC2528,

The QDC module uses deceleration ramp rates when moving its outputs to a lower setpoint during execution of a profile. They affect selected and unselected valves alike. A ramp rate of zero disables ramping, and the QDC module steps directly from setpoint to setpoint.

PKC2528, HDC2528, and PLC2528)

Determine Setoutput Values for End of Profiles

We recorded zero on corresponding worksheets. Important: The valve spanning procedures in chapter 9 require zero

acceleration and deceleration ramp rates. We help you select the correct final values required by your application in chapter 10. For additional information, refer to section 3 of the Plastic Molding Module Reference Manual (publication 1771-6.5.88).

EndofProfile Setoutput Values

(HDC3336

The QDC module sets its outputs to these values every time it completes the appropriate profile when commanded NOT to “bridge” to the next profile or movement. Set-outputs remain in effect until the QDC module is commanded to start the next programmed profile (or movement) or is stopped using stop command DYC02-B15.

Record values that correspond to zero pressure or zero flow on worksheets. For assistance in determining your set-output values, refer to Table 7-A.

Important: The valve spanning procedures in chapter 9 require no flow or pressure after profile execution. We help you select the correct final values required by your application in chapter 10. For additional information, refer to section 3 of the Plastic Molding Module Reference Manual (publication 1771-6.5.88).

and PLC3336)

7-18

Chapter 7

Load Initial Configuration Values

Set Pressure Control Limits

Setting pressure control limits lets you span your selected valve outputs for effective control with either direct- or reverse-acting valves. Your machine manufacturer typically provides you with values to configure these limits.

Minimum Ram (Screw) Pressure Control Limit

(INC41, PKC41, HDC41, and PLC41)

The value in this word corresponds to the minimum controllable ram (screw) pressure during the respective profile. The QDC module uses this word with Selected Pressure Valve, Output for Minimum (word 43) below. The QDC module expects this pressure when setting the selected ram (screw) pressure valve to the percentage output you enter in word 43.

We recorded zero on corresponding worksheets.

Maximum Ram (Screw) Pressure Control Limit

(INC42, PKC42, HDC42, and PLC42)

The value in this word corresponds to the maximum controllable ram (screw) pressure during the respective profile. The QDC module uses this word with Selected Pressure Valve, Output for Maximum (word 44) below. The QDC expects this pressure when setting the selected ram (screw) pressure valve to the percentage output you enter in word 44.

Record an initial control limit equal to the maximum pressure available through the selected ram (screw) pressure valve during the profile.

Selected Ram (Screw) Pressure Valve, Output for Minimum

(INC43, PKC43, HDC43, and PLC43)

The QDC module uses this word with Minimum Pressure Control Limit (word 41) above. Enter the %-signal output that the QDC module uses to drive the selected ram (screw) pressure valve for minimum profile pressure. The QDC module expects a pressure equal to word 41 when setting the selected ram (screw) pressure valve to this percentage output.

Determine Output for Minimum values as follows:

0 (0%) for uni-directional direct acting valves 5000 (50%) for bi-directional valves 9999 (100%) for uni-directional reverse acting valves

If your selected pressure valve is:

Direct acting less than value in word 44 less than value in word 43

Reverse acting greater than value in word 44 greater than value in word 43

Then the value in word 43 should be

And during the profile, the QDC module does NOT drive the valve with a % output

Record initial Output for Minimum values on corresponding worksheets.

7-19

Chapter 7

Load Initial Configuration Values

Selected Ram (Screw) Pressure Valve, Output for Maximum

(INC44, PKC44, HDC44, and PLC44)

The QDC module uses this word with Maximum Ram (Screw) Pressure Control Limit (word 42) above. Enter the %-signal output that the QDC module uses to drive the selected ram (screw) pressure valve for maximum profile pressure. The QDC expects a pressure equal to word 42 when setting the selected ram (screw) pressure valve to this percentage output.

Determine Output for Maximum values as follows:

9999 (100%) for uni-directional direct acting valves 0 (0%) or 9999 (100%) for bi-directional valves depending on direction 0 (0%) for uni-directional reverse acting valves

If your selected pressure valve is:

Direct acting greater than value in word 43 greater than value in word 44

Reverse acting less than value in word 43 less than value in word 44

Then the value in word 44 should be

And during the profile, the QDC module does NOT drive the valve with a % output

Record initial Output for Maximum values on corresponding worksheets.

