Rockwell Automation 1771-QDC, D17716.5.87 User Manual

Plastic Molding Module

(Cat. No. 1771-QDC)

Clamp and Eject Mode

Important User Information

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

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

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

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

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

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

ATTENTION helps you:

- identify a hazard

- avoid the hazard

- recognize the consequences

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

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



1993 Allen-Bradley Company

PLC is a registered trademark of Allen-Bradley Company
ProSet, PanelView

, PanelBuilder

, Inc.

, Inc.

, and ERC are trademarks of AllenBradley Company

, Inc.

Summary of Changes

Summary of Changes

Summary of Changes

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

For These Changes Refer to Page or Chapter

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

Added the section, Record I/O Ranges 21

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

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

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

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

Added data codes to Configuration Block worksheets.

Added headers to improve the organization

Added data codes to Profile Block worksheets.

Added headers to improve the organizatrion

36, 311
A3, A4

Chapters 3 and 4

Chapter 7 and Appendix A

Chapter 7

Chapter 8 and Appendix A

Chapter 8

Placed 2page worksheets on facing pages Chapter 8

Changed the title Test Your Values to Test for Linearity. Chapter 9

Changed our recommendation on module calibration. 113

Added Block ID codes to blank worksheets. Appendix A

Revised the index. Index

Minor corrections as found

To Help You Find Changes

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

Table of Contents

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

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

Manual

Objectives
Audience P2
Use
Related

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

of T

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

Publications

Overview of the Clamp and Eject Mode 11. . . . . . . . . . . . . . .

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

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

Chapter
Clamp and Eject Mode Operation 11
Clamp Control 12
Ejector Control 18

Objectives

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

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

Chapter
Record
Set Module Jumpers 22
Key Your I/O Chassis 25
Install Your QDC Module 26
Wire
Ground and Shield Your I/O Devices 29
Plan for ESTOPs and Machine Interlocks 211

Objectives

I/O Ranges

the QDC Module

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

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

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

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Configure the QDC Module's Inputs and Outputs 31. . . . . . . .

Chapter
Select Module Parameters and I/O Ranges 32
Determine Initial Sensorconfiguration Values 35
Download
Use the Setoutput Operation to Move the Clamp and Ejector 39
Complete your Sensor Configuration 311
Optional Configurations 317

Objectives

MCC V

alues to the QDC Module

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

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37. . . . . . . . . . . . . . . . .

. . . .

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

Chapter
Configuration Concepts 41
Special Command and Status Blocks 42
Overview of the 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
Determine
Jog Your Machine 54
Configure Jogs for the Screw and Injection Cylinder 56

Objectives

Initial Clamp and Ejector Jog V

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

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

alues 52. . . . . . . . . . . . . .

. . . . . . . . . . .

Select Command and Status Bits to Sequence

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

Chapter
Assess Your Logic Requirements 61
Use
Chapter
Use Configuration Command Block Worksheets 72
Procedure to Determine and Record Worksheet Values 724
Determine

Select the T
Determine Word Selections: Set ERC Values and Timer Presets 726
Determine Unselected Valve Setoutput Values 728
Set your Accel/Decel Ramp Rates 731
Determine Setoutput Values for End of Profiles 732
Set Pressure Control Limits 733
Set V
Set Profile Gain Constants and Pressure Alarm Setpoints 737
Enter and Download your Worksheet Values 738

Objectives

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

Bit T

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

Objectives

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. . . . . . . . .

Bit Selections: Assign Module Outputs for

Your Control Valves 724. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ype of PID Algorithm

. .

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elocity Control Limits

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

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

725. . . . . . . . . . . . . . . . . . . . . . . . .

735. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Load

Initial Profile V

Chapter
Determine and Enter Setpoints for the Clamp Close Profile (CPC) 81
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7
Determine and Enter Clamp Open Profile (OPC) 88
Determine Bit Selections for Worksheet 8B 810
Determine Word Values for Worksheet 8B 811
Enter and Download your Worksheet Values 813
Determine and Enter Ejector Profile (EPC) 814
Determine Bit Selections for Worksheet 8C 816
Determine Word Values for Worksheet 8C 819
Enter and Download your Worksheet Values 822

Objectives

alues for Machine Tuning 81. . . . . . . . . .

