Rockwell Automation 1771-QDC, D17716.5.93 User Manual

Plastic Molding Module

(Cat. No. 1771-QDC)

Inject, Clamp, and Eject 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

Table of Contents

Important Information P1. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Manual

Objectives
Audience P2
Use
Related

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

of T

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

Publications

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

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

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

Chapter
Inject Control 11
Clamp Control 19
Ejector Control 113
System Pressure 115
Example
Summary

Objectives

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

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

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

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

Hydraulic Circuits for the Inject, Clamp, and Eject Mode

of Inject, Clamp, and Eject Mode of Operation

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

116. .

120. . . . . . . .

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

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

Configure the QDC Module'

Chapter
Select Module Parameters and I/O Ranges 32
Determine Initial Sensorconfiguration Values 34
Download MCC Parameters to the QDC Module 35
Use Setoutput Operation to Move the Ram (screw),

Complete your Sensor Configuration 38
Select

Objectives

I/O Ranges

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

the I/O Chassis

the QDC Module

I/O Devices

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

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

s I/O

Objectives

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

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

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

Clamp, and Ejector 37

Optional Configurations

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

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

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

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

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

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

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

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

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

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

Table of Contentsii

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

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

Objectives

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

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

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

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

. . . . . . . . . . .

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), Clamp, and Ejector 57
Configure Screwrotate Jogs for Indirect Control 57
Write Ladder Logic to Assist with Screwrotate Jogs 58
Rotate the Screw 59

Objectives

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

Initial 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 These Worksheets 72
Procedure to Determine and Record Initial Values 719
Determine

Select the T
Determine Word Values:

Determine Unselected Valve Setoutput Values 722
Set Your Acceleration/Deceleration Ramp Rates 724
Determine Setoutput Values for End of Profiles 725
Set Pressure Control Limits 726
Set V
Set Profile Gain Constants, PressureAlarm Setpoints,

Enter and Download your Worksheet Values 731

Objectives

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

Command and Status Bit T

Objectives

Bit Selections: Assign Module Outputs for

Your Control Valves 719. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ype of PID Algorithm

Select V

and Watchdog Timer Presets 729

alues for Expert Response Compensation (ERC) 722. . . . .

elocity Control Limits

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

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

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

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

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

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

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

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

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

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

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

721. . . . . . . . . . . . . . . . . . . . . . . . .

728. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Load

Initial Profile Setpoints

Table of Contents iii

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

Chapter
Use These Worksheets 81
Determine and Record Setpoints for the Clamp Close Profile (CPC) 82

Determine Bit Selections for Worksheet 8A 85. . . . . . . . . . . . . . . . .

Determine Word Values for Worksheet 8A 87
Enter and Download Your Worksheet Values 89
Determine and Record Setpoints for the Injection Profile (IPC) 810
Determine Bit Selections for Worksheet 8B 813
Determine Word Values for Worksheet 8B 814
Enter and Download your Worksheet Values 818
Determine and Record Setpoints for the Pack/Hold Profile (HPC) 818
Determine Bit Selections for Worksheet 8C 821
Determine Word Values for Worksheet 8C 822
Enter and Download your Worksheet Values 823
Determine and Record Setpoints for the Plastication Profile (PPC) 824
Determine Bit Selections for Worksheet 8D 827
Determine Word Values for Worksheet 8D 828
Enter and Download your Worksheet Values 830
Determine and Record Setpoints for the Clamp Open Profile (OPC) 831

Determine Bit Selections for Worksheet 8E 834. . . . . . . . . . . . . . . . .

Determine Word Values for Worksheet 8E 836
Enter and Download Your Worksheet Values 838
Determine and Record Setpoints for the Ejector Profile (EPC) 839
Determine Bit Selections for Worksheet 8F 842
Determine Word Values for Worksheet 8F 845
Enter and Download Your Worksheet Values 849

Objectives

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

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

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

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

. . . .

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

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

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

.

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

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

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

.

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

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

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

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

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

. . . .

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

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

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

Span Your V

Chapter
Choose Only Applicable ValveSpanning Procedures 91
Referenced Worksheets 93
LPC Profile - Low Pressure Valve 94
FCC, SCC, TCC Profiles - Pressure Valve(s) 910
FCC,

SCC, TCC Profiles - V

INC Profile - Pressure Valve 920

Profile - V

INC
PKC and HDC Profiles - Pressure Valves 931
PLC Profile - Pressure Valve 937
FOC,

SOC, T

FOC,

SOC, T
EAC, ERC Profiles - Pressure Valve(s) 953
EAC, ERC Profiles - Velocity (Flow) Valve(s) 958

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

Objectives

. . . . . . . . . .

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

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

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

elocity (Flow) Valve(s) 915. . . . . . . . . . . .

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

elocity V

OC, OSC Profiles - Pressure Valve(s) 942. . . . . . . . . . .

OC, OSC Profiles - V

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

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

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

elocity (Flow) Valve(s) 948. . . . . . .

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

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

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

Table of Contentsiv

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

Chapter
Closedloop Tuning 102
Injection Tuning Considerations for Producing Parts 1010
Tuning Considerations for Clamp and Ejector Operations 1023

Objectives

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

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

. . . . . . . . . . .

. . . . . . .

Table of Contents v

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

Chapter
Use LEDs to Troubleshoot Your QDC Module 111

Objectives

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

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

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

Preface

Important Information

Manual

Objectives

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

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

Perform this task: As discussed in this chapter:

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

Learn about the inject, clamp, and eject process.
This describes how the QDC module controls your
injection molding system.

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

Learn about the configuration process.
This describes procedures you perform using this
manual.

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

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

Set up communications between your PLC5 processor
and the QDC module. You write ladder logic to handle
command bit interaction between the two devices.

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

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

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

Tune the machine for parts production. Chapter 10

Troubleshoot problems that may occur with QDC module. Chapter 11

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

All chapters

Chapter 1

Chapter 2

Chapter 3

Chapter 4

Chapter 5

Chapter 6

Chapter 7

Chapter 8

Chapter 9

Appendix A

P-1

Preface

Audience

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 PLC programmer

(especially with the Allen-Bradley PLC-5 family of processors)

an hydraulics designer or technician

We use abbreviated catalog numbers when referring to Allen-Bradley
equipment:

Abbreviated Name: Title:

QDC module 1771QDC Plastic Molding Module

PLC5 processor PLC5 Programmable Controller

T45 or T47
T50 oe T53 terminal

ProSet 600 Software

PanelView Color display
ERC Expert Response Compensation

1784T45 or 47 Portable Programming Terminal
1784T50 or 53 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 modules algorithms the selected valve.

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

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

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

to the QDC module.

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

to make configuration changes or to initiate machine actions.

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

processor about the QDC module's current operating status.

Profile Block Command block containing mold/part setpoints.

Configuration Block Command block containing machine setpoints.

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

increasing signal input.

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

decreasing signal input.

P-2

Preface

Command Blocks

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

Acronym: Description:

MCC Module Configuration Command Block

JGC Jog Configuration Command Block

FCC First Clamp Close Configuration Command Block

SCC Second Clamp Close Configuration Command Block

TCC Third Clamp Close Configuration Command Block

LPC Clamp Low Pressure Close Configuration Command Block

CFC Clamp Close Profile Command Block

INC Injection Configuration Command Block

IPC Injection Profile Command Block

PKC Pack Configuration Command Block

HDC Hold Configuration Command Block

HPC Pack/Hold Profile Command Block

PRC Predecompression Configuration Command Block

PLC Plastication Configuration Command Block

PPC Plastication Profile Command Block

PSC Postdecompression Configuration Command Block

FOC First Clamp Open Configuration Command Block

SOC Second Clamp Open Configuration Command Block

TOC Third Clamp Open Configuration Command Block

OSC Clamp Open Slow Configuration Command Block

OPC Clamp Open Profile Command Block

EAC Ejector Advance Command Block

ERC Ejector Retract Command Block

EPC Ejector Profile Command Block

DYC Dynamic Command Block

RLC Inject ERC Values Command Block

CLC Clamp and Eject ERC Values Command Block

P-3

Preface

Status Blocks

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

Acronym: Description:

SYS System Status Block

CPS Clamp Close Profile Status Block

IPS Injection Profile Status Block

HPS Pack/Hold Profile Status Block

PPS Plastication Profile Status Block

OPS Clamp Open Profile Status Block

EPS Ejector Profile Status block

RLS Inject ERC Values Status Block

CLS Clamp and Eject ERC Values Status Block

Word and bit Numbering

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

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

Specific: MCC09-B15 General: MCCxx-Byy

where:

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

P-4

Preface

Related

Publications

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

Publication Use this documentation: To :

17856.6.1 PLC5 Family Programmable

Controller Installation Manual

6200N8.001 6200 PLC5 Programming

Software Documentation Set

17714.10 Plastic Molding Module

Application Guide

17716.5.85
17716.5.86
17716.5.87

17716.5.88 Plastic Molding Module

Plastic Molding Module User
Manuals for other modes.

Reference Manual

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

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

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

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

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

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

a summary of each data block used by the QDC module

(abbreviated command and status blocks)

programming error codes returned by the QDC module for each data

block, and recommended procedures to correct these errors

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

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

operational, electrical, and environmental specifications of your module

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

Publication Use this documentation: To :

65006.5.11 ProSet 600 Software

Designers Guide

65006.5.12 ProSet 600 Software

Assembly Manual

65006.5.13 ProSet 600 Software

Overlay Installation Manual

65006.5.14 ProSet 600 Software

Customization Manual

65006.5.15 ProSet 600 Software

Reference Manual

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

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

Install ProSet 600 overlays into your application
files.

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

Support customizing your software control
system.

P-5

Chapter

1

Overview of Inject, Clamp, and Eject Mode

Chapter

Objectives

Inject Control

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

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

Next we describe the control operations of this mode.

You can control the inject operation with these phases:

injection
transition
pack
hold
pre-decompression
plastication
post-decompression

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)

1-1

Chapter 1

Overview of Inject, Clamp, and Eject Mode

Injection Phase

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

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

Figure 1.2
Example

Injection Profile

11 10 9

Velocity or Pressure

87654321

Position or Time

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

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

Velocity vs. Position Speed Length of the shot

Distributed over the:

1-2

Pressurelimited1
Velocity vs. position

Pressure vs. Position Pressure Length of the shot

Pressure vs. Time Pressure Time for a shot

1

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

Speed with a
maximum pressure

Length of the shot

Chapter 1

Overview of Inject, Clamp, and Eject Mode

Example Benefits of Profiling an Injection Phase

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

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

Mold Cavity

54 3

Flow into mold

Figure 1.3
Velocity

1

2

Example

Gate

Mold
End

Injection Profile

5

4

Position

Sequence of execution

Velocity

23

1

Back
Point

1-3

Chapter 1

Overview of Inject, Clamp, and Eject Mode

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

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

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

Figure 1.4
Flash

Prevention Example

1. Initial Velocity Profile

Velocity

bca

Position Position

3. Final Velocity Profile

Velocity

b ca

Position

2. Resulting Pressure Profile

ba

4. Resulting Pressure Profile

ba

Position

Flash
Point

Pressure

c

Flash
Point

c

Pressure

1-4

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

Chapter 1

Overview of Inject, Clamp, and Eject Mode

Injectiontopack Transition

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

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

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

Pack Phase

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

Figure 1.5

Phase Example

Pack

Pressure

4

5

Time

123

1-5

Chapter 1

Overview of Inject, Clamp, and Eject Mode

Example Benefit of Profiling the Pack Phase

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

Figure 1.6
Uneven

Lower density
(last zone filled)

Density in Mold Cavity

Cooling in Pack Phase

Pack Profile

Higher density
(gate zone,
greater pressure)

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

5

5

Pack Profile

Time

Time

234

1

Pressure

234

1

1-6

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

Chapter 1

Overview of Inject, Clamp, and Eject Mode

Hold Phase

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

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

Predecompression Movement

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

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

Plastication Phase

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

You chose from two plastication profiles:

Backpressure vs. position
Backpressure vs. time

1-7

Chapter 1

Overview of Inject, Clamp, and Eject Mode

Figure 1.8
Plastication

BackPressure

Mold
End

Phase Example

12 34 5

Position or Time

hotter

Temperature Gradient

Barrel Containing the Melt

6

7891011

cooler

Back
Point

Example Benefits of Profiling a Plastication Phase

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

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

Postdecompression Movement

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

1-8

Chapter 1

Overview of Inject, Clamp, and Eject Mode

Clamp Control

Ejector advance

Ejector retract

You control clamp operation with these phases:

clamp close
low pressure close
clamp open
open slow

Figure 1.9
Clamp

1st
Close

Open
Slow

Portion of a T

ypical Machine Cycle

2nd
Close

3rd
Open

3rd
Close

2nd
Open

Low Pressure
Close

1st
Open

Clamp Close

Inject

Clamp
Cylinder

You may configure three separate clamp close profiles:

first close
second close
third close

You may select from these control modes:

velocity vs. position
pressure vs. position

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

Figure 1.10
Example

Moving
Platen

Clamp Close

Stationary
Platen

Velocity

1st Close
Profile

2nd

Close

Profile

3rd

Close

Profile

L

Position

1-9

Chapter 1

Overview of Inject, Clamp, and Eject Mode

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

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

begin the next profile

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

Clamp
Cylinder

L

Moving
Platen

Figure 1.11
Example

Clamp Close Position Segments

Stationary
Platen

0

X

Velocity

2

1

1st Close
Profile

3

Segments

2

1

2nd

Close

Profile

Position

3

1

2

3

3rd

Close

Profile

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

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

1-10

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

Low Pressure Close

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

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

Chapter 1

Overview of Inject, Clamp, and Eject Mode

Clamp
Cylinder

Figure 1.12
Example

Low Pressure Close

Moving
Platen

L

0

X

Stationary
Platen

Low Pressure Close

Segments

1

2

Pressure

Position

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

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

Clamp Open

Clamp
Cylinder

Moving
Platen

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 relatively high velocity or pressure (Figure 1.13). Y is
close to your fully open position (L), yet far enough away for deceleration
into the open slow profile. This aids positioning accuracy at position (L).

