Plastic Molding Module (Cat. No.
Important User Information Because of the variety of uses for this product and because of the differences between solid state products and electromechanical products, those responsible for applying and using this product must satisfy themselves as to the acceptability of each application and use of this product. For more information, refer to publication SGI–1.1 (Safety Guidelines For The Application, Installation and Maintenance of Solid State Control).
Summary of Changes Summary of Changes Summary of Changes We revised this publication to include changes due to upgrading the 1771-QDC/B module to a 1771-QDC/C. For These Changes Refer to Page or Chapter Loss of sensor detection input range changed back to 0.00 to 10V dc 3 5, 3 9 A 2, 3 Added the section, Record I/O Ranges. 2 1 Changed the title Ground the QDC Module to Ground and Shield Your I/O Devices to better describe the task. 2 9 Added data codes to configuration worksheets.
Table of Contents Summary of Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1 Using This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P 1 Manual Objectives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Audience . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Use of Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Related Publications . . . . . . . . . . . . . . . . .
ii Table of Contents Jog Your Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 1 Chapter Objectives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . About Jogging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Use These Worksheets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Determine Initial Jog Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . Write Ladder Logic . . . . . . . . . . . . . . . . . . .
Table of Contents iii Determine Word Values for Worksheet 8 C . . . . . . . . . . . . . . . . . . Enter and Download your Worksheet Values . . . . . . . . . . . . . . . . Determine and Enter Setpoints for Plastication Profile (PPC) . . . . . Determine Bit Selections for Worksheet 8 D . . . . . . . . . . . . . . . . . Determine Word Values for Worksheet 8 D . . . . . . . . . . . . . . . . . . Enter and Download your Worksheet Values . . . . . . . . . . . . . . . .
iv Table of Contents Acceleration and Deceleration Ramp Rates . . . . . . . . . . . . . . . . . Pressure Alarm Setpoints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Profile Watchdog Timer Presets . . . . . . . . . . . . . . . . . . . . . . . . . Expert Response Compensation . . . . . . . . . . . . . . . . . . . . . . . . . 10 30 10 32 10 33 10 33 Troubleshoot with LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . 11 1 Chapter Objectives . . . . . . . . . . . . . . . . . . . . .
Preface Using This Manual 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.
Preface Audience 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 Use of Terms We use these abbreviations: Abbreviated Name: Title: QDC module 1771 QDC Plastic Molding Module PLC 5 processor PLC 5 Programmable Controller T47 or T50 terminal 1784 T47 or 1784 T50 Programming Terminal Pro Set 600 S
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.
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.
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 Install the PLC 5 processor and I/O modules. 6200 N8.001 6200 PLC 5 Programming Software Documentation Set Select instructions and organize memory when writing ladder logic to run your machine. 1771 4.
Chapter 1 Overview of Inject and Clamp Mode Chapter Objectives This chapter presents an overview of the 1771-QDC Plastic Molding Module in the inject and clamp mode. We present a summary of inject and clamp features followed by sample applications. Important: This manual assumes you have already read your Plastic Molding Module Application Guide (publication 1771-4.10) and have chosen inject and clamp as your QDC module’s mode of operation.
Chapter 1 Overview of Inject and Clamp Mode Clamp Phase: Description: 1st Close 2nd Close 3rd Close You can program a single step clamp close profile and not use a second or third profile.
Chapter 1 Overview of Inject and Clamp Mode Injection Phase You can vary the velocity of the ram (screw), or the pressure driving it, so the leading edge of the melt moves through the mold cavity at the desired speed. The pattern of velocity or pressure variation during injection is called the injection profile. The QDC module lets you chose from four different injection profiles: velocity vs. position pressure-limited velocity vs. position pressure vs. position pressure vs.
Chapter 1 Overview of Inject and Clamp Mode Example Benefits of Profiling an Injection Phase The injection phase should force the melt through the mold as fast as possible without flashing the mold or burning the melt at a mold gate.
Chapter 1 Overview of Inject and Clamp Mode Flash Prevention Example - With a velocity profile (Figure 1.4 part 1), the pressure may reach a peak and flash the mold at ram (screw) position segments that correspond to events such as: the initial surge (2.a) when the melt front enters a constriction in the mold cavity (2.b) You can remedy this (part 3) by decreasing the ram (screw) velocity at segments (3.a) and (3.b) that correspond to flash points. Conversely, you can boost velocity at segment (3.