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

.

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Table of Contents iii

Span Your Clamp and Ejector Valves 91. . . . . . . . . . . . . . . . .

Chapter
Span Your Low Pressure Close Valve 93
Span Your Clamp Close Pressure Valve(s) 99
Span Your Clamp Close Velocity (Flow) Valve(s) 914
Span Your Clamp Open Pressure Valve(s) 918
Span Your Clamp Open Velocity (Flow) Valve(s) 923
Span Your Ejector Pressure Valve(s) 927
Span Your Ejector Velocity (Flow) Valve(s) 934

Objectives

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

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

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

Chapter
Chapter Assumptions 101
Openloop or Closedloop? 102
What to do Next 103
Tune in Closedloop Mode 103
Other Tuning Considerations 1011

Objectives

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

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

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Troubleshoot with LED's 111. . . . . . . . . . . . . . . . . . . . . . . . . .

Chapter
Use
Module

Objectives

LED'

s to Troubleshoot Your QDC Module 111. . . . . . . . . . . . . . .

Calibration

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

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

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

Using This Manual

Preface

Manual

Objectives

Use this preface to familiarize yourself with this manual so you can use it
effectively. This manual shows you how to apply the QDC module to your
molding machine in 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 chapter:

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

Overview of clamp and eject operation: how the QDC
module controls the clamp and eject phases 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. This includes configuring your QDC module to
communicate to the different inputs and outputs.

Overview of remaining configuration procedures that you
are to perform through the remainder of this manual.

Jog the Clamp and Ejector. This task requires jog setpoints
to be configured along with jog pressure alarm setpoints.

Set up communications between your PLC and the QDC
module. This task includes selecting command and status
bits that you use when writing your ladder logic.

Load initial configuration values for the QDC module. This
task requires you to determine and enter values into the
clamp and ejector configuration blocks.

Load your initial profile values for the QDC module. This
task is performed in preparation to run and span your
machine's valves.

Span your clamp and ejector valves. This is done using
setoutput and openloop modes.

Tune the machine in closedloop mode. Chapter 10

Troubleshoot problems that may occur during module
operation.

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

All chapters

Chapter 1

Chapter 2

Chapter 3

Chapter 4

Chapter 5

Chapter 6

Chapter 7

Chapter 8

Chapter 9

Chapter 11

Appendix A

P-1

Preface

Using this Manual

Audience

of T

Use

erms

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

an injection molding professional
an experienced programmer (especially with A-B PLC-5 processors)
familiar with hydraulics

We use these abbreviations:

Abbreviated Name: Item:

QDC module 1771QDC Plastic Molding Module

PLC Processor PLC5 Programmable Controller

T47 or T50 terminal 1784T47 or 1784T50 Industrial Terminal

ProSet 600 Software

PanelView Terminal PanelView Operator Interface Terminal (2711KC1)
ERC

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

Expert Response Compensation

The following table presents other terms we 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.
Multiple axis of control, such as the clamp and ejector cylinders, may
require additional control valves.

Unselected 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 unselected valves.

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

operation to the QDC module.

Command Block Blocks downloaded from the PLC data table to the QDC module to

make configuration changes or to initiate machine actions.

Status Block Blocks used by the QDC module to relay information to the PLC

processor about the QDC module's current operating status.

Profile Block Command block containing mold/part setpoints.

Configuration Block Command block containing machine setpoints.

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

with increasing signal input.

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

with decreasing signal input.