Figure 1.13
Example

Clamp Open

Stationary
Platen

Velocity

3rd

Open

Profile

2nd

Open

Profile

1st Open
Profile

L0

Y

Position

1-11

Chapter 1

Overview of Inject, Clamp, and Eject Mode

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

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

begin the next profile.

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

Clamp
Cylinder

Moving
Platen

Figure 1.14
Example

L0

Y

Clamp Open Position Segments

Stationary
Platen

Velocity

2

3

3rd Open
Profile

1

Segments

2

3

2nd Open
Profile

Position

1

3

1st Open
Profile

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

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

2

1

1-12

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

Open Slow

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

You may select from these control modes:

velocity vs. position
pressure vs. position

Chapter 1

Overview of Inject, Clamp, and Eject Mode

Ejector Control

Figure 1.15
Example

Clamp
Cylinder

Open Slow

Moving
Platen

L0Y

Open Slow

Segments

Stationary
Platen

2

Velocity

Position

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

In this section, we describe the eject operation for expelling molded parts.
The operation consists of:

ejector advance
ejector retract

1

Ejector retract

Ejector advance

Figure 1.16

and Eject Portion of a T

Clamp

Clamp Close

Open Slow

ypical Machine Cycle

Low Pressure
Close

Inject

Clamp Open

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 your PLC program

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

1-13

Chapter 1

Overview of Inject, Clamp, and Eject Mode

You may use up to three ejector-advance profile segments, and select from
these control modes:

velocity vs. position
pressure vs. position

Figure 1.17
Example

Ejector

Ejector Advance

0

Velocity

Fully Advanced Position

Ejector Advance

Segments

1

Velocity

Position

2

3

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

Ejector Retract

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

velocity vs. position
pressure vs. position

1-14

Figure 1.18
Example

Ejector

Ejector Retract

Ejector Retract

Segments

Velocity

3

Velocity

0

Fully Advanced Position

Position

1

2

Chapter 1

Overview of Inject, Clamp, and Eject Mode

Other Eject Features

The QDC module gives you the following additional features:

Multiple Cycles – 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 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

System

Pressure

Figure 1.19
Advance,

Retract and T

Full
Retract

ip Strokes

First Full Advance

Tip Retract

Tip Advance

Tip Retract

:
:

Last Retract

Tip Strokes

Ejector

Ejector

Full
Advance

Forward Dwell

Forward Dwell

We define system pressure for the Inject, Clamp, and Eject mode as the
pressure continuously detected by the single pressure sensor connected to
the QDC module at input 2. Depending on machine hydraulics, a single
pressure valve may control inject, clamp, and/or eject mode profiles.

ATTENTION: Your control system may not work as expected
with possibly machine damage if you attempt to control a
pressure profile of a phase (inject, clamp, or eject) not
hydraulically plumbed for pressure control.

1-15

Chapter 1

Overview of Inject, Clamp, and Eject Mode

Because system pressure may change from one phase to the next, we
recommend that you:

assign pressure control to phases that require pressure profiles

(and are hydraulically plumbed to support it)
place the system pressure sensor accordingly in the hydraulic circuit
configure the remaining phases with velocity profiles

We define open-loop pressure control as when the QDC module controls
phase pressure without input from the system pressure sensor. For example:
when the system pressure sensor monitors the clamp for closed-loop pressure
control, the QDC module can control:

ram (screw) pressure for pack, hold, and plastication in open loop
ejector velocity in closed- or open-loop using a position sensor

For example:

Example Hydraulic Circuits
for the Inject, Clamp, and
Eject Mode

For this Phase The QDC Module Can Control it With

clamp close and open closedloop pressure

injection openloop pressurelimited velocity

pack/hold openloop pressure

plastication openloop pressure

ejector advance and retract velocity

In general:

If your system pressure sensor
reads pressure for only ONE of
these modes:

inject clamp, eject

clamp inject , eject

eject inject, clamp

Then you must control the other modes by either of:

1. closed or openloop velocity

2. openloop pressure

We illustrate three examples of hydraulic circuits compatible with the QDC
module in the inject, clamp, and eject mode:

4-valve system with system pressure sensor
3-valve system with ram (screw) pressure sensor
2-valve system for inject phase with clamp and ejector position inputs

(clamp and ejector direction solenoid valves controlled by ladder logic)

1-16

Chapter 1

Overview of Inject, Clamp, and Eject Mode

Example 4valve System with System Pressure Sensor

With this hydraulic system, a QDC module in the Inject, Clamp, and Eject
mode, has maximum control flexibility. It can control all profiles with:

pressure or velocity
open or closed loop

Clamp
Flow Valve

Figure 1.20
Example

Clamp

AB

PT

4valve System for Inject/Clamp/Eject Control

Ejector

Tank

Ejector
Flow Valve

AB

T

P

Ram (Screw)
Flow Valve

Tank

Ram (Screw)

AB

PT

Tank

System
Pressure Valve

Tank

Pump

P

System
Pressure
Sensor

QDC

I/O:

Input 1 Ram (screw) Position

Input 2 System Pressure

Input 3 Clamp Position

Input 4 Ejector Position

Output 1 Ram (screw) Flow

Output 2 System Pressure

Output 3 Clamp Flow

Output 4 Ejector Flow

Designation

12468I

1-17

Chapter 1

Overview of Inject, Clamp, and Eject Mode

Example 3valve System with Ram (Screw) Pressure Sensor

With this hydraulic system, one QDC module in the Inject, Clamp, and
Eject mode, can control the following:

closed-loop pressure for injection, pack, hold, and plastication profiles
closed-loop velocity for injection profiles
open-loop pressure for clamp and ejector profiles
closed-loop velocity for clamp and ejector profiles

Figure 1.21
3Valve

System for Inject and Clamp Control Example

Clamp
Flow Valve

Pump

Clamp Ram (Screw)

AB

PT

Tank

System
Flow Valve

System
Pressure
Valve

Tank

Ejector

AB

P

T

Ejector
Directional
Valve

Tank

QDC

I/O:

Input 1 Ram (Screw) Position

Input 2 System Pressure

Input 3 Clamp Position

Input 4 Ejector Pressure

Output 1 System Flow

Output 2 System Pressure

Output 3 Clamp Flow

Output 4 Not Used

AB

P

Designation

P

Pressure
Sensor

Ram (Screw)
Directional
Valve

T

Tank

1-18

12469I

Chapter 1

Overview of Inject, Clamp, and Eject Mode

Example 2valve System for Injection Control
with Clamp and Ejector Position Inputs

With this hydraulic system, the QDC module in the Inject, Clamp, and
Eject mode sends clamp and ejector position data to the PLC-5 processor.

The QDC module can control the following:

closed-loop pressure for injection, pack, hold, and plastication profiles
closed-loop velocity for injection profiles

The PLC-5 processor can control:

clamp and ejector hydraulic directional valves
other hydraulic and machine sequencing

Figure 1.22

System: Injection Control

2Valve
(Clamp and Ejector Valves Controlled by Ladder Logic)

Pressure
Control Valve

Flow
Control Valve

Tank

QDC I/O:

Input 1 Ram (Screw) Position

Input 2 System Pressure

Input 3 Clamp Position

Input 4 Ejector Position

Output 1 Injection Flow Control

Output 2 Injection Pressure Control

Output 3 Not Used

Output 4 Not Used

Pump

Designations

Ram (Screw)

AB

PT

Tank

12470I

1-19

Chapter 1

Overview of Inject, Clamp, and Eject Mode

Summary of Inject, Clamp, and Eject Mode of 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

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

Transition Detects when injection is complete.

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

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

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

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

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

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

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

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

When you select this mode, you can use the following phases of operation:

Postdecompression
(optional)

1st Close
2nd Close
3rd Close

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

1st Open
2nd Open
3rd Open

Open Slow

Ejector Advance
Ejector Retract

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

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

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

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

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

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

• drop out a third mold plate

• pull cores

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

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

You can advance and retract the ejector in a single stroke or in multiple strokes using closed or openloop
control.

after the first advance stroke and ending before the last retract stroke.

when the ejectors are extended.

1-20

Chapter

Install the QDC Module

2

Chapter

Objectives

Record I/O Ranges

This chapter helps you install the QDC module with these procedures:

record I/O ranges
set module jumpers
key the I/O chassis
install the QDC module
wire I/O devices to the QDC module
ground and shield I/O devices
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 10V dc 1 to 5V dc 4 to 20 mA

Input 2 (System 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 (Ejector position) 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 select with jumper plugs the
I/O ranges that you recorded on Worksheet 2-A

Access and Position the Jumpers

Access the jumper plugs 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 jumpers.

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 jumpers.

5. Set the jumpers according to Table 2.A (next page) using

your I/O ranges from Worksheet 2-A
needle-nose pliers.

6. After setting the jumpers, carefully re-assemble the module with steps

3, 2, and 1.

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 positions as left, right, top, and bottom.
This represents the position of the jumper 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 Run = left

E5 I/O Density Standard = top

E6
E7
E8
E9

E10
E14
E13
E17

E11
E12
E15
E16

1

Factory Defaults

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

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

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

1

Calibrate = right

Do not use bottom position

Current = left
Voltage = right

Current = top
Voltage = bottom

-10 to +10V dc = top
0 to +10V dc or

4 to 20mA = bottom

1

1

1

1

Important: If you select current output with jumpers E10, E14, E13, E17,
then you must select 4 to 20mA with jumpers E11, E12, E15, E16.

ATTENTION: If an output is not used, set its jumper (E11,
E12, E15, or E16) to 0 - 10V dc (bottom position). Otherwise,
setting the jumper for –10 to +10V dc could cause the QH
module to output –10V dc on that channel (a hazard): because
when the system is stopped or when a system reset occurs, all
outputs are forced to 0% but 0% output = –10V dc in this
example (see graph).

10

8
5
3
0

-3

-5

Output Voltage

-8

-10

0 102030405060708090100

%

Output Requested

2-4

Chapter 2

Install the QDC Module

Key

the I/O Chassis

Use plastic keying bands, shipped with each I/O chassis, for keying the
backplane connector to accept only one type of module. Do this to prevent
inadvertent installation of the wrong module into the designated slot
location.

Important: You must use the following slot location in the I/O chassis for
the QDC module because this is the address used by your Pro-Set 600
software to communicate with the QDC module.

rack 0
module group 0
slot 0

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

Keying
Bands

1771QDC

2
4
6
8
10
12
14
16
18
20
22
24
26
28
30
32
34
36

12676

2-5

Chapter 2

Install the QDC Module

Install the QDC Module

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

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

ATTENTION: Remove power from the 1771 I/O chassis back-

plane and wiring arm before removing or installing a 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 injury, module damage, and/or degradation of
module performance.