Minimum Cavity Pressure Control Limit

(PKC45 and HDC45)

The value in this word corresponds to the minimum controllable cavity pressure during pack and hold profiles. The QDC module uses this word with Selected Cavity Pressure Valve, Output for Minimum (word 47) below. The QDC module expects this pressure when setting the selected cavity pressure valve to the percentage output you enter in word 47.

We recorded zero on corresponding worksheets.

Maximum Cavity Pressure Control Limit

(PKC46 and HDC46)

7-20

The value in this word corresponds to the maximum controllable cavity pressure during pack and hold profiles. The QDC module uses this word with Selected Cavity Pressure Valve, Output for Maximum (word 48) below. The QDC expects this pressure when setting the selected cavity pressure valve to the percentage output you enter in word 48.

Record on corresponding worksheets a maximum control limit equal to the maximum obtainable cavity pressure based on valve settings during respective profiles.

Chapter 7

Load Initial Configuration Values

Selected Cavity Pressure Valve, Output for Minimum

(PKC47and HDC47)

The QDC module uses this word with Minimum Cavity Pressure Control Limit (word 45) above. Enter the %-signal output that the QDC module uses to drive the selected cavity pressure valve for minimum profile pressure. The QDC module expects a pressure equal to word 45 when setting the selected cavity pressure valve to this %-output.

Determine Output for Minimum values as follows:

0 (0%) for uni-directional direct acting valves 5000 (50%) for bi-directional valves 9999 (100%) for uni-directional reverse acting valves

If your selected pressure valve is:

Direct acting less than value in word 48 less than value in word 47

Reverse acting greater than value in word 48 greater than value in word 47

Then the value in word 47 should be

And during the profile, the QDC module does NOT drive the valve with a % output

Record initial Output for Minimum values on corresponding worksheets.

Selected Cavity Pressure Valve, Output for Maximum

(PKC48 and HDC48)

The QDC module uses this word with Maximum Cavity Pressure Control Limit (word 46) above. Enter the %-signal output that the QDC module uses to drive the selected cavity pressure valve for maximum profile pressure. The QDC module expects a pressure equal to word 46 when setting the selected cavity pressure valve to this %-output.

Determine Output for Maximum values as follows:

9999 (100%) for uni-directional direct acting valves 0 (0%) or 9999 (100%) for bi-directional valves depending on direction 0 (0%) for uni-directional reverse acting valves

If your selected pressure valve is:

Direct acting greater than value in word 47 greater than value in word 48

Reverse acting less than value in word 47 less than value in word 48

Then the value in word 48 should be

And during the profile, the QDC module does NOT drive the valve with a % output

Record initial Output for Maximum values on corresponding worksheets. Important: The valve spanning procedures in chapter 9 require these

initial values. In that chapter we help you select correct final values for your application. For additional information, refer to section 3 of the Plastic Molding Module Reference Manual (publication 1771-6.5.88).

7-21

Chapter 7

Load Initial Configuration Values

Set Velocity Control Limits

Minimum Velocity Control Limit

(INC45)

The value in this word corresponds to the minimum controllable ram (screw) velocity during the injection profile. The QDC module uses this word with Selected Velocity Valve, Output for Minimum (INC47) below. The QDC module expects this velocity when setting its selected velocity valve to the percentage output you enter in INC47.

We recorded zero on Worksheet 7-A.

Maximum Velocity Control Limit

(INC46)

The value in this word corresponds to the maximum controllable ram (screw) velocity during the injection profile. The QDC module uses this word with Selected Velocity Valve, Output for Maximum (INC48) below. The QDC module expects this velocity when setting its selected velocity valve to the percentage output you enter in INC48.

Record the maximum ram (screw) speed per your OEM specifications on Worksheet 7-A.

Selected Velocity Valve, Output for Minimum

(INC47)

The QDC module uses this word with Minimum Velocity Control Limit (INC45) above. Enter the %-signal output that the QDC module uses to drive the selected velocity valve for minimum profile velocity. The QDC expects a velocity equal to INC45 when setting the selected velocity valve to this %-output.

The QDC module uses this setpoint to drive the selected velocity valve when attempting to attain zero ram (screw) velocity. It should drive the selected velocity valve to a spool position that prohibits any hydraulic flow into the hydraulic cylinder during injection.

Determine the Output for Minimum value as follows:

0 (0%) for uni-directional direct acting valves 5000 (50%) for bi-directional valves 9999 (100%) for uni-directional reverse acting valves

If your selected velocity valve is:

Direct acting less than value in INC48 less than value in INC47

Reverse acting greater than value in INC48 greater than value in INC47

Then the value in INC47 should be

And during the profile, the QDC module does NOT drive the valve with a % output

7-22

Record the initial Output for Minimum value on Worksheet 7-A.