P-2

Preface

Using this Manual

Command Blocks

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

Acronym: Description:

MCC Module Configuration Block

JGC Jog Configuration Block

FCC First Clamp Close Configuration Block

SCC Second Clamp Close Configuration Block

TCC Third Clamp Close Configuration Block

LPC Low Press Clamp Close Configuration Block

CPC Clamp Close Profile Block

FOC First Clamp Open Configuration Block

SOC Second Clamp Open Configuration Block

TOC Third Clamp Open Configuration Block

OSC Clamp Open Slow Configuration Block

OPC Clamp Open Profile Block

EAC Ejector Advance Configuration Block

ERC Ejector Retract Configuration Block

EPC Ejector Profile Block

DYC Dynamic Command Block

CLC Clamp & Eject ERC Values Block

Status Blocks

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

Acronym: Description:

SYS System Status Block

CPS Clamp Close Profile Status Block

OPS Clamp Open Profile Status Block

EPS Ejector Profile Status Block

CLS Clamp & Eject ERC Values Status Block

P-3

Preface

Using this Manual

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)

Related

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6.5.88 Plastic Molding Module

17716.5.85
17716.5.86
17716.5.93

17714.10 Plastic Molding Module

#:

Use this documentation: To:

Controller Installation Manual

Software Documentation Set

Reference Manual

Plastic Molding Module User
Manual for other modes

Application Guide

Install the PLC processor and I/O modules.

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

Information on block transfers between PLC
processor and QDC module. Also,
information on PLC data transfer logic.

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

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

P-4

Preface

Using this Manual

Reference information for the QDC module is contained in a separate
document titled “Plastic Molding Module Reference Manual”. Take time
now to familiarize yourself with this reference manual’s content and
purpose. The four sections, in brief, include:

a summary of each data block used by the QDC module for all

command and status blocks (abbreviated command and status blocks)

the programming error codes returned by the QDC module on a block

by block basis as well as recommended procedures to correct these
errors

a detailed listing and explanation of each command word and bit used

by the QDC module, as well as each status word and bit returned from
the QDC module

operational, mechanical, electrical, and environmental specifications

about your module

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

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 processor and PanelView application
files.

Install ProSet 600 overlay(s) into your
application files.

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

Support customizing your software
control system.

P-5

Chapter

1

Overview of the Clamp and Eject Mode

Chapter

Objectives

Clamp and Eject Mode Operation

Clamp Phase: Description:

1st Close
2nd Close
3rd Close

Low Pressure
Close

This chapter presents an overview of the 1771-QDC Plastic Molding
Module’s Clamp and Eject Mode. A summary of clamp and eject features
is followed by sample applications of the QDC Module in Clamp and Eject
Mode.

Important: This manual assumes you have already read your Plastic
Molding Module Application Guide (pub. no. 1771-4.10) and have chosen
Clamp and Eject as your QDC module’s mode of operation.

When you select the Clamp and Eject mode of operation, you can use the
following phases:

Table 1.A
Glossary

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

• pick up a third mold plate

• set cores

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

To guard against damaging the mold when the two mold surfaces make contact and to detect part obstructions, you
close the mold slowly with low pressure in closedloop or openloop control. Low Pressure Close can only be
controlled through a pressure vs. position profile.

of Clamp and Eject Mode

1st Open
2nd Open
3rd Open

Open Slow

Eject Phase: Description:

Ejector Advance You advance the ejector in a singlestep or in multiple steps using closedloop or openloop control. Multiple strokes

Ejector Retract You retract the ejector in a singlestep or in multiple steps using closedloop or openloop control. Multiple strokes

Tip Strokes You can shake the part off the ejector tip by programming rapid singlestroke interim ejector cycles starting after the

Forward Dwell You can pause after the first advance stroke or before the last retract stroke to let a robot remove the part when the

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

• drop out a third mold plate

• pull cores

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

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

may be programmed.

may be programmed.

first advance stroke and ending before the last retract stroke.

ejectors are extended.