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

slot that slides the module into position.

Important: Pro-Set 600 software expects your QDC module (configured
for inject, clamp, and eject mode) to be placed in rack 0, module group 0,
slot 0. If you choose to install it in some other slot, you must modify your
PLC-5 application program accordingly (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

I/O Devices

+

Customer
PS

–

+

Screw
Position
Sensor

–

+

System
Pressure
Sensor

–

+

Clamp
Position
Sensor

–

+

Ejector
Position
Sensor

–

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

Figure 2.3
I/O

W

iring and Grounding

Input 1

–

Customer
PS

Input 2

Input 3

Input 4

18

+

–

+

Amplifier
Valve 1

+

–

+

–

To Valve 1

+

–

Amplifier
Valve 2

Amplifier
Valve 3

+

–

To Valve 2

+

–

17
16
15
14
13
12

11

10
9

8
7

6

5
4

3
2
1

Output 1

Output 2

Output 3

Earth Ground

Wiring Arm
1771WF

Output 4

+

–

Amplifier
Valve 4

To Valve 3

+

–

To Valve 4

10909I

2-7

Chapter 2

Install the QDC Module

Table 2.B

T

erminal Designations

I/O

Transducer: I/O Designation: Terminal:

Screw position
(see Important below)

System pressure
(see ATTENTION below)

N/A Input common 14

Clamp position
(see Important below)

Ejector position
(see Important below)

Valve 1 Output 1 (+)

Valve 2 Output 2 (+)

Valve 3 Output 3 (+)

Valve 4 Output 4 (+)

Not used 01

Input 1 (+)
(-)

Input 2 (+)
(-)

Input 3 (+)
(-)

Input 4 (+)
(-)

Output common

Output common

Output common

Output common

18
17

16
15

13
12

11
10

09
08

07
06

05
04

03
02

Important: For the QDC module to operate in the inject, clamp, and eject
mode, you must connect position sensors to these two inputs:

2-8

input 1 (screw position)
input 3 (clamp position)

ATTENTION: Your control system may not work as expected
with possibly machine damage if you attempt to control a
pressure profile of a phase (inject, clamp, or eject) not
hydraulically plumbed for pressure control.

Because system pressure may change from one phase to the next, we
recommend that you:

assign pressure control to phases that require pressure profiles

(and are hydraulically plumbed to support it)
place the system pressure sensor accordingly in the hydraulic circuit
configure the remaining phases with velocity profiles

Chapter 2

Install the QDC Module

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

Ground and Shield

our I/O Devices

Y

Input Sensor

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

Guidelines:

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

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

cable such as Belden 8760.

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

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

Figure 2.4
Shielding

Differential Inputs

18
17

QDC Module Input

+

–

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

14

Input Module Common
(should float)

10910I

2-9

Chapter 2

Install the QDC Module

Figure 2.5
Shielding

QDC Module Output

Singleended Outputs

Customer Valve Amplifier

+

–

9

8

Connect

the cable shield to earth ground at

the valve amplifier

Input
Ground
Chassis Ground

17182

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

1/8 ohm

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

specified in the Exceptions section, below.

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

separate grounded conduits

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

Where conduit runs must cross, cross them at right angles

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

Exceptions

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

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

disconnecting the shield from the transducer

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

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

2-10

Chapter 2

Install the QDC Module

Plan for ESTOPs and
Machine Interlocks

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

design your system

assemble mechanical/hydraulic components

wire system components

develop system ladder logic

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

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

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

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

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

2-11

Chapter 2

Install the QDC Module

Disconnect

Figure 2.6

PLC5 Power Distribution with Interlocks

Typical

L1

L2
L3

Incoming
AC

Use any number
of E-Stop switches
in Series

CRM

Input
Device

1FU
2FU

3FU

H

H

1

H

3

4

H

2

Step-down
Transformer

4

FUSE

X

X

1

2

Start

CRM

I/O Chassis

Power Supply

1

LN

GND

3

** See WARNING for Interlock Wiring Instructions **

2

Output

Input

Device

Module
Wiring
Arm

Output
Module

Wiring
Arm

CRM

1

Back-Panel
Ground Bus

5

L1

L2
L3

To Motor
Starters

Equipment
Grounding
Conductors

User DC

Supply

CRM

To DC I/O
Devices

Enclosure
Wall

Grounding Electrode
Conductor to
Grounding Electrode
System

Connect
When
Applicable

+–

1

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

2

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

3

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

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

4

output circuits.

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

•

5

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

•

2-12

10907I

Chapter

3

Configure the QDC Module's I/O

Chapter

Objectives

Your QDC module needs to know the characteristics of your ram (screw),
clamp, and ejector sensors. In this chapter, we describe how to determine

these characteristics and download them to the QDC module for the following:

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

minimum and maximum pressures and positions
alarm values and travel limits

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

Select Module Parameters and I/O Ranges
Determine Initial Sensor-configuration Values
Download MCC Parameters to the QDC module
Use Set-output Mode to Move the Ram (screw), Clamp, and Ejector
Complete Your Sensor Configuration
Select Optional 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
done so.

3-1

Chapter 3

Configure the QDC Module's I/O

Select

Module Parameters

and I/O Ranges

You select module parameters and I/O ranges by setting configuration bits
in control words.

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:

Select module parameters with Worksheet 3-A:

Operating mode of the QDC module to inject, clamp, and eject
Units of measure to English or metric

Select I/O ranges with Worksheets 3-B and 3-C.

Refer to Worksheet 2-A from chapter 2 which you filled out when setting
the QDC module’s jumper plugs. Apply this information to Worksheet 3-B
for input ranges and Worksheet 3-C for output ranges.

Important: Software input/output selections that you are about to make in
MCC03 and MCC04 must match the jumper plug settings for each
respective input and output that you configured in chapter 2.

Important: The QDC module detects loss of sensor at all four inputs
regardless of the input range you select. When detected, the QDC module:

sets status bits SYS08-B00, 01, 02, and 03 for inputs 1, 2, 3, and 4
E-stops the profile in progress
ignores any action execution commands in DYC02

Worksheet 3A

Module Parameters

Select

Control W

ProSet 600 Addr. B34/bit

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

ord MCC02Bxx

15 14 13 12

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

11 10

Select Inject , Clamp, and Eject Mode

With

bit 05 = 04 = 1

09 08 07 06 05 04 03 02 01 00

Required bit 03 = 1
(0 generates a programming error)

Select English = 0
metric = 1

Example: If you select Inject, Clamp, and Eject mode with English units:

MCC02 = 00000000 00111000

3-2

Worksheet 3B

Input Ranges for your Sensors

Select

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 (Ejector Position) Range with bits 07, 06
Select Input 3 (Clamp Position) Range with bits 05, 04
Select Input 2 (System Pressure) Range with bits 03, 02
Select

Input 1 (Ram Screw Position) Range with bits 01, 00

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

MCC03 = 11111111 10101010.

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

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

Worksheet 3C

Control W

ord MCC04Bxx

ProSet 600 Addr. B34/bit

Output Ranges for your V

Select

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

alves

Value 1 1 1 1 1 1 1 1

Select Output 4 Range with bits 07, 06

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

Output 1 Range with bits 01, 00

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

MCC04 = 11111111 01010101.

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

Output

Range -10
to +10V dc0 0
0 to +10V dc 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

0  099.99% 75% 07500

0  99.99 inch 7.32 inch 00732

0  0999.9 mm 432.6 mm 4326

4.00  020.00 mA 16 mA 01600

0  010.00V dc 5.6V dc 00560

0  009.99 sec 0.47 sec 00047

0  09999 psi 321 psi 00321

0  0999.9 Bar 222 Bar 2220

Enter this Value:

Table 3.A
Determine

Initial Sensorconfiguration V

alues for W

Use this
Format:

orksheet 3D

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

Minimum Position (Lines 1, 9, and 13) N/A zero

Maximum Position (Lines 2, 10, and 14) Actuator is fully extended full travel of the sensor

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

(Lines 3, 11, and 15) sensor is reverseacting high end of your selected range

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

(Lines 4, 12, and 16) sensor is reverseacting low end of your selected range

Minimum System Pressure (Line 5) N/A min range value specified by manufacturer

Maximum System Pressure (Lines 6) N/A max range value specified by manufacturer

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

(Line 7) sensors are reverseacting high end of your selected range

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

(Line 8) sensors are reverseacting low end of your selected range

3-4

Worksheet 3D
Determine Initial Sensorconfiguration V

Record Your Initial Values Here

Chapter 3

Configure the QDC Module's I/O

alues

Input Line Control Word ProSet

600 Addr

. Value Description

1 1 MCC09 N40:5 0 Minimum Screw Position

2 MCC10 N40:6 Maximum Screw Position

3 MCC11 N40:7 Analog Signal @ Min Screw Position

4 MCC12 N40:8 Analog Signal @ Max Screw Position

2 5 MCC57 N40:53 0 Minimum System Pressure

6 MCC58 N40:54 Maximum System Pressure

7 MCC59 N40:55 Analog Signal @ Min System Pressure

8 MCC60 N40:56 Analog Signal @ Max System Pressure

3 9 MCC23 N40:19 0 Minimum Clamp Position

10 MCC24 N40:20 Maximum Clamp Position

11 MCC25 N40:21 Analog Signal @ Min Clamp Position

12 MCC26 N40.22 Analog Signal @ Max Clamp Position

4 13 MCC31 N40:27 0 Minimum Ejector Position

14 MCC32 N40:28 Maximum Ejector Position

15 MCC33 N40:29 Analog Signal @ Min Ejector Position

16 MCC34 N40:30 Analog Signal @ Max Ejector Position

1

Incremental Distance

00.00

to 99.99in

000.0

to 999.9mm

2

Input Signal Range

00.00 to 10.00VDC or

01.00 to 05.00VDC or

04.00

to 20.00MADC

1

1

2

2

3

3

2

2

1

1

2

2

1

1

2

2

3

Pressure

0000

to 9999 PSI

000.0 to 999.9 Bar

Download

MCC Parameters

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 parameters into the PLC-5 data table
download them to the QDC module (with PLC-5 processor in run mode)
correct any programming errors

Next, we describe the general steps.

Enter MCC Parameters into Your PLC5 Data Table

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

1. Switch the PLC-5 processor to

2. Display your PLC-5 data table.

PROGRAM mode.

3-5

Chapter 3

Configure the QDC Module's I/O

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 Parameters

To download the MCC block to the QDC module, switch the PLC-5
processor from
downloads the MCC to the QDC module for you.

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

PROGRAM mode to

RUN

mode. Pro-Set 600 software

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 the Plastic
Molding Module Reference Manual (pub. no.
17716.5.88).

Important: Pro-Set 600 software downloads all command blocks when
your PLC-5 processor enters run mode and after a valid MCC is accepted.
All programming errors reported in SYS62 (N40:214) are referenced to the
MCC until SYS01-B08 (B34/08) equals zero.

Correct Any Dataentry Errors

Upon receipt of 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 errors, refer to Section 2 of the Plastic
Molding Module Reference Manual, publication 1771-6.5.88.

3-6

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 is accepted
and the QDC module returns SYS01-B08 (B34/08) equal to 1.

Chapter 3

Configure the QDC Module's I/O

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

To finish configuring the QDC module, you actuate the ram (screw),
clamp, and ejector axes with the QDC module’s set-output operation that
applies percentage values to your QDC module’s outputs to move the
actuator in a controllable fashion. To do this, you apply a %-output signal
to a module output so you can move the actuator over its intended range.

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

10

8
5
3
0

-3

Output Voltage

-5

-8

-10

0 102030405060708090100

%

Output Requested

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

3-7

Chapter 3

Configure the QDC Module's I/O

Follow this procedure to actuate the ram (screw), clamp, and ejector:

1. Enter values in words DYC09-12 that result in no motion.

Output: In Data Word: At ProSet 600 Address:

1 DYC09 N40:121

2 DYC10 N40:122

3 DYC11 N40:123

4 DYC12 N40:124

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

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

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 your Sensor Configuration

3. With your programming terminal, slowly change the %-output value
of each output, one at a time, as you observe the corresponding

actuator movement.

4. Increase the %-output value until you reach a safe actuator speed to

use in the next procedure.