Chapter 1 Overview of Inject and Clamp Mode Injection to pack Transition The QDC module ends the injection phase and automatically starts the pack or hold phase when it detects the first of up to three events occurred: Ram (screw) position exceeds a preset limit Ram (screw) pressure exceeds a preset limit Injection phase elapsed time exceeds a preset limit You select which of these events you want monitored for transition by entering the appropriate setpoint, or zero for ignoring the event.
Chapter 1 Overview of Inject and Clamp Mode Example Benefit of Profiling the Pack Phase Molten plastic may cool unevenly in the mold causing variations in density with the end result of warpage and distortion as shown in Figure 1.6. Figure 1.
Chapter 1 Overview of Inject and Clamp Mode Hold Phase The QDC module controls the hold phase with a pressure vs. time profile. You create the profile based on controlling the hydraulic pressure against the ram (screw). The pressure can be controlled using up to five segments. You determine the pressure setpoints and time durations for the hold profile based on molding requirements.
Chapter 1 Overview of Inject and Clamp Mode Back Pressure Figure 1.8 Plastication Phase Example 1 2 hotter Mold End 3 4 6 5 7 Position or Time Temperature Gradient Barrel Containing the Melt 8 9 10 11 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.
Chapter 1 Overview of Inject and Clamp Mode Clamp Control You control clamp operation with these phases: clamp close low pressure close clamp open open slow Figure 1.9 Clamp Portion of a Typical Machine Cycle 1st Close 2nd Close 3rd Close Low Pressure Close Ejector retract Inject Ejector advance Open Slow 3rd Open 2nd Open 1st Open Clamp Close Three separate clamp close profiles may be configured: first close second close third close You may select from these control modes: velocity vs.
Chapter 1 Overview of Inject and Clamp Mode Moving Platen Clamp Cylinder L Stationary Platen Velocity Figure 1.
Chapter 1 Overview of Inject and Clamp Mode Low Pressure Close Use the low pressure close profile to decelerate closing motion to guard against damaging the mold halves and detect for part obstructions. The pressure setpoint(s) that you select to control low pressure close should prohibit the mold from fully closing if there is an obstruction. Up to two low pressure close profile segments may be used (Figure 1.12). You will use pressure vs. position for low pressure close. Figure 1.
Chapter 1 Overview of Inject and Clamp Mode Figure 1.13 Example Clamp Open Moving Platen Stationary Platen L Y 3rd Open Profile Velocity Clamp Cylinder 2nd Open Profile 1st Open Profile Position 0 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.
Chapter 1 Overview of Inject and Clamp Mode After completing the last configured open profile, the QDC module either switches immediately to the first programmed segment of the open slow profile, or waits for a command from your PLC-5 program to continue. Open Slow Use the open slow profile to accurately position the clamp for ejecting the part(s). You may decelerate clamp motion twice with this profile using up to two profile segments (Figure 1.15). You may select from these control modes: velocity vs.
Chapter 2 Install the QDC Module Chapter Objectives This chapter guides you through the following procedures: record I/O ranges set module jumper plugs key your I/O chassis install the QDC module wire the QDC module ground your system plan for E-STOPs and machine interlocks Record I/O Ranges To match your QDC module to your I/O devices, record the I/O ranges of your I/O devices on Worksheet 2-A.
Chapter 2 Install the QDC Module Set Module Jumper Plugs Before installing the QDC module, you must select with jumper plugs the I/O ranges that you recorded on Worksheet 2-A. Access and Position the Jumpers Access the jumpers and set them as follows: ATTENTION: To avoid damage to internal circuits, observe handling precautions and rid yourself of any electrostatic charge. Use an anti-static work station when setting jumper plugs. 2-2 1. Remove the label-side cover plate by removing the four screws.
Chapter 2 Install the QDC Module Figure 2.1 Jumper Locations on the QDC Module's Circuit Board TOP E1 E5 E6 LEFT RIGHT E7 E8 E9 E10 E11 E15 E14 E13 E12 E17 E16 BOTTOM 10908 I Important: We define jumper plug positions as left, right, top, and bottom. This represents the position of the jumper plug on the 3-pin connector as relative to the sides of the circuit board shown above.