1-1

Chapter 1

Overview of the Clamp and Eject Mode

Clamp Control

Ejector retract

Ejector advance

You control clamp operation with these phases:

clamp close
low pressure close
clamp open
open slow

Figure 1.1
Clamp

1st
Close

Open
Slow

Portion of a T

ypical Machine Cycle

2nd
Close

3rd
Open

3rd
Close

Low Pressure
Close

2nd
Open

Clamp Close

Inject

1st
Open

Three separate clamp close profiles may be configured:

first close
second close
third close

You may select from these control modes:

velocity vs. position
pressure vs. position

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

1-2

Chapter 1

Overview of the Clamp and Eject Mode

Clamp
Cylinder

L

Moving
Platen

Figure 1.2
Example

Clamp Close

0

X

Stationary
Platen

Velocity

1st
Close
Profile

2nd
Close
Profile

Position

3rd
Close
Profile

Three different close profiles have been provided to allow you to initiate
the following operations between profiles:

pick up the 3rd plate of a mold (on a floating 3-plate mold) or set cores
program other events for all valves
either automatically bridge between profiles or allow user programming

to decide when to begin the next profile

Each of these three profiles is subdivided into three position segments
(shown above each profile as in Figure 1.3). You can change clamp
velocity or pressure up to three times in each profile, or up to nine times
for the entire clamp close phase.

Clamp
Cylinder

L

Moving
Platen

Figure 1.3
Example

Clamp Close Position Segments

Stationary
Platen

0

X

11

1st
Close
Profile

Velocity

Segments

2

3

2nd
Close
Profile

Position

2

1

3

3rd
Close
Profile

2

3

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

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

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

1-3

Chapter 1

Overview of the Clamp and Eject Mode

Low Pressure Close

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

You will use the pressure vs. position control mode for low pressure close.

Clamp
Cylinder

Figure 1.4
Example

Low Pressure Close

Moving
Platen

L

0

X

Stationary
Platen

Low Pressure Close

Segments

1

2

Pressure

Position

Important: If you need only one Low Pressure Close segment, configure
the 1st segment of the Low Pressure Close Profile.

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

1-4

Chapter 1

Overview of the Clamp and Eject Mode

Clamp Open

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

first open
second open
third open

You may select from these control modes:

velocity vs. position
pressure vs. position

Use Clamp Open to move the platen from the fully closed position (0) to
some position Y at a relatively high velocity or pressure. Y is a position
relatively close to your fully open position (L), yet far enough away to
allow deceleration into Open Slow. This is to increase positioning
accuracy at the full open position (L).

Clamp
Cylinder

Moving
Platen

Figure 1.5
Example

L0

Y

Clamp Open

Stationary
Platen

Three different open profiles have been provided to allow you to initiate
the following operations between profiles:

drop off the third plate of a mold (on a floating 3-plate mold) or pull

cores
program other events for all valves
either automatically bridge between profiles or allow user programming

to decide when to begin the next profile.

Each of these three profiles is subdivided into three position segments
(shown above each profile in Figure 1.6). You can change clamp velocity
or pressure up to three times in each profile, or up to nine times for the
entire clamp open phase.

Velocity

3rd
Open
Profile

2nd
Open
Profile

Position

1st
Open
Profile

1-5

Chapter 1

Overview of the Clamp and Eject Mode

Clamp
Cylinder

Moving
Platen

Figure 1.6
Example

L0

Y

Clamp Open Position Segments

Stationary
Platen

33

3rd
Open
Profile

Velocity

Segments

2

1

2nd Open
Profile

Position

2

3

1

1st Open
Profile

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

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

2

1

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

1-6

Chapter 1

Overview of the Clamp and Eject Mode

Open Slow

Use the Open Slow Profile to accurately position the clamp for ejecting the
part(s). You may decelerate clamp motion twice with this profile using up
to two profile segments.