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:

ram (screw) position sensor values
system pressure sensor values
clamp position sensor values
ejector position sensor values

In the procedures that follow, measure and record:

min/max positions and corresponding signal values
min/max system pressure and corresponding signal values

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

3-8

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

Worksheet 3E
Final Sensorconfiguration V

Chapter 3

Configure the QDC Module's I/O

alues

Record Your Final V

alues Here

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

1 1 MCC09 N40:5 0 Minimum Screw Position

2 MCC10 N40:6 Maximum Screw Position

3 MCC11 N40:7 Analog Signal @ Min Screw Position

4 MCC12 N40:8 Analog Signal @ Max Screw Position

2 5 MCC57 N40:53 0 Minimum System Pressure

6 MCC58 N40:54 Maximum System Pressure

7 MCC59 N40:55 Analog Signal @ Min System Pressure

8 MCC60 N40:56 Analog Signal @ Max System Pressure

3 9 MCC23 N40:19 0 Minimum Clamp Position

10 MCC24 N40:20 Maximum Clamp Position

11 MCC25 N40:21 Analog Signal @ Min Clamp Position

12 MCC26 N40:22 Analog Signal @ Max Clamp Position

4 13 MCC31 N40:27 0 Minimum Ejector Position

14 MCC32 N40:28 Maximum Ejector Position

15 MCC33 N40:29 Analog Signal @ Min Ejector Position

16 MCC34 N40:30 Analog Signal @ Max Ejector Position

1

Incremental Distance

00.00

to 99.99in

000.0 to 999.9mm

2

Input Signal Range

00.00 to 10.00VDC or

01.00 to 05.00VDC or

04.00 to 20.00MADC

1

1

3

3

1

1

1

1

3

Pressure

0000 to 9999 PSI

000.0 to 999.9 Bar

2

2

2

2

2

2

2

2

Determine Values for Ram (Screw) Position Sensor

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

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

1. Move the ram (screw) forward until it reaches its mechanical stop at
the nozzle end. This is the zero position.

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

3-9

Chapter 3

Configure the QDC Module's I/O

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

4. With your programming terminal, read the signal level returned in
SYS33 (N40:185) from your position sensor.

Important: If your position sensor has a potentiometer for setting the zero
reference, do so now.

5. Record this value on line 3 for MCC11 (should be at minimum signal
if you zeroed your position sensor in step 4).

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

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

8. Measure the distance travelled.

9. Record this distance on line 2 for MCC10.

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

SYS33 (N40:185) from your positioning sensor.

Important: If your position sensor has a potentiometer to set the span
(linear resolution), do so now.

11. Record this value on line 4 for MCC12.

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

Determine Values for the Clamp Position Sensor

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

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

3-10

1. Move the clamp forward until it reaches its mechanical close stop.
This is the zero position.

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

Chapter 3

Configure the QDC Module's I/O

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

4. With your programming terminal, read the signal level returned in
SYS35 (N40:187) from your position sensor.

Important: If your position sensor has a potentiometer to set the zero
reference, do so now.

5. Record this value on line 11 for MCC25 (should be at minimum
signal if you zeroed your position sensor in step 4).

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

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

8. Measure the distance travelled.

9. Record this distance on line 10 for MCC24.

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

SYS35 (N40:187) from your positioning sensor.

Important: If your position sensor has a potentiometer to set the span
(linear resolution), do so now.

11. Record this value on line 12 for MCC26.

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

Determine Values for Ejector Position Sensor

ATTENTION: Be sure to open the clamp sufficiently to allow
full ejector travel before proceeding. Otherwise, you could
damage the ejectors and/or the mold.

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

1. Move the ejector backward until it reaches its mechanical retract stop.
This is the zero position.

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

3. Record this position value (normally 0000) on line 13 for MCC31 on

Worksheet 3-E.

3-11

Chapter 3

Configure the QDC Module's I/O

4. With your programming terminal, read the signal level returned in
SYS33 (N40:185) from your position sensor.

Important: If your position sensor has a potentiometer for setting the zero
reference, do so now

5. Record this value on line 15 for MCC33 (should be at minimum
signal if you zeroed your position sensor in step 4).

6. Move the ejector forward to the mechanical advance stop.

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

8. Measure the distance travelled by the ejector.

9. Record this distance on line 14 for MCC32.

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

SYS33 (N40:185) from your positioning sensor.

Important: If your position sensor has a potentiometer to set the span
(linear resolution), do so now.

11. Record this value on line 16 for MCC34.

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 System Pressure Sensor

To complete the sensor configuration procedure, record minimum and
maximum system pressures and corresponding signal levels from the
sensor manufacturer’s specifications onto Worksheet 3-E, words
MCC57-60. Most applications require no further spanning. If your
application requires greater accuracy, follow the procedure below:

1. Release system pressure to a minimum.

2. Read the system pressure gauge.

3. Record minimum pressure (normally 0000) on line 5 for MCC57 on

Worksheet 4-E.

4. With your programming terminal, read the signal level returned in
SYS34 (N40:186) from your pressure sensor.

3-12

Important: If your pressure sensor has a potentiometer for setting the zero
reference, do so now

5. Record this signal level on line 7 for MCC59. It should be at
minimum signal if you zeroed your pressure sensor in step 4.

Chapter 3

Configure the QDC Module's I/O

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

ATTENTION: If the ram (screw), clamp, and/or ejectors are
not disconnected from the hydraulic circuit, be sure that they are
fully retracted with their hydraulics aligned in the retract
position. This forces the cylinders to press against the
mechanical limits of travel and builds max system pressure.
Otherwise, they could suddenly move, 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 maximum.

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

mechanically bound from moving.

9. Record this maximum pressure on line 6 for MCC58.

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

SYS34 (N40:186) from your pressure sensor.

Important: If your pressure sensor has a potentiometer to set the span
(linear resolution), do so now.

11. Record this signal level on line 8 for MCC60.

12. Release pressure.

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

3-13

Chapter 3

Configure the QDC Module's I/O

Select Optional Configurations

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

Use this Option: For this Benefit:

Software Travel Limits to guard against damaging the nozzle, mold, or ejectors

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

Digital Filter to compensate for electrical noise on position inputs

Configure Software Travel Limits

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

Figure 3.1
Software

Restrictions

Physical Travel Range

dd

Safe Zone

d = deadband

Max SWTL Min SWTL

Max Position Min Position

Important: With the orientation shown, clamp movement is from left to
right. By convention, ram (screw) and ejector movement is reversed.

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

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

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

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

ATTENTION: When jogging or when performing a set-output
operation, the QDC module ignores SWTLs. In these modes, it
will not zero its outputs so equipment damage could occur.

3-14

Chapter 3

Configure the QDC Module's I/O

Configure the QDC module for SWTL alarms as follows:

1. Determine these SWTL values for ram (screw), clamp, and/or ejector
travel with respect to the range of physical travel.

SWTL deadband
Maximum SWTL
Minimum SWTL

2. Record non-zero SWTL values on Worksheet 3-F. Zero values
disable the corresponding SWTLs.

ATTENTION: Leaving your SWTL settings at zero (MCC13,
14, 27, 28, 41, 42) inhibits the QDC module from performing
this safety function.

Worksheet 3F

Configuration V

SWTL

alues

Record Your SWTL Configuration Values Here

Control Word ProSet 600 Addr. Value Description

MCC13 N40:9 Screw Minimum SWTL

MCC14 N40:10 Screw Maximum SWTL

MCC15 N40:11 10 Screw SWTL Deadband

MCC27 N40:23 Clamp Minimum SWTL

MCC28 N40:24 Clamp Maximum SWTL

MCC29 N40:25 10 Clamp SWTL Deadband

MCC41 N40:37 Ejector Minimum SWTL

MCC42 N40:38 Ejector Maximum SWTL

MCC43 N40:39 10 Ejector SWTL Deadband

1

Incremental

00.00 to 99.99 Inches 00.00 to 99.99 Inches

000.0 to 999.9 Millimeters 000.0 to 999.9 Millimeters

distance measured from zero

2

Incremental distance measured as noted

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

1

1

2

1

1

2

1

1

2

3-15

Chapter 3

Configure the QDC Module's I/O

Set Up Maximum Pressure Alarms and Time Delays

The QDC module continuously monitors the system pressure input. When
it detects that the process input equals or exceeds a preset alarm setpoint,
the QDC module sets an alarm bit. A setpoint of zero disables the
associated alarm.

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

Configure the QDC module for the system pressure alarm as follows:

1. Determine these values:

pressure-alarm setpoint
time-delay setpoint

2. Record non-zero setpoints on Worksheet 3-G for the pressure alarm
and time delay.

3. Download them to the QDC module using the procedures presented
earlier in this chapter.

Worksheet 3G
Pressurealarm

Enter Your Pressurealarm and T

Control Word ProSet 600 Addr. Value Description

MCC61 N40:57 System Pressurealarm Setpoint

MCC62 N40:58 System Pressure Timedelay Setpoint

1

and T

imedelay Values Here

Time

Measured in Seconds

00.00

to 00.99

imedelay Setpoints

2

Pressure
0000 to 9999 PSI

000.0 to 999.9 Bar

2

1

3-16

Chapter 3

Configure the QDC Module's I/O

Configure Digital Filters for Position Inputs

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

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

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

Ram (Screw) SYS25 N40:177

Clamp SYS27 N40:179

Ejector SYS28 N40:180

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

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

Ram (Screw) MCC16 N40:12

Clamp MCC30 N40:26

Ejector MCC44 N40:40

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

For example, with a clamp velocity of 2 inches/sec, a 00.01 time constant
allows a 0.20 inch travel before the QDC module can react to a travel limit.

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

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

3-17

Chapter

Overview of Remaining
Configuration Procedures

4

Chapter

Objectives

Configuration Concepts

This chapter gives you and overview of the remaining configuration
procedures necessary to successfully configure your QDC module for the
inject, clamp, and eject mode

Important: You must follow the configuration procedures presented in
chapters 5-10 in given order. Please use this chapter as a guide.

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

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

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

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

to the PLC-5 processor about current operating status

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

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

configuration procedure

Command Blocks

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

4-1

Chapter 4

Overview of Remaining
Configuration Procedures

There are two types of command blocks, presented in the following table:

Type of Command Block: Which Contains: Examples:

Configuration Information necessary to configure your

module to run a certain portion of a profile.

Profile Actual process setpoints necessary to

produce a desired part.

Valve spanning
information for the 1st
clamp close profile.

1st clamp close profile
operating setpoints.

Status Blocks

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

Type of Block: Which Contains: Examples:

Status Information about machine operation and

QDC module operating status.

The molding machine is
currently performing an
injection operation.

System Command and Status Blocks

The Module Configuration Block (MCC), Dynamic Command Block
DYC), and the System Status Block (SYS) are system data blocks because
of functions they perform:

Type of Block: Description: Examples:

Module Configuration
(MCC)

Dynamic Command
(DYC)

System Status
(SYS)

Contains configuration information used
throughout all phases of machine
operation.

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

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

Sensor spanning information
and global alarm setpoints.

Command to start the injection
phase.

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

4-2

Chapter 4

Overview of Remaining
Configuration Procedures

Overview of Procedures

Step: Procedure: Description: Refer to:

1 Jog Your Machine You enter machine jog pressure and flow setpoints

2 Select Command and Status

3 Load Initial

4 Load Initial Profile Setpoints You load Initial setpoints for process control, such

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

Bits to Sequence Machine
Operation

Configuration Values

into the Jog Configuration (JGC) block.

You jog your ram (screw), clamp, and ejector

with commands in the DYC block to further refine
your jog configuration.

You enter jog pressure alarm setpoints into the JGC
block.

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

You load initial values for controlling pressure or
flow, ramp rates, pressure alarms.

as pressure, velocity, position, and time setpoints.

Chapter 5

Chapter 6

Chapter 7

(Used in
Chapters 9 & 10)

Chapter 8

(Used in
Chapters 9 & 10)

5 Span your Valves You span your inject, clamp, and ejector valves.

and set profile pressure alarms.

6 Tune your Machine for

Producing Parts

7 Troubleshoot the QDC

Module with LEDs

We discuss topics to consider when tuning your
machine.

We present a troubleshooting table based on LED
indicator conditions

Important: Throughout the rest of this manual, we refer to system
pressure during profile or axis movement as corresponding to:

inject pressure, or
clamp pressure, or
ejector pressure

All three are the pressure measured at input 2 of the QDC module.

For additional information, refer to System Pressure in chapter 1.