Chapter 7

Load Initial Configuration Values

Selected Velocity Valve, Output for Maximum

(INC48)

The QDC module uses this word with Maximum Velocity Control Limit (INC46) above. Enter the %-signal output that the QDC module uses to drive the selected velocity valve for maximum profile velocity. The QDC module expects a velocity equal to INC46 when setting the selected velocity valve to this %-output.

The QDC module uses this setpoint to drive the selected velocity valve when attempting to attain maximum ram (screw) velocity. It should drive the selected velocity valve to a spool position that provides full hydraulic flow into the hydraulic cylinder during injection.

Determine the Output for Maximum value as follows:

9999 (100%) for uni-directional direct acting valves 0 (0%) or 9999 (100%) for bi-directional valves depending on direction 0 (0%) for uni-directional reverse acting valves

Set RPM Control Limits

If your selected velocity valve is:

Direct acting greater than value in INC47 greater than value in INC48

Reverse acting less than value in INC47 less than value in INC48

Then the value in INC48 should be

And during the profile, the QDC module does NOT drive the valve with a % output

Record the initial Output for Maximum value on Worksheet 7-A. Important: The valve spanning procedures in chapter 9 require these

initial velocity control limits. For additional information, refer to section 3 of the Plastic Molding Module Reference Manual (publication 1771-6.5.88).

Minimum RPM Control Limit

(PLC45)

The value in this word corresponds to the minimum controllable RPM during the plastication profile. The QDC module uses this word with the Selected RPM Valve, Output for Minimum (word 47) below. The QDC module expects this RPM when setting the selected RPM valve to the percentage output you enter in word 47.

We recorded zero on Worksheet 7-D.

7-23

Chapter 7

Load Initial Configuration Values

Maximum RPM Control Limit

(PLC46)

The value in this word corresponds to the maximum controllable RPM during the plastication profile. The QDC module uses this word with the Selected RPM Valve, Output for Maximum (word 48) below. The QDC module expects this RPM when setting the selected RPM valve to the percentage output you enter in word 48.

Record the maximum screw RPM per your OEM specifications on Worksheet 7-D.

Selected RPM Valve, Output for Minimum

(PLC47)

The QDC module uses this word with the Minimum RPM Control Limit (word 45) above. Enter the %-signal output that the QDC module uses to drive the selected RPM valve for minimum profile RPM. The QDC module expects an RPM equal to word 45 when setting the selected RPM valve to this percentage output.

Determine Output for Minimum values as follows:

0 (0%) for uni-directional direct acting valves 5000 (50%) for bi-directional valves 9999 (100%) for uni-directional reverse acting valves

If your selected pressure valve is:

Direct Acting less than the value in word 48 less than the value in word 47

Reverse Acting greater than the value in word 48 greater than the value in word 47

Then the value in word 47 should be:

And during the profile, the QDC module does NOT drive the valve with a % output:

Record your initial Output for Minimum value on worksheet 7-D.

Selected RPM Valve, Output for Maximum

(PLC48)

The QDC module uses this word with the Maximum RPM Control Limit (word 48) above. Enter the %-signal output that the QDC module uses to drive the selected RPM valve for maximum profile RPM. The QDC expects an RPM equal to word 46 when setting the selected RPM valve to this percentage output.

7-24

Chapter 7

Load Initial Configuration Values

Determine Output for Maximum values as follows:

9999 (100%) for uni-directional direct acting valves 0 (0%) or 9999 (100%) for bi-directional valves depending on direction 0 (0%) for uni-directional reverse acting valves

Set Profile Tuning Constants, PressureAlarm Setpoints, and Watchdog

imer Preset

If your selected pressure valve is:

Direct Acting greater than the value in word 47 greater than the value in word 48

Reverse Acting less than the value in word 47 less than the value in word 48

Then the value in word 48 should be:

And during the profile, the QDC module does NOT drive the valve with a % output:

Record your initial Output for Maximum value on Worksheet 7-D.

Profile Tuning Constants

(INC4953,

The QDC module’s PID and velocity feedforward(VelFF) algorithms are different from classic PID and VelFF algorithms. QDC module algorithms are sensitive to changes in load (not changes in setpoint) because the QDC module must respond to a system that is undergoing constant load changes when hydraulic fluid is introduced into or relieved from the hydraulic circuit. The algorithm gain constants are typically lower than those used to control a process that reacts to setpoints changes.