You may select from these control modes:

velocity vs. position
pressure vs. position

Figure 1.7
Example

Clamp
Cylinder

Open Slow

Moving
Platen

L0Y

Stationary
Platen

Open Slow

Segments

2

Velocity

Position

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

1

1-7

Chapter 1

Overview of the Clamp and Eject Mode

Ejector Control

Ejector retract

Ejector advance

In this section, we describe Eject operation for expelling parts from the
mold. The operation consists of:

ejector advance
ejector retract

Figure 1.8

and Eject Portion of a T

Clamp

Clamp Close
(Multiphase)

Open Slow

ypical Machine Cycle

Low Pressure
Close

Inject

Clamp Open
(Multiphase)

Ejector Advance

The QDC module starts advancing the ejector after detecting either one of
these events that you configure/program:

clamp position reaching a pre-determined setpoint
command from the user PLC program

You may advance the ejector while the clamp is still opening the mold, or
wait until the mold is fully open.

Up to three ejector advance profile segments may be used. You may select
from these control modes:

velocity vs. position
pressure vs. position

1-8

Chapter 1

Overview of the Clamp and Eject Mode

Figure 1.9
Example

Ejector

Ejector Advance

0

Velocity

Fully Advanced Position

Ejector Advance

1

Velocity

Position

Segments

2

3

Important: If you need only one ejector advance motion, configure only
the 1st Advance segment.

Ejector Retract

After the ejector advance is completed, ejector retract is executed. Similar
to advancing the ejector, you retract it with up to three profile segments.
You may select from these control modes:

velocity vs. position
pressure vs. position

Figure 1.10
Example

Ejector

Ejector Retract

0

Velocity

Fully Advanced Position

Ejector Retract

3

Velocity

Position

Segments

2

1

1-9

Chapter 1

Overview of the Clamp and Eject Mode

Other Eject Features

The QDC Module gives you the following additional features:

the ability to repeat the ejector cycle a number of times, changing from

advance to retract determined either automatically or by command from

your PLC program

Ejector Forward Dwell - the ability to pause after completing the first or

last ejector advance stroke. Use this feature so a robot can pick off a

part when ejectors are fully extended

Ejector “Tip” Strokes - the ability to “shake” the part off the ejector.

You may program interim single-segment advance and retract tip strokes

that occur after the first advance stroke and before the last retract stroke

Full
Retract

Figure 1.11
Advance,

First Full Advance

Tip Retract

Tip Advance

Tip Retract

Retract and T

:
:

Last Retract

Tip Strokes

1

ip Strokes

1

1

Full
Advance

= Ejector Forward  Dwell

1-10

Chapter

Install the QDC Module

2

Chapter

Objectives

Record I/O Ranges

This chapter guides you through the process of installing your QDC
module to assure reliable, safe performance. Major topics described in this
chapter include how to:

set module jumpers
key your I/O rack
install your module
wire I/O devices to your 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 setting jumper plugs, and in chapter 3 to configure the module’s
inputs and outputs with software.

Circle or check your selections for I/O ranges on Worksheet 2-A.

Worksheet 2A

I/O Ranges

Record

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

Input 1 (Ejector position) 0 to 10V dc 1 to 5V dc 4 to 20 mA

Input 2 (Ejector pressure) 0 to 10V dc 1 to 5V dc 4 to 20 mA

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

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

Output 1 10 to 10V dc 0 to 10V dc 4 to 20 mA

Output 2 10 to 10V dc 0 to 10V dc 4 to 20 mA

Output 3 10 to 10V dc 0 to 10V dc 4 to 20 mA

Output 4 10 to 10V dc 0 to 10V dc 4 to 20 mA

2-1

Chapter 2

Install the QDC Module

Set Module Jumpers

Before installing the QDC module, you must use jumper plugs to configure
the I/O ranges that you selected with 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. Also, this should be done on an anti-static work station.

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. Locate the jumpers (Figure 2.1).

5. Set the jumper plugs as shown in Table 2.A using a small needle-nose

pliers (Figure 2.1).