Chapter 9

Chapter 10

Chapter 11

4-3

Chapter 4

Overview of Remaining
Configuration Procedures

Enter Data T

able V

alues

and Download Data Blocks

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

enter data table values
download data blocks

Enter Values into Your PLC Data Table

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

1. Switch the PLC-5 processor to

PROGRAM mode.

2. Display your PLC-5 data table

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

individual worksheets.

4. Enter the value for each word and bit.

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

Download Data Blocks

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

The following steps outline the procedure to download data blocks from
the PLC-5 data table to the QDC module.

Important: The exception to this procedure is the MCC block that has its
own download procedure already outlined in chapter 3. The QDC module
must store a valid MCC block before you can use the following procedure.

1. For the block you want to download (subject block), get its ID
number from Table 4.A and enter it into DYC61.

4-4

Chapter 4

Overview of Remaining
Configuration Procedures

Table 4.A
Information

Block to
Download:

JGC 02 1

FCC 03 2 CPC

SCC 04 3 CPC

TCC 05 4 CPC

LPC 06 5 CPC

CPC 07 6

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

FOC 17 16 OPC

SOC 18 17 OPC

TOC 19 18 OPC

OSC 20 19 OPC

OPC 21 20

EAC 22 21 EPC

ERC 23 22 EPC

EPC 24 23

Required to Download a Block

ProSet 600
Block ID.:

ProSet 600
Download Bit B21/

Companion
Block:

2. Confirm that the QDC module returns the ID in SYS61.

Important: If the value returned in SYS61 is NOT the ID number

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

If SYS61 has
this value:

1 MCC Refer to chapter 3 Correct Programming Errors in MCC"

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

This block
has errors:

Fix them as follows:

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

when SYS61=DYC61=ID number of the subject block

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

Important: 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.

Jog Your Machine

Chapter

5

Chapter

Objectives

About Jogging

This chapter describes how to:

configure jog block values necessary to jog the

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

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

ram (screw) forward and backward
clamp open and closed
ejector advance and retract

Although the QDC module (in the inject, clamp, and eject mode) may not
directly control your machine’s screw-rotate jogs, your hydraulics may
require that valves connected to QDC module outputs assume a certain
position to assure proper screw-rotate 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 worksheets for recording initial values in the
JGC block to configure the QDC module for jogging the ram (screw),
clamp, and ejector.

To configure the QDC module
for jogging the:

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

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),
clamp, and ejector in both directions. 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 +10V dc, zero output occurs @ 50%
(See Warning on next page.)

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

pressure alarm setpoints for ram (screw), clamp, and/or ejector jogs

The QDC module sets an alarm any time system pressure equals or

exceeds the corresponding alarm setpoints during a jog. A zero entry

inhibits alarm actuation.

Important: The system high pressure alarm that you set in chapter 4 is

also active during jog functions.

5-2

Chapter 5

Jog Your Machine

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

Record Your Initial Values Here

Block Word ProSet 600 Addr. Value Description

Inject, Forward Jog

JGC17 N40:73 Setoutput Values Output #1

JGC18 N40:74 Output #2

JGC19 N40:75 Output #3

JGC20 N40:76 Output #4

Inject, Reverse Jog

JGC25 N40:81 Setoutput Values Output #1

JGC26 N40:82 Output #2

JGC27 N40:83 Output #3

JGC28 N40:84 Output #4

Clamp, Forward Jog

JGC33 N40:89 Setoutput Values Output #1

JGC34 N40:90 Output #2

JGC35 N40:91 Output #3

JGC36 N40:92 Output #4

Clamp, Reverse Jog

JGC41 N40:97 Setoutput Values Output #1

JGC42 N40:98 Output #2

JGC43 N40:99 Output #3

JGC44 N40:100 Output #4

Ejector, Advance Jog

JGC49 N40:105 Set Output Values Output #1

JGC50 N40:106 Output #2

JGC51 N40:107 Output #3

JGC52 N40:108 Output #4

Ejector, Retract Jog

JGC57 N40:113 Set Output Values Output #1

JGC58 N40:114 Output #2

JGC59 N40:115 Output #3

JGC60 N40:116 Output #4

Jog Pressure Alarms

JGC06 N40:62 Ram Jog Pressure, Alarm Setpoint

JGC07 N40:63 Clamp Jog Pressure, Alarm Setpoint

JGC08 N40:64 Ejector Jog Pressure, Alarm Setpoint

1

%

Signal Output

00.00 to 99.99 %

2

Pressure
0000 to 9999 PSI

000.0 to 999.9 Bar

alues

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

2

2

2

5-3

Chapter 5

Jog Your Machine

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

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

10V dc, an output of 50% corresponds to zero

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

10

5

0

Output Voltage

-5

-10

0 102030405060708090100

%

Output Requested

Enter and Download Initial Jog Values

Enter values from Worksheet 5-A into PLC-5 data table and download the
JGC block to the QDC module with your programming terminal. Use the
procedures from chapter 4, Enter Data Table Values and Download Data
Blocks. We repeat the JGC block download data.

5-4

To download Set B21/

JGC 1

Chapter 5

Jog Your Machine

Write Ladder Logic

Take time now to develop ladder logic (independent of Pro-Set 600
software) to jog the ram (screw), clamp, and ejector. You may 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), clamp, and ejector.

Table 5.A
Enable

Bits for Ram (Screw), Clamp, and Ejector Jogs

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

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

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

DYC01B12 B34/396 Execute Clamp Jog Forward

DYC01B13 B34/397 Execute Clamp Jog Reverse

DYC01B14 B34/398 Execute Ejector Jog Advance

DYC01B15 B34/399 Execute Ejector Jog Retract

Table 5.B

Bits for Ram (Screw), Clamp, and Ejector Jogs

Status

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

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

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

SYS01B12 B34/12 Clamp Jog Forward in Progress

SYS01B13 B34/13 Clamp Jog Reverse in Progress

SYS01B14 B34/14 Ejector Jog Advance in Progress

SYS01B15 B34/15 Ejector Jog Retract 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), clamp, and/or ejector travel hydraulically when
you command the QDC module to jog in reverse.

5-5

Chapter 5

Jog Your Machine

Figure 5.1
Example

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

| STOP EXECUTE |
| CONDITION ALL STOP |
| EXISTS COMMAND |
| B3 B34 |
+––––] [–––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––( )–––––+
| 0 415 |
Rung 6:2
| CYCLE | MANUAL |DIRECTION DYC01-B10 |
| CONTROL | SCREW |SOLENOIDS ********** |
| SELECTOR | FORWARD |ALIGNED TO EXECUTE |
| (A/S/M) IN| JOG |MOVE SCREW SCREW |
| “MANUAL” | ALLOWED |FORWARD FWD JOG |
| I:003 B11 B11 B34 |
+––––] [––––––––] [––––––––] [–––––––––––––––––––––––––––––––––––––––––( )–––––+
| 05 1 8 394 |
Rung 6:3
| CYCLE | MANUAL |DIRECTION DYC01-B11 |
| CONTROL | SCREW |SOLENOIDS ********** |
| SELECTOR | REVERSE |ALIGNED TO EXECUTE |
| (A/S/M) IN| JOG |MOVE SCREW SCREW |
| “MANUAL” | ALLOWED |REVERSE REV JOG |
| I:003 B11 B11 B34 |
+––––] [––––––––] [––––––––] [–––––––––––––––––––––––––––––––––––––––––( )–––––+
| 05 2 9 395 |
Rung 6:4 |
| CYCLE | |DIRECTION DYC01-B12 |
| CONTROL | MANUAL |SOLENOIDS ********** |
| SELECTOR |CLAMP JOG |ALIGNED TO EXECUTE |
| (A/S/M) IN| FORWARD |MOVE CLAMP CLAMP |
| “MANUAL” | ALLOWED |FORWARD FWD JOG |
| I:003 B11 B11 B34 |
+––––] [––––––––] [––––––––] [–––––––––––––––––––––––––––––––––––––––––( )–––––+
| 05 4 11 396 |
Rung 6:5
| CYCLE | |DIRECTION DYC01-B13 |
| CONTROL | MANUAL |SOLENOIDS ********** |
| SELECTOR |CLAMP JOG |ALIGNED TO EXECUTE |
| (A/S/M) IN| REVERSE |MOVE CLAMP CLAMP |
| “MANUAL” | ALLOWED |REVERSE REV JOG |
| I:003 B11 B11 B34 |
+––––] [––––––––] [––––––––] [–––––––––––––––––––––––––––––––––––––––––( )–––––+
| 05 5 12 397 |
Rung 6:6 |
| CYCLE | MANUAL |DIRECTION DYC01-B14 |
| CONTROL | EJECTOR |SOLENOIDS ********** |
| SELECTOR | JOG |ALIGNED TO EXECUTE |
| (A/S/M) IN| ADVANCE |ADVANCE EJECTOR |
| “MANUAL” | ALLOWED |EJECTOR ADV JOG |
| I:003 B11 B11 B34 |
+––––] [––––––––] [––––––––] [–––––––––––––––––––––––––––––––––––––––––( )–––––+
| 05 6 13 398 |
Rung 6:7
| CYCLE | MANUAL |DIRECTION DYC01-B15 |
| CONTROL | EJECTOR |SOLENOIDS ********** |
| SELECTOR | JOG |ALIGNED TO EXECUTE |
| (A/S/M) IN| RETRACT |RETRACT EJECTOR |
| “MANUAL” | ALLOWED |EJECTOR RET JOG |
| I:003 B11 B11 B34 |
+––––] [––––––––] [––––––––] [–––––––––––––––––––––––––––––––––––––––––( )–––––+
| 05 7 14 399 |

Programming for Ram (Screw), Clamp, and Ejector Jogs

5-6

Chapter 5

Jog Your Machine

Jog Your Ram (Screw), Clamp, and Ejector

Configure Screwrotate Jogs
for Indirect Control

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

If You Observe This Condition: Then Make This Adjustment:

Rough jerky acceleration or deceleration
(hammering hydraulics)

Sluggish acceleration or deceleration 1) Boost jog pressure

1) Decrease jog pressure

2) Decrease jog flow

You must download the JGC block to the QDC module each time you
change one or more of its values to implement the new value(s). Use the
procedures in chapter 4 to change values in the JGC block and download it
to the QDC module. We repeat the JGC block download data.

To download Set B21/

JGC 1

Although the QDC module may not directly control your machine’s
screw-rotate jog, your hydraulics may require valves connected to this
QDC module’s outputs to go to a certain position to assure proper
screw-rotate 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 to assist with the screw-rotate jog. Otherwise, omit the
rest of this chapter.

Whenever the appropriate screw-rotate 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 to successfully execute the screw-rotate jog.

Important: Jog-specific high pressure alarms are NOT activated during
the screw-rotate jog.

2. Download the jog configuration block (JGC) with download bit

B21/1 using the download procedure outlined in chapter 4.

5-7

Chapter 5

Jog Your Machine

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

Enter Your Initial Values Here

Block Word ProSet 600 Addr. Value Description

Screw Rotate Jog

JGC09 N40:65 Set Output Values Output #1

JGC10 N40:66 Output #2

JGC11 N40:67 Output #3

JGC12 N40:68 Output #4

1

% Signal Output

00.00 to 99.99 %

1

1

1

1

Write Ladder Logic to Assist
with Screwrotate Jogs

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

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

Table 5.C

Bits for Screwrotate Jogs

Enable

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

DYC01B09 B34/393 Execute Screwrotate Jog

Table 5.D

Bits for Screwrotate Jogs

Status

Status Block Word: ProSet 600

Address:

Description:

5-8

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

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.

Chapter 5

Jog Your Machine

Rotate

the Screw

Figure 5.2
Example

Rung 6:6
| CYCLE | MANUAL |DIRECTION DYC01-B09 |
| CONTROL | SCREW |SOLENOIDS ********** |
| SELECTOR | ROTATE |ALIGNED TO EXECUTE |
| (A/S/M) IN| JOG | ROTATE SCREW ROTATE |
| “MANUAL” | ALLOWED | SCREW JOG |
| I:003 B11 B11 B34 |
+––––] [––––––––] [––––––––] [–––––––––––––––––––––––––––––––––––––––––( )–––––+
| 05 3 10 393 |

Programming for Assisting Screwrotate Jogs

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

Rotate the ram (screw) by jogging. Experiment with values you entered in
the jog configuration block (JGC) until you obtain the desired jog
operation.