We entered all profile tuning constants on corresponding worksheets.

PKC4954, HDC4954, and PLC4954)

Profile Pressure Alarm Setpoints

(INC5758,

The QDC module compares the ram (screw) or cavity pressure against these entries when executing the appropriate profile. The QDC module sets a corresponding alarm bit any time ram (screw) or cavity pressure equals or exceeds these entries during the respective profile. A zero entry inhibits each respective alarm.

We recorded zero for each alarm setpoint on corresponding worksheets.

PKC5758, HDC5758, and PLC57)

7-25

Chapter 7

Load Initial Configuration Values

Watchdog Timer Preset

(PLC08)

Use the watchdog timer to signal an alarm if the plastication profile takes longer than expected. To inhibit the timer, enter a preset of zero.

When the QDC module starts the plastication profile, it:

starts the internal timer stops the timer, reports execution time, and resets the accumulated value

to zero when it completes profile

sets an alarm bit if the accumulated value exceeds this preset

We recorded zero on Worksheet 7-D to inhibit the timer.

The closed-loop tuning procedures in chapter 10 require these initial values. In that chapter, we help you select the correct final values required by your application. For additional information, refer to section 3 of the Plastic Molding Module Reference Manual (publication 1771-6.5.88).

Enter and Download your

orksheet V

alues

After you determine initial values and enter them on configuration worksheets, you are ready to proceed.

1. Enter all worksheet values into your PLC-5 data table.

Important: Be sure that you have not altered any setpoints, and that you

have entered each and every setpoint exactly as on the worksheets.

2. Use the procedure described in chapter 4 to download command

blocks to the QDC module. For your convenience, we repeat download information from chapter 4 (Table 7.B).

Important: Do not download companion blocks at this time.

Table 7.B Information

Block to Download:

INC 08 7

PKC 10 9

HDC 11 10

PLC 14 13

Required to Download a Block

ProSet 600 Block ID.:

ProSet 600 Download Command Bit in B21:

7-26

Chapter

Load Initial Profile Values

Chapter

Objectives

Use These W

orksheets

This chapter describes how to load setpoints for inject-mode profiles. You determine initial values and enter setpoints into PLC-5 data table for the following profiles:

Injection Profile (IPC) Pack/Hold Profile (HPC) Plastication Profile (PPC)

Then, you download them to the QDC module. Important: This chapter continues the procedure for loading information

into the QDC module. Complete chapter 7 before starting this chapter.

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

To configure the QDC module with this profile block

Injection Profile Command Block (IPC) 8A 8-3 Pack/Hold Profile Command Block (HPC) 8B 8-10 Plastication Profile Command Block (PPC) 8C 8-17

See this Worksheet

On Page

Take a moment now to browse through the first worksheet.

Notice that it contains two parts:

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

Also notice that many parameters repeat within the profile block. For example: segments 1-11 for velocity setpoints

Because many parameters repeat within a worksheet, we present each worksheet followed by text telling you how to determine initial values. Complete one worksheet before going to the next. This differs from the procedure in chapter 7.

8-1

Chapter 8

Load Initial Profile Values

Determine and Record Setpoints for the Injection Profile (IPC)

Use Worksheet 8-A to enter setpoints for pressure vs. time and velocity vs. position injection profiles. The valve spanning procedures in chapter 9 require specific values. We have already entered many values for you, and help you determine other values in the text that follows.

Worksheet 8A Injection

Control Word IPC01Bxx

ProSet 600 Addr. B38/bit

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 1 0 0 1

Control W

ProSet 600 Addr. B38/bit

ord IPC03Bxx

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

111 110 109 108 107 106 105 104 103 102 101 100 99 98 97 96

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

Velocity Units 0 = Parameters in Percent Velocity" 1 = Parameters in Inches (mm)/Sec

Sign of Pressure Offset 0 = Positive 1 = Negative

Profile Command Block (IPC)

Sign of Velocity Offset 0 = Positive 1 = Negative

IPC Block Identifier

Algorithm Selection

00 = Vel/Pos 01 = Vel/Pos (pressure limited) 10 = Press/Pos 11 = Press/Time

Control W

ProSet 600 Addr. B38/bit

ord IPC04Bxx

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

127 126 125 124 123 122 121 120 11 9 118 11 7 116 11 5 114 11 3 112

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

Code:

Your value

Control Word ProSet 600 Addr. Value Description Units

IPC09 N44:65 * Segment 1 Velocity Setpoint Velocity IPC10 N44:66 * Segment 1 Pressure Setpoint Pressure IPC11 N44:67 * Endof Segment 1 Position Setpoint Distance from Moldend IPC12 N44:68 100 Segment 1 Time Setpoint Time IPC13 N44:69 * Segment 2 Velocity Setpoint Velocity IPC14 N44:70 * Segment 2 Pressure Setpoint Pressure

Required initial value

or 1

loaded by ProSet 600

Enter Y

our V

alues Here

0 = ERC On for Press/Time 1 = ERC Off

0 = ERC On for Press/Pos 1 = ERC Off

0 = ERC On for Vel/Pos (limited) 1 = ERC Off

0 = ERC On for Vel/Pos 1 = ERC Off

0 = Press/Time Closed Loop 1 = Open Loop

0 = Press/Pos Closed Loop 1 = Open Loop

0 = Vel/Pos (limited) Closed Loop 1 = Open Loop

0 = Vel/Pos Closed Loop 1 = Open Loop

8-2

Chapter 8

Load Initial Profile Values

IPC15 N44:71 * Endof Segment 2 Position Setpoint Distance from Moldend IPC16 N44:72 100 Segment 2 Time Setpoint Time IPC17 N44:73 * Segment 3 Velocity Setpoint Velocity IPC18 N44:74 * Segment 3 Pressure Setpoint Pressure

IPC19 N44:75 * Endof Segment 3 Position Setpoint Distance from Moldend IPC20 N44:76 100 Segment 3 Time Setpoint Time IPC21 N44:77 * Segment 4 Velocity Setpoint Velocity IPC22 N44:78 * Segment 4 Pressure Setpoint Pressure

IPC23 N44:79 * Endof Segment 4 Position Setpoint Distance from Moldend IPC24 N44:80 100 Segment 4 Time Setpoint Time IPC25 N44:81 * Segment 5 Velocity Setpoint Velocity IPC26 N44:82 * Segment 5 Pressure Setpoint Pressure

IPC27 N44:83 * Endof Segment 5 Position Setpoint Distance from Moldend IPC28 N44:84 100 Segment 5 Time Setpoint Time IPC29 N44:85 * Segment 6 Velocity Setpoint Velocity IPC30 N44:86 * Segment 6 Pressure Setpoint Pressure

IPC31 N44:87 * Endof Segment 6 Position Setpoint Distance from Moldend IPC32 N44:88 100 Segment 6 Time Setpoint Time IPC33 N44:89 * Segment 7 Velocity Setpoint Velocity IPC34 N44:90 * Segment 7 Pressure Setpoint Pressure

IPC35 N44:91 * Endof Segment 7 Position Setpoint Distance from Moldend IPC36 N44:92 100 Segment 7 Time Setpoint Time IPC37 N44:93 * Segment 8 Velocity Setpoint Velocity IPC38 N44:94 * Segment 8 Pressure Setpoint Pressure

IPC39 N44:95 * Endof Segment 8 Position Setpoint Distance from Moldend IPC40 N44:96 100 Segment 8 Time Setpoint Time IPC41 N44:97 * Segment 9 Velocity Setpoint Velocity IPC42 N44:98 * Segment 9 Pressure Setpoint Pressure

IPC43 N44:99 * Endof Segment 9 Position Setpoint Distance from Moldend IPC44 N44:100 100 Segment 9 Time Setpoint Time IPC45 N44:101 * Segment 10 Velocity Setpoint Velocity IPC46 N44:102 * Segment 10 Pressure Setpoint Pressure

IPC47 N44:103 * Endof Segment 10 Position Setpoint Distance from Moldend IPC48 N44:104 100 Segment 10 Time Setpoint Time IPC49 N44:105 * Segment 11 Velocity Setpoint Velocity IPC50 N44:106 * Segment 11 Pressure Setpoint Pressure IPC51 N44:107 0 Profile Velocity Offset Velocity IPC52 N44:108 0 Profile Pressure Offset Pressure IPC57 N44:113 0 Ram Pressure Limit for Pressurelimit Velocity Control Pressure

IPC58 N44:114 0 Start of Zone for Pressurelimit Velocity Control Distance from Moldend IPC59 N44:115 0 Time Delay for Pressurelimit Velocity Control Time IPC60 N44:116 1000 Time Limit for Transition Time