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

2-2

Chapter 2

Install the QDC Module

Figure 2.1
Jumper

LEFT

Locations on the QDC Module'

TOP

E5

s Circuit Board

E1

E6

RIGHT

E7

E8

E9

E10

E11

E12

E15

E16

E14

E13

E17

BOTTOM

10908I

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

2-3

Chapter 2

Install the QDC Module

Table 2.A
Jumper

Settings

Jumper: Function: Setting:

E1 Run/Calibrate Calibrate = right

Run = left

E5 I/O Density Standard = top

Do not use bottom position

E6
E7
E8
E9

E10
E14
E13
E17

E11
E12
E15
E16

1

Factory Defaults

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

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

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

Voltage = right
Current = left

Current = top
Voltage = bottom

-10 to +10V dc = top
0 to +10V dc or 4 to 20mA = bottom

1

1

1

1

1

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

ATTENTION: If an output is unconnected, set the jumper
(E11, E12, E15, and/or E16) that corresponds to that output to 0

- 10V dc (bottom position). Setting the jumpers for –10 to
+10V dc and later configuring the output as “unconnected” may
cause the QDC module to output –10V dc on that channel. This
occurs when the system is stopped or when a system reset
occurs and all outputs are forced to 0% (i.e. 0% output equals
–10V dc).

2-4

Chapter 2

Install the QDC Module

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

10

8
5
3
0

-3

Output Voltage

-5

-8

-10

0 102030405060708090100

%

Output Requested

Key Your I/O Chassis

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

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

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

between 20 and 22
between 26 and 28

Figure 2.2

Positions

Keying

2
4
6
8
10
12
14
16
18
20

Keying

Bands

22
24
26
28
30
32
34
36

1771QDC

12676

2-5

Chapter 2

Install the QDC Module

Install Your QDC Module

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

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.

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

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

slot that slides the module into position.

Important: Be aware that Pro-Set 600 software expects your Clamp and
Eject QDC module to be placed in slot 1 of your I/O rack. If you choose to
install your QDC module in some other slot, some modifications to your
PLC application program may be necessary (refer to your Pro-Set 600
documentation for details).

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

even pressure on the module to seat it properly.

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

5. Connect the wiring arm to the module.

2-6

Chapter 2

Install the QDC Module

Wire the QDC Module

+

Customer
PS

–

Ejector
Position
Sensor

Ejector
Pressure
Sensor

Clamp
Position
Sensor

Clamp
Pressure
Sensor

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

Figure 2.3

W

iring and Grounding

I/O

+

–

+

–

+

–

+

–

Input 3

Input 4

Input 1

Input 2

–

Customer
PS

18

+

–

+

Amplifier
Valve 1

+

–

+

–

To Valve 1

+

–

Amplifier
Valve 2

Amplifier
Valve 3

+

–

To Valve 2

+

–

17
16
15
14
13
12

11

10
9

8
7

6

5
4

3
2
1

Output 1

Output 2

Output 3

Earth Ground

Wiring Arm
1771WF

Output 4

+

–

Amplifier
Valve 4

To Valve 3

+

–

To Valve 4

10909I

2-7

Chapter 2

Install the QDC Module

Table 2.B

and Eject Mode

Clamp
I/O Terminal Designations

Transducer: I/O Designation: Terminal:

Ejector position Input 1 (+)

(-)

Ejector pressure Input 2 (+)

(-)

Input common 14

Clamp position Input 3 (+)

(-)

Clamp pressure Input 4 (+)

(-)

Valve 1 Output 1 (+)

Output common

Valve 2 Output 2 (+)

Output common

Valve 3 Output 3 (+)

Output common

Valve 4 Output 4 (+)

Output common

Not used 01

18
17

16
15

13
12

11
10

09
08

07
06

05
04

03
02

2-8

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:

+12V dc input (18 thru 10) any mode

+12V dc output (09 thru 02) voltage mode

+24V dc output (09 thru 02) current mode

Chapter 2

Install the QDC Module

Ground and Shield

our I/O Devices

Y

Input Sensor

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

Guidelines:

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

wire, such as Belden 8761 (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

+15V

+

–

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

14

No User Connections.
For Test Purposes, Only.

-15V

Input Module Common
should float

109102

2-9