If You Observe This Condition: Then Make This Adjustment:

Rough jerky acceleration or deceleration
(hammering hydraulics)

Sluggish acceleration or deceleration 1) Boost jog pressure

1) Decrease jog pressure

2) Decrease jog flow

You must download the JGC block to the QDC module each time you
change one or more of its values to implement the new value(s). Use
download bit B21/1. If necessary, refer to the download procedure in
chapter 4.

5-9

Chapter

6

Select Command and Status Bits to Sequence
Machine Operation

Chapter

Assess Y

Objectives

our

Logic Requirements

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

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

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

Important: You must write your own ladder logic for machine sequencing
because it depends on your machine’s hydraulic configuration and your
application. It is not included in Pro-Set 600 software.

Assess your logic requirements according to how your machine must be
sequenced.

If you need to Refer to this table for required

Execute phases of the inject, clamp,
and eject 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 movement between profiles 6.D

Trigger new events 6.E

Review all available status bits 6.F

Review all available command
and configuration bits 6.G

command and/or status bits

no additional ladder logic required

6.A

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: ProSet

Direct Setoutput DYC01B08 392 SYS01B08 08

Unassigned #1 Jog DYC01B09 393 SYS01B09 09

Ram (screw) Forward Jog DYC01B10 394 SYS01B10 10

Ram (screw) Reverse Jog DYC01B11 395 SYS01B11 11

Clamp Forward Jog DYC01B12 396 SYS01B12 12

Clamp Reverse Jog DYC01B13 397 SYS01B13 13

Ejector Advance Jog DYC01B14 398 SYS01B14 14

Ejector Retract Jog DYC01B15 399 SYS01B15 15

Stop DYC02B15 415 SYS02B15 31

Table 6.B
Command

and Status Bits for Manual Control

B34/xx:

Bits for Starting Profiles

The QDC sets this bit
during execution:

ProSet
B34/xx:

To initiate this
Profile/Movement:

1st Clamp Close 00 400 --- --- ---

2nd Clamp Close 01 401 CPC03B08 B37/296 1st Clamp Close

3rd Clamp Close 02 402 CPC03B09 B37/297 2nd Clamp Close

Low Pressure Close 03 403 CPC03B10 B37/298 3rd Clamp Close

Injection 04 404

Pack 05 405

Hold 06 406

Predecompression 07 407 HPC03B08 B38/296 Hold

Plastication 08 408 HPC03B09 B38/297 Predecompression

Postdecompression 09 409 PPC03B08 B38/488 Plastication

1st Clamp Open 10 410 --- --- ---

2nd Clamp Open 11 411 OPC03B08 B37/616 1st Clamp Open

3rd Clamp Open 12 412 OPC03B09 B37/617 2nd Clamp Open

Clamp Open Slow 13 413 OPC03B10 B37/618 3rd Clamp Open

1st Ejector Advance 14 414 EPC03B08 B39/168 On Clamp Position During Open

Ejector Continue

1

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

Toggle this
bit in DYC02:

15 415 EPC03B12 B39/172 Previous Ejector Stroke

ProSet
B34/xx:

If this bit is
Reset:

1

--- --- ---

1

--- --- Injection

1

--- --- Pack

ProSet
Address:

The Profile/Movement in column 1
starts automatically after:

6-2

Chapter 6

Select Command and Status Bits to
Sequence Machine Operation

Table 6.C

and Command Bit Interaction for Profile Execution

Status

For this
Profile/Movement:

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

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

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

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

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

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

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

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

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

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

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

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

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

During Execution
this bit in B34 is:

SET RESET SET RESET also SET also SET

At Completion
this bit in B34 is:

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

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

Ejector Advance SYS21B14 SYS02B14 SYS21B14 SYS02B14 EPC03B12 SYS22B14

Ejector Retract
(tip strokes)

Final Ejector Retract SYS21B14 SYS02B14 SYS02B14 SYS21B14 --- SYS22B15

SYS21B14 SYS02B14 SYS21B14 SYS02B14 EPC03B12 SYS22B15

where:

These Bits: Report These Functions: or Command These Functions:

SYS21B00 thru B14 profile in progress

SYS02B00 thru B14 profile complete

SYS22B00 thru B03 and B06 thru B15 executing endofprofile %outputs

CPC03/HPC03/PPC03/OPC03/EPC03
Bits B08, 09, 10, 12

interrupt movement between profiles
(see tables 6.B and 6.D)

6-3

Chapter 6

Select Command and Status Bits to
Sequence Machine Operation

Table 6.D

Bits T

Command

To Perform T his Function Use This Bit ProSet

Start 2nd clamp close profile @ endof 1st
Stop and setoutput @ endof 1st

Start 3rd clamp close profile @ endof 2nd
Stop and setoutput @ endof 2nd

Start LP close profile @ endof 3rd
Stop and setoutput @ endof 3rd

Start 2nd clamp open profile @ endof 1st
Stop and setoutput @ endof 1st

Start 3rd clamp open profile @ endof 2nd
Stop and setoutput @ endof 2nd

Start clamp open slow profile @ endof 3rd
Stop and setoutput @ endof 3rd

Start ejector profile on clamp position
Start ejector profile on command

Enable ejector profile
Disable ejector profile

Run ejector profile without interruption
Stop and notify @ end of ejector stroke

Start predecompression movement @ endof hold
Stop and set output @ endof hold

Start plastication profile @ endof predecompression
Stop and set output @ endof predecompression

Start postdecompression movement @ endof plastication
Stop and set output @ endof plastication

o Interrupt Movement Between Profiles

CPC03B08 = 0

CPC03B09 = 0

CPC03B10 = 0

OPC03B08 = 0

OPC03B09 = 0

OPC03B10 = 0

EPC03B08 = 0

EPC03B09 = 0

EPC03B12 = 0

HPC03B08 = 0

HPC03B09 = 0

PPC03B08 = 0

Address:

B37/296

= 1

B37/297

= 1

B37/298

= 1

B37/616

= 1

B37/617

= 1

B37/618

= 1

B39/168

= 1

B39/169

= 1

B39/172

= 1

B38/296

= 1

B38/297

= 1

B38/488

= 1

6-4

Important: In any of these bit tables, disregard bits not needed by your
application.

Chapter 6

Select Command and Status Bits to
Sequence Machine Operation

Table 6.E
Miscellaneous

Reason for Using: Bit Description: QDC Block

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

To drop pump adders, or shift solenoids Clamp in moldprotect zone SYS03B00 32

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

To start inject cycle Tonnage complete SYS03B02 34

To inhibit clamp from opening in auto mode Cure timer timing SYS03B03 35

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

To drop pump adders, or shift solenoids Clamp in openslow zone SYS03B06 38

To idle the machine until starting next action Mold fully open SYS03B07 39

To shift solenoids before starting next ejector stroke
after the 1st advance strode

To prevent starting next cycle with machine in auto
mode

Status Bits T

o T

rigger New Action

Address:

Injection complete SYS02B04

Mold safe SYS03B01 33

SYS03B04,

Cure time complete

Ejector profile stopped at end of stroke SYS03B08 40

Opendwell timer is timing SYS03B09 41

and B05

ProSet
B34/xx:

36,
37

To prevent starting ejector retract
until valves have shifted

To start next cycle with machine in auto mode Cycle complete SYS03B11 43

To start ejector retract Ejector fully advanced SYS03B12 44

To start ejector retract when tip stroking is ON Ejector is beyond tip advance position SYS03B13 45

To start ejector advance when tip stroking is ON Ejector is within tip retract position SYS03B14 46

To start ejector advance Ejector fully retracted SYS03B15 47

To reopen the clamp when the part is stuck LP close watchdog timeout SYS04B03 51

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 342

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

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

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

Ejector forward dwell timer is timing SYS03B10 42

Watchdog for plastication phase SYS04B08 56

SYS22B07 343

predecompression

SYS22B08 344

plastication

SYS22B09 345

postdecompression

6-5

Chapter 6

Select Command and Status Bits to
Sequence Machine Operation

Table 6.F

Bits

Status

Category: Bit Status

(when = 1):

Jog Status executing unassigned #1 jog SYS01B09 09

executing ram (screw) forward jog SYS01B10 10

executing ram (screw) reverse jog SYS01B11 11

executing clamp forward jog SYS01B12 12

executing clamp reverse jog SYS01B13 13

executing ejector advance jog SYS01B14 14

executing ejector retract jog SYS01B15 15

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

2nd clamp close profile complete SYS02B01 17

3rd clamp close profile complete SYS02B02 18

LP close profile complete SYS02B03 19

injection profile complete SYS02B04 20

pack profile complete SYS02B05 21

hold profile complete SYS02B06 22

predecompress movement complete SYS02B07 23

plastication profile complete SYS02B08 24

QDC Block
Address

ProSet
B34/xx:

postdecompress movement complete SYS02B09 25

1st clamp open profile complete SYS02B10 26

2nd clamp open profile complete SYS02B11 27

3rd clamp open profile complete SYS02B12 28

clamp open slow profile complete SYS02B13 29

ejector profile complete SYS02B14 30

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

Miscellaneous Status clamp in mold protection zone SYS03B00 32

mold safe SYS03B01 33

tonnage complete SYS03B02 34

cure timer timing SYS03B03 35

ram (screw) retracted SYS03B04 36

cure time complete SYS03B05 37

clamp in openslow zone SYS03B06 38

mold open SYS03B07 39

ejector stopped at end of stroke SYS03B08 40

mold opendwell timer is timing SYS03B09 41

6-6

Table 6.F

Bits (continued)

Status

Chapter 6

Select Command and Status Bits to
Sequence Machine Operation

Category: Bit Status

(when = 1):

ejector forward dwell timer is timing SYS03B10 42

cycle complete SYS03B11 43

ejector fully advanced SYS03B12 44

ejector is beyond tip advance position SYS03B13 45

ejector is within tip retract position SYS03B14 46

ejector fully retracted SYS03B15 47

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

2nd clamp close watchdog timed out SYS04B01 49

3rd clamp close watchdog timed out SYS04B02 50

LP close watchdog timed out SYS04B03 51

predecompress watchdog timed out SYS04B07 55

plastication watchdog timed out SYS04B08 56

postdecompress watchdog timed out SYS04B09 57

1st clamp open watchdog timed out SYS04B10 58

2nd clamp open watchdog timed out SYS04B11 59

3rd clamp open watchdog timed out SYS04B12 60

clamp open slow watchdog timed out SYS04B13 61

ejector watchdog timed out SYS04B14 62

tonnage watchdog timed out SYS04B15 63

Profile Status executing 1st close profile SYS21B00 320

executing 2nd close profile SYS21B01 321

executing 3rd close profile SYS21B02 322

executing LP close profile SYS21B03 323

QDC Block
Address

ProSet
B34/xx:

executing injection profile SYS21B04 324

executing pack profile SYS21B05 325

executing hold profile SYS21B06 326

executing predecompress movement SYS21B07 327

executing plastication profile SYS21B08 328

executing postdecompress movement SYS21B09 329

executing 1st clamp open profile SYS21B10 330

executing 2nd clamp open profile SYS21B11 331

executing 3rd clamp open profile SYS21B12 332

6-7

Chapter 6

Select Command and Status Bits to
Sequence Machine Operation

Table 6.F

Bits (continued)

Status

Category: Bit Status

executing clamp open slow profile SYS21B13 333

Endof Profile
Setoutput Status

(when = 1):

executing ejector profile SYS21B14 334

executing endof 1st clamp close
setoutput

executing endof 2nd clamp close
setoutput

executing endof 3rd clamp close
setoutput

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

executing end of hold setoutput SYS22B06 342

executing end of predecompression
setoutput

executing end of plastication setoutput SYS22B08 344

executing end of postdecompression
setoutput

executing endof 1st clamp open
setoutput

executing endof 2nd clamp open
setoutput

executing endof 3rd clamp open
setoutput

executing endof clamp open slow
setoutput

executing endof ejector advance
setoutput

executing endof ejector retract
setoutput

QDC Block
Address:

SYS22B00 336

SYS22B01 337

SYS22B02 338

SYS22B07 343

SYS22B09 345

SYS22B10 346

SYS22B11 347

SYS22B12 348

SYS22B13 349

SYS22B14 350

SYS22B15 351

ProSet
B34/xx:

6-8

Chapter 6

Select Command and Status Bits to
Sequence Machine Operation

Table 6.G
Command

Operation: Function Enabled

Nonprofiled execute setoutput DYC01B08 392

Action Commands execute unassigned # 1 jog DYC01B09 393

execute ram (screw) forward jog DYC01B10 394

execute ram (screw) reverse jog DYC01B11 395

execute clamp forward jog DYC01B12 396

execute clamp reverse jog DYC01B13 397

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

Commands execute 2nd clamp close profile DYC02B01 401

execute 3rd clamp close profile DYC02B02 402

execute LP clamp close profile DYC02B03 403

and Configuration Bits

(when = 1):

execute ejector advance jog DYC01B14 398

execute ejector retract jog DYC01B15 399

execute injection profile DYC02B04 404

execute pack profile DYC02B05 405

execute hold profile DYC02B06 406

QDC Block
Address:

ProSet
B34/xx:

execute predecompression movement DYC02B07 407

execute plastication profile DYC02B08 408

execute postdecompression movement DYC02B09 409

execute 1st clamp open profile DYC02B10 410

execute 2nd clamp open profile DYC02B11 411

execute 3rd clamp open profile DYC02B12 412

execute clamp open slow profile DYC02B13 413

execute ejector profile DYC02B14 414

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

Miscellaneous reset tonnage watchdog timer DYC03B00 416

Commands reset cure timer DYC03B01 417

reset SYS01B08 DYC03B08 424

reset latched alarms DYC03B09 425

reset complete bits DYC03B10 426

continue ejector profile DYC03B15 431

6-9

Chapter 6

Select Command and Status Bits to
Sequence Machine Operation

Table 6.G

(continued)

Command and Configuration Bits

Operation: Function Enabled

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

Configured
Protection from
Clampzone
Overrun

Additional Ejector
Configuration

(when = 1):

(0 = start 2nd clamp close profile)

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

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

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

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

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

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

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

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

set output @ end of all ejector strokes
(0 = start each new stroke at end of previous)

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

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

start ejector profile on command from PLC processor
(0 = start ejector profile on position during clamp open)

disable ejector profile
(0 = enable ejector profile)

change intermediate strokes to tip strokes
(0 = all ejector strokes are full strokes)

execute forward dwell after 1st advance stroke
(0 = execute forward dwell after last advance stroke)

QDC Block
Address:

CPC03B08 B37/296

CPC03B09 B37/297

CPC03B10 B37/298

HPC03B08 B38/296

HPC03B09 B38/297

PPC03B08 B38/488

OPC03B08 B37/616

OPC03B09 B37/617

OPC03B10 B37/618

EPC03B12 B39/172

CPC03B11 B37/299

OPC03B11 B37/619

EPC03B08 B39/168

EPC03B09 B39/169

EPC03B13 B39/173

EPC03B15 B39/175

ProSet
Address:

6-10

Chapter

7

Load Initial Configuration Values

Chapter

Objectives

This chapter helps you load the QDC module with machine-specific
configuration values by performing four tasks:

Determine initial configuration values
Record them on worksheets
Enter them in PLC-5 data table
Download them to the QDC module

Initial values that you load include:

configuration bits
set-output values
acceleration and deceleration ramp rates
pressure or velocity control limits
pressure or velocity gain constants
pressure alarm setpoints

We already recorded many initial values on worksheets for you.
Important: Do not start this chapter until you have:

spanned your sensors, and moved hydraulic cylinders (chapter 3)
jogged the ram (screw), clamp, and ejector (chapter 5)

7-1

Chapter 7

Load Initial Configuration Values

Use

These W

orksheets

The following table lists configuration blocks and corresponding
worksheets for recording your initial values to configure the QDC module.

To configure the QDC module with these configuration blocks: Use worksheet: On page:

Clamp Close Configuration Blocks (FCC, SCC, and TCC) 7A 73

Low Pressure Close Configuration Block (LPC) 7B 75

Injection Configuration Block (INC) 7C 77

Pack Configuration Block (PKC) 7D 79

Hold Configuration Block (HDC) 7E 711

Plastication Configuration Block (PLC) 7F 713

Clamp Open Configuration Blocks (FOC, SOC, TOC, and OSC) 7G 715

Ejector Configuration Blocks (EAC and ERC) 7H 717

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 we
grouped clamp close configuration blocks onto one worksheet, and clamp
open configuration blocks onto another because they are similar.
Otherwise, each configuration block has its own worksheet.

Each configuration block has two types of storage words:

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

Many parameters repeat from one configuration block to the next. 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 placed worksheets
together, followed by the text to describe how to determine initial values.

We give you the procedure immediately following the worksheets.

7-2

Chapter 7

Load Initial Configuration Values

Worksheet 7A
Clamp Close Configuration Blocks (FCC, SCC, and TCC)

W

ord

FCC01

B15 thru 00

Bit Address B37/Bit

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

W

ord

SCC01

B15 thru 00

Bit Address B37/Bit

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

W

ord

TCC01

B15 thru 00

Bit Address B37/Bit

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

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

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

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

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

Important: Record values only in words used.

Record zeros in words not used.
You must configure at least FCC02

W

ord

FCC02

B15 thru 00

Bit Address B37/Bit

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

Block Identifier

Value 0 0 0 0 0 0 0 0 1 0

W

ord

SCC02

B15 thru 00

Bit Address B37/Bit

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

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

Value 0 0 0 0 0 0 0 0 1 0

Word

TCC02

B15 thru 00

Bit Address B37/Bit

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

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

Value 0 0 0 0 0 0 0 0 1 0

Code:

Your

0

Required initial value

or 1

loaded by ProSet 600

0V

value

alue not used

PID

0 = Dependent Gains (ISA)
1 = Independent Gains (AB)

Pressure Control Valve

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

Velocity Control Valve

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

Important: You must configure at least the FCC configuration block.

7-3

Chapter 7

Load Initial Configuration Values

Worksheet 7A

(continued)

Clamp Close Configuration Blocks (FCC, SCC, and TCC)

Enter Your V

For these Parameters (footnote = units) Word FCC N43: FCC Value SCC N43: SCC Value TCC N43: TCC Value

Minimum ERC Percentage - Velocity

Minimum ERC Percentage - Pressure

Profile Watchdog Timer Preset

Output #1 Selected Valve %Output During Profile 4 09 5 * 65 * 125 *

Output #2 Selected Valve %Output During Profile 4 10 6 * 66 * 126 *

Output #3 Selected Valve %Output During Profile 4 11 7 * 67 * 127 *

Output #4 Selected Valve %Output During Profile 4 12 8 * 68 * 128 *

Output #1 Acceleration Ramp Rate During Profile

Output #2 Acceleration Ramp Rate During Profile

Output #3 Acceleration Ramp Rate During Profile

Output #4 Acceleration Ramp Rate During Profile

Output #1 Deceleration Ramp Rate During Profile

Output #2 Deceleration Ramp Rate During Profile

Output #3 Deceleration Ramp Rate During Profile

Output #4 Deceleration Ramp Rate During Profile

Output #1 Endofprofile Setoutput Value

Output #2 Endofprofile Setoutput Value

Output #3 Endofprofile Setoutput Value

Output #4 Endofprofile Setoutput Value

Pressure Minimum Control Limit

Pressure Maximum Control Limit

Selected Pressure Valve Output for Minimum

Selected Pressure Valve Output for Maximum

Velocity Minimum Control Limit

Velocity Maximum Control Limit

Selected Velocity Valve Output for Minimum

Selected Velocity Valve Output for Maximum

Proportional Gain for Pressure Control

Integral Gain for Pressure Control

Derivative Gain for Pressure Control

Proportional Gain for Velocity Control

Feed Forward Gain for Velocity Control

Profile High Pressure Alarm Setpoint

1

Time

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

5

Percent Signal Output per Second

0000 to 9999

*Important

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

1

3

3

2

2

alues Here

8

8

(none)

6

7

6

(none)

3

05 1 1000 61 1000 121 1000

06 2 1000 62 1000 122 1000

08 4 0 64 0 124 0

5

17 13 0 73 0 133 0

5

18 14 0 74 0 134 0

5

19 15 0 75 0 135 0

5

20 16 0 76 0 136 0

5

25 21 0 81 0 141 0

5

26 22 0 82 0 142 0

5

27 23 0 83 0 143 0

5

28 24 0 84 0 144 0

4

4

4

4

33 29 * 89 * 149 *

34 30 * 90 * 150 *

35 31 * 91 * 151 *

36 32 * 92 * 152 *

41 37 0 97 0 157 0

42 38 Syst Press 98 Syst Press 158 Syst Press

4

4

43 39 * 99 * 159 *

44 40 * 100 * 160 *

45 41 0 101 0 161 0

46 42 per OEM * 102 per OEM * 162 per OEM *

4

4

47 43 * 103 * 163 *

48 44 * 104 * 164 *

49 45 100 105 100 165 100

50 46 400 106 400 166 400

51 47 0 107 0 167 0

52 48 200 108 200 168 200

53 49 0 109 0 169 0

57 53 0 113 0 173 0

2

Velocity along Axis

000.0 to 999.9 Millimeters per Sec

6

Inverse T

ime (Algorithm)

00.00 to 99.99 Minutes 00.00 to 99.99 Minutes

00.00 to 99.99 Seconds

3

Pressure

000.0 to 999.9 Bar

7

T

ime (Algorithm)

4

Percent Signal Output

00.00 to 99.99

8

Percent

00.00 to 99.99

7-4

Chapter 7

Load Initial Configuration Values

Worksheet 7B
Low Pressure Close Configuration Block (LPC)

Word

LPC01

Bits 15 thru 00

Bit Addresses B37/Bxxx

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

Important:

Verify

W

ord

block identifier

LPC02

Bits 15 thru 00

.

Bit Addresses B37/Bxxx

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

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

Block Identifier

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

Code:

0

or 1

0V

Your

value

Required initial value
loaded by ProSet 600

alue not used

PID

0 = Dependent Gains (ISA)
1 = Independent Gains (AB)

Pressure Control Valve

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

Important: You must configure the LPC configuration block.

7-5

Chapter 7

Load Initial Configuration Values

Worksheet 7B

(continued)

Low Pressure Close Configuration Block (LPC)

Enter Your V

For these Parameters (footnote = units) Word LPC N43: LPC Value

Minimum ERC Percentage

Tonnage Watchdog Timer Preset

Profile Watchdog Timer Preset

#1 Selected Valve SetOutput During Profile

#2 Selected Valve SetOutput During Profile

#3 Selected Valve SetOutput During Profile

#4 Selected Valve SetOutput During Profile

Output #1 Acceleration Ramp Rate During Profile

Output #2 Acceleration Ramp Rate During Profile

Output #3 Acceleration Ramp Rate During Profile

Output #4 Acceleration Ramp Rate During Profile

Output #1 Deceleration Ramp Rate During Profile

Output #2 Deceleration Ramp Rate During Profile

Output #3 Deceleration Ramp Rate During Profile

Output #4 Deceleration Ramp Rate During Profile

#1 Endofprofile Setoutput Value

#2 Endofprofile Setoutput Value

#3 Endofprofile Setoutput Value

#4 Endofprofile Setoutput Value

Pressure Minimum Control Limit

Pressure Maximum Control Limit

Selected Pressure Valve Output for Minimum

Selected Pressure Valve Output for Maximum

Proportional Gain for Pressure Control

Integral Gain for Pressure Control

Derivative Gain for Pressure Control

Profile High Pressure Alarm Setpoint

1

Time

00.00 to 99.99 Sec 0000 to 9999 PSI

6

Inverse T

ime (Algorithm)

00.00 to 99.99 Minutes 00.00 to 99.99 Minutes

00.00 to 99.99 Sec

* Important

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

8

1

1

4

4

4

4

3

3

6

7

3

Pressure

000.0 to 999.9 Bar

7

T

ime (Algorithm)

4

4

4

4

5

5

5

5

5

5

5

5

4

4

(none)

3

4

8

alues Here

06 182 1000

07 183 0

08 184 0

09 185 *

10 186 *

11 187 *

12 188 *

17 193 0

18 194 0

19 195 0

20 196 0

25 201 0

26 202 0

27 203 0

28 204 0

33 209 *

34 210 *

35 211 *

36 212 *

41 217 0

42 218 System Pressure

43 219 *

44 220 *

49 225 100

50 226 400

51 227 0

57 233 0

Percent

Signal Output

00.00 to 99.99

Percent

00.00 to 99.99

5

Percent Signal Output per Sec
0000 to 9999

7-6

Worksheet 7C
Injection Configuration Block (INC)