IPC61 N44:117 0 Ram (screw) Position for Transition Distance from Moldend IPC62 N44:118 0 Ram (screw) Pressure for Transition Pressure IPC63 N44:119 0 Cavity Pressure for Transition Pressure

IPC64 N44:120 0 Start of Zone for Pressure Transition Distance from Moldend

Time

00.00 to 99.99 seconds

Time 000.0

00.00 to 00.99 seconds

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

Distance

from MCC13 (if not zero) or MCC09

00.00 to 99.99 inches to 999.9 millimeters

Pressure 0000 to 9999 PSI

000.0 to 999.9 Bar

Velocity

00.00 to 99.99 in/sec

000.0 to 999.9 mm/sec

Pressure 00000 to 20,000 PSI

0000.0 to 2000.0 Bar

8-3

Chapter 8

Load Initial Profile Values

Determine Bit Selections for Worksheet 8A

Injection Profile Block Identifier

(IPC01)

Bits 07-00 of this word identify it as the first word in a series used to define the injection profile. These bits must be set to 00001001.

We recorded these bits on Worksheet 8-A.

Velocity Units

(IPC03)

The following bit determines units of measure for injection velocity values.

-BIT 14 selects units of measure.

0 = Percent velocity 1 = Inches or millimeters per second

We recorded B14 = 1 for units per second on Worksheet 8-A.

Profile Offset Sign

(IPC03)

Profile offsets let you shift the amplitude of entire profiles up or down, if necessary. The offset sign determines the direction of shift.

-BIT 13 controls the direction of pressure profile offset.

0 = Pressure offset is positive (more pressure) 1 = Pressure offset is negative (less pressure)

We recorded B13 = 0 for positive offset on Worksheet 8-A.

-BIT 12 controls the direction of velocity profile offset.

0 = Velocity offset is positive (more velocity) 1 = Velocity offset is negative (less velocity)

We recorded B12 = 0 for positive offset on Worksheet 8-A.

Profile Algorithm

(IPC03)

The following bits determine the type of injection profile.

-BITS 01 and 00 select the algorithm for the injection profile.

00 = Velocity vs. Position 01 = Velocity vs. Position (pressure-limited) 10 = Pressure vs. Position 11 = Pressure vs. Time

We recorded B01 = B00 = 1 for pressure vs. time on Worksheet 8-A.

Important: All other bit selections in IPC03 should be zero.

8-4

Chapter 8

Load Initial Profile Values

Expert Response Compensation

(IPC04)

-BITS 11, 10, 09, and 08 determine whether you apply Expert

Response Compensation exclusive algorithm that adjusts for changes in your machine, hydraulics, raw materials, and other process variables. It compensates for abrupt upsets and long term deviations. 0 = Expert Response Compensation ON

1 = Expert Response Compensation OFF

We recorded these bits = 1 (ERC = Off) on worksheet 8-A

 (ERC) to injection profiles. ERC is an

Open or Closedloop Control

(IPC04)

-BITS 03, 02, 01, and 00 determine whether you use open- or

closed-loop control of injection profiles. In open loop, you set a valve position to move the cylinder without sensor feedback . In closed loop, you use sensor feedback to control the valve regulating pressure or velocity. 0 = Closed loop

1 = Open loop

Determine Word Values for Worksheet 8A

We recorded these bits = 1 for open-loop control on worksheet 8-A.

Important: All other bit selections in IPC04 should be zero.

The valve spanning procedures in chapter 9 require these initial bit settings. Where required, we help you select correct final bit settings for your application in chapter 10. For additional information, refer to the Plastic Molding Module Reference Manual (publication 1771-6.5.88).

Velocity Setpoints

(IPC09,

Use these words when configuring velocity vs. position profiles. Each velocity setpoint is used between the last completed profile segment and the end-of-segment position setpoint. You may use from 1 to 11 segments in your profile. The procedures in chapter 9 require all eleven.

We recommend that you use initial velocity setpoints equal to the maximum velocity your ram (screw) is capable of traveling. Get this value from your OEM specs for your specific machine.

Record this initial value for all 11 velocity setpoints on Worksheet 8-A. The valve spanning procedures in chapter 9 require these initial values.

For additional information, refer to the Plastic Molding Module Reference Manual (publication 1771-6.5.88).

13, 17, 21, 25, 29, 33, 37, 41, 45, and 49)

8-5

Rockwell Automation 1771-QDC, D17716.5.85 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Summary of Changes

Table of Contents

Preface