Chapter 7

Load Initial Configuration Values

Control W

ProSet 600 Addr. B38/bit

ord INC01Bxx

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

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

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

INC

Block Identifier

Control W

ProSet 600 Addr. B38/bit

ord INC02Bxx

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

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

Value 0 0 0 0 0 0 0 0 1 0

Code:

Your

value

0

Required initial value

or 1

loaded by ProSet 600

0V

alue not used

Selected
Pressure Valve

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

Selected
Velocity Valve

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

PID Pressure Algorithm

0 = Dependent Gains
1 = Independent Gains

7-7

Chapter 7

Load Initial Configuration Values

Worksheet 7C

(continued)

Injection Configuration Block (INC)

Enter Y

our V

alues Here

Control Word ProSet 600 Addr. Value Description

INC05 N44:1 1000 Minimum ERC PercentageVelocity

INC06 N44:2 1000 Minimum ERC PercentagePressure

INC09 N44:5 * Output #1 Setoutput Value During Profile

INC10 N44:6 * Output #2 Setoutput Value During Profile

INC11 N44:7 * Output #3 Setoutput Value During Profile

INC12 N44:8 * Output #4 Setoutput Value During Profile

INC17 N44:13 0 Output #1 Acceleration Ramp Rate During Profile

INC18 N44:14 0 Output #2 Acceleration Ramp Rate During Profile

INC19 N44:15 0 Output #3 Acceleration Ramp Rate During Profile

INC20 N44:16 0 Output #4 Acceleration Ramp Rate During Profile

INC25 N44:21 0 Output #1 Deceleration Ramp Rate During Profile

INC26 N44:22 0 Output #2 Deceleration Ramp Rate During Profile

INC27 N44:23 0 Output #3 Deceleration Ramp Rate During Profile

INC28 N44:24 0 Output #4 Deceleration Ramp Rate During Profile

INC41 N44:37 0 Pressure Minimum Control Limit

INC42 N44:38 * Pressure Maximum Control Limit

INC43 N44:39 * Selected Pressure Valve, Output for Minimum

INC44 N44:40 * Selected Pressure Valve, Output for Maximum

INC45 N44:41 0 Velocity Minimum Control Limit

INC46 N44:42 * Velocity Maximum Control Limit

INC47 N44:43 * Selected Velocity Valve, Output for Minimum

INC48 N44:44 * Selected Velocity Valve, Output for Maximum

INC49 N44:45 100 Proportional Gain for Pressure Control

INC50 N44:46 400 Integral Gain for Pressure Control

INC51 N44:47 0 Derivative Gain for Pressure Control

INC52 N44:48 200 Proportional Gain for Velocity Control

INC53 N44:49 0 Feed Forward Gain for Velocity Control

INC57 N44:53 0 Profile High Pressure Alarm Setpoint

2

Velocity along Axis

00.00 to 99.99 inches per second

000.0 to 999.9 millimeters per second

5

Percent Signal Output per Second
0000 to 9999

3

Pressure
0000 to 9999 PSI

000.0 to 999.9 Bar

6

Inverse T

ime (Algorithm)

00.00 to 99.99 Minutes (ISA) 00.00 to 99.99 Minutes (ISA)

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

4

Percent Signal Output

00.00 to 99.99

7

T

ime (Algorithm)

8

8

4

4

4

4

3

3

4

4

2

2

4

4

none

6

7

6

none

3

8

Percent

00.00 to 99.99

5

5

5

5

5

5

5

5

*

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

7-8

Worksheet 7D
Pack Configuration Block (PKC)

Chapter 7

Load Initial Configuration Values

Control W

ProSet 600 Addr. B38/bit

ord PKC01Bxx

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

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

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

PKC

Block Identifier

Control Word PKC02Bxx

ProSet 600 Addr. B38/bit

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

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

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

Code:

0

or 1

Your

value

Required initial value
loaded by ProSet 600

Selected
Pressure Valve

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

0V

alue not used

PID Pressure Algorithm

0 = Dependent Gains
1 = Independent Gains

7-9

Chapter 7

Load Initial Configuration Values

Worksheet 7D

(continued)

Pack Configuration Block (PKC)

Enter Y

our V

alues Here

Control Word ProSet 600 Addr. Value Description Units

PKC06 N44:122 1000 Minimum ERC PercentagePressure Percent

PKC09 N44:125 * Output #1 Setoutput Value During Profile Percent Signal Output

PKC10 N44:126 * Output #2 Setoutput Value During Profile Percent Signal Output

PKC11 N44:127 * Output #3 Setoutput Value During Profile Percent Signal Output

PKC12 N44:128 * Output #4 Setoutput Value During Profile Percent Signal Output

PKC17 N44:133 0 Output #1 Acceleration Ramp Rate During Profile Percent Signal Output per Second

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

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

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

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

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

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

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

PKC41 N44:157 0 Pressure Minimum Control Limit Pressure

PKC42 N44:158 * Pressure Maximum Control Limit Pressure

PKC43 N44:159 * Selected Pressure Valve, Output for Minimum Percent Signal Output

PKC44 N44:160 * Selected Pressure Valve, Output for Maximum Percent Signal Output

PKC49 N44:165 100 Proportional Gain for Pressure Control None

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

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

PKC57 N44:173 0 Profile High Pressure Alarm Setpoint Pressure

3

Pressure
0000 to 9999 PSI

000.0 to 999.9 Bar

5

Percent Signal Output per Second
0000 to 9999

4

Percent

Signal Output

00.00 to 99.99

6

Inverse T

ime (Algorithm)

00.00 to 99.99 Minutes (ISA)

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

7

T

ime (Algorithm)

00.00 to 99.99 Minutes (ISA)

8

3

3

3

8

Percent

00.00 to 99.99

4

4

4

4

4

4

6

7

5

5

5

5

5

5

5

5

*

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

7-10

Worksheet 7E
Hold Configuration Block (HDC)

Chapter 7

Load Initial Configuration Values

Control W

ProSet 600 Addr. B38/bit

ord HDC01Bxx

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

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

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

HDC

Block Identifier

Control W

ProSet 600 Addr. B38/bit

ord HDC02Bxx

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

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

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

Code:

0

or 1

Your

value

Required initial value
loaded by ProSet 600

Selected
Pressure Valve

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

0V

alue not used

PID Pressure Algorithm
0 = Dependent Gains

1 = Independent Gains

7-11

Chapter 7

Load Initial Configuration Values

Worksheet 7E

(continued)

Hold Configuration Block (HDC)

Enter Y

our V

alues Here

Control Word ProSet 600 Addr. Value Description Units

HDC06 N44:182 1000 Minimum ERC PercentagePressure Percent

HDC09 N44:185 * Output #1 Setoutput Value During Profile Percent Signal Output

HDC10 N44:186 * Output #2 Setoutput Value During Profile Percent Signal Output

HDC11 N44:187 * Output #3 Setoutput Value During Profile Percent Signal Output

HDC12 N44:188 * Output #4 Setoutput Value During Profile Percent Signal Output

HDC17 N44:193 0 Output #1 Acceleration Ramp Rate During Profile Percent Signal Output per Second

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

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

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

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

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

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

HDC28 N44:204 0 Output #4 Deceleration Ramp Rate During Profile Percent Signal Output per Second

HDC33 N44:209 * Output #1 Setoutput Value at Endof Profile Percent Signal Output

HDC34 N44:210 * Output #2 Setoutput Value at Endof Profile Percent Signal Output

HDC35 N44:211 * Output #3 Setoutput Value at Endof Profile Percent Signal Output

HDC36 N44:212 * Output #4 Setoutput Value at Endof Profile Percent Signal Output

HDC41 N44:217 0 Pressure Minimum Control Limit Pressure

HDC42 N44:218 * Pressure Maximum Control Limit Pressure

HDC43 N44:219 * Selected Pressure Valve, Output for Minimum Percent Signal Output

HDC44 N44:220 * Selected Pressure Valve, Output for Maximum Percent Signal Output

HDC49 N44:225 100 Proportional Gain for Pressure Control None

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

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

HDC57 N44:233 0 Profile High Pressure Alarm Setpoint Pressure

3

Pressure
0000 to 9999 PSI

000.0 to 999.9 Bar

5

Percent Signal Output per Second
0000 to 9999

4

Percent

Signal Output

00.00 to 99.99

6

Inverse T

ime (Algorithm)

00.00 to 99.99 Minutes (ISA) 00.00 to 99.99 Minutes (ISA)

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

7

T

ime (Algorithm)

8

3

3

3

8

Percent

00.00 to 99.99

4

4

4

4

4

4

4

4

4

4

6

7

5

5

5

5

5

5

5

5

*

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

7-12

Worksheet 7F
Plastication Configuration Block (PLC)

Chapter 7

Load Initial Configuration Values

Control Word PLC01Bxx

ProSet 600 Addr. B38/bit

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

399 398 397 396 395 394 393 392 391 390 389 388 387 386 385 384

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

PLC

Block Identifier

Control Word PLC02Bxx

ProSet 600 Addr. B38/bit

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

415 414 413 412 411 410 409 408 407 406 405 404 403 402 401 400

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

Code:

0

or 1

Your

value

Required initial value
loaded by ProSet 600

Selected
Pressure Valve

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

0V

alue not used

PID Pressure Algorithm
0 = Dependent Gains

1 = Independent Gains

7-13

Chapter 7

Load Initial Configuration Values

Worksheet 7F

(continued)

Plastication Configuration Block (PLC)

Enter Y

our V

alues Here

Control Word ProSet 600 Addr. Value Description Units

PLC06 N44:362 1000 Minimum ERC PercentagePressure Percent

PLC08 N44:364 0 Profile Watchdog Timer Preset Time

PLC09 N44:365 * Output #1 Setoutput Value During Profile Percent Signal Output

PLC10 N44:366 * Output #2 Setoutput Value During Profile Percent Signal Output

PLC11 N44:367 * Output #3 Setoutput Value During Profile Percent Signal Output

PLC12 N44:368 * Output #4 Setoutput Value During Profile Percent Signal Output

PLC17 N44:373 0 Output #1 Acceleration Ramp Rate During Profile Percent Signal Output per Second

PLC18 N44:374 0 Output #2 Acceleration Ramp Rate During Profile Percent Signal Output per Second

PLC19 N44:375 0 Output #3 Acceleration Ramp Rate During Profile Percent Signal Output per Second

PLC20 N44:376 0 Output #4 Acceleration Ramp Rate During Profile Percent Signal Output per Second

PLC25 N44:381 0 Output #1 Deceleration Ramp Rate During Profile Percent Signal Output per Second

PLC26 N44:382 0 Output #2 Deceleration Ramp Rate During Profile Percent Signal Output per Second

PLC27 N44:383 0 Output #3 Deceleration Ramp Rate During Profile Percent Signal Output per Second

PLC28 N44:384 0 Output #4 Deceleration Ramp Rate During Profile Percent Signal Output per Second

PLC33 N44:389 * Output #1 Setoutput Value at Endof Profile Percent Signal Output

PLC34 N44:390 * Output #2 Setoutput Value at Endof Profile Percent Signal Output

PLC35 N44:391 * Output #3 Setoutput Value at Endof Profile Percent Signal Output

PLC36 N44:392 * Output #4 Setoutput Value at Endof Profile Percent Signal Output

PLC41 N44:397 0 Pressure Minimum Control Limit Pressure

PLC42 N44:398 * Pressure Maximum Control Limit Pressure

PLC43 N44:399 * Selected Pressure Valve, Output for Minimum Percent Signal Output

PLC44 N44:400 * Selected Pressure Valve, Output for Maximum Percent Signal Output

PLC49 N44:405 100 Proportional Gain for Pressure Control None

PLC50 N44:406 400 Integral Gain for Pressure Control Inverse Time (Algorithm)

PLC51 N44:407 0 Derivative Gain for Pressure Control Time (Algorithm)

PLC57 N44:413 0 Profile High Pressure Alarm Setpoint Pressure

1

Time

00.00 to 99.99 seconds

5

Percent Signal Output per Second
0000 to 9999

3

Pressure
0000 to 9999 PSI

000.0 to 999.9 Bar

6

Inverse T

ime (Algorithm)

00.00 to 99.99 Minutes (ISA) 00.00 to 99.99 Minutes (ISA)

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

4

Percent

00.00 to 99.99

7

T

ime (Algorithm)

Signal Output

8

1

8

Percent

00.00 to 99.99

4

4

4

4

4

4

4

4

3

3

4

4

6

7

3

5

5

5

5

5

5

5

5

*

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

7-14