Chapter 2 Install the QDC Module Table 2.
Chapter 2 Install the QDC Module Output Voltage Important: Selecting –10 to +10 Vdc with jumper E11, E12, E15, and/or E16 sets the QDC module for bi-directional valve operation. The relationship to percentage output is as follows: 10 8 5 3 0 -3 -5 -8 -10 0 10 20 30 40 50 60 70 80 90 100 % Output Requested Key Your I/O Chassis Use the plastic keying bands, shipped with each I/O chassis, for keying I/O slots to accept only one type of module.
Chapter 2 Install the QDC Module Install the QDC Module To install your QDC module in an I/O chassis, complete the following: 1. Turn off power to the I/O chassis. ATTENTION: Remove power from the 1771 I/O chassis backplane and wiring arm before removing or installing a QDC module. Failure to remove power from the backplane could cause injury or equipment damage due to possible unexpected operation.
Chapter 2 Install the QDC Module Wire the QDC Module Use the wiring arm (1771-WF) supplied with the QDC module to wire I/O devices (Figure 2.3). The wiring arm lets you install or remove the QDC module from the I/O chassis without rewiring. Wiring arm terminals are numbered in descending order, from the top down, starting with terminal 18 (Table 2.B). Figure 2.
Chapter 2 Install the QDC Module Table 2.
Chapter 2 Install the QDC Module Ground and Shield Your I/O Devices Analog inputs and outputs are sensitive to electrical noise interference. Take care to shield them properly. Guidelines: Use 22-gage (or larger) twisted-pair cable, 100% shielded with drain wire, such as Belden 8761. For cable distances over 50 ft, use 18-gage cable such as Belden 8760. Ground the cable shield at one end only; generally at the sensor or amplifier end of the cable, not at the I/O chassis (see Figure 2.4 and Figure 2.
Chapter 2 Install the QDC Module Figure 2.
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.
Chapter 2 Install the QDC Module Figure 2.
Chapter 3 Configure the QDC Module's I/O Chapter Objectives Your QDC module needs to know the characteristics of your ram (screw) and clamp sensors. In this chapter, we describe how to determine these characteristics and download them to the QDC module.
Chapter 3 Configure the QDC Module's I/O Worksheet 3 A Select Module Parameters Control Word MCC02 Bxx 15 14 13 12 11 10 09 08 07 06 05 04 03 02 01 00 Pro Set 600 Addr.
Chapter 3 Configure the QDC Module's I/O Worksheet 3 C Select Output Ranges for your Valves Control Word MCC04 Bxx 15 14 13 12 11 10 09 08 07 06 05 04 03 02 01 00 Pro Set 600 Addr.
Chapter 3 Configure the QDC Module's I/O Table 3.A Determine Initial Sensor configuration Values for Worksheet 3 D Category: If your: Then Use a Value Equal to: Minimum Position (Lines 1 and 9) N/A zero Maximum Position (Lines 2 and 10) ram (screw) is fully extended to the maximum range value specified by the mold end (ram bottom), and the manufacturer (full travel of the sensor mold closed position is zero.
Chapter 3 Configure the QDC Module's I/O Worksheet 3 D Determine Initial Sensor configuration Values Enter Your Initial Values Here Input 1 2 3 4 1 Line Control Word Pro Set 600 Addr.
Chapter 3 Configure the QDC Module's I/O 4. Enter the value for each word and bit. When you enter bit selections in words prefixed with file identifier B (example: B34), the PLC-5 processor automatically switches the radix to binary format so you can conveniently enter binary data. Download MCC Values to the QDC Module To download the MCC block to the QDC module, switch the PLC-5 processor from program to run mode. Pro-Set 600 software downloads the MCC block to the QDC module for you.
Chapter 3 Configure the QDC Module's I/O To finish configuring the QDC module, you actuate the ram (screw) and clamp with the QDC module’s set-output operation that applies percentage values to your QDC module’s outputs to move the ram (screw) or clamp in a controllable fashion. To do this, you apply %-output signals to all module outputs so you can move the actuator over its intended range. Sensor spanning values can then be refined per the actual values monitored by the QDC module.
Chapter 3 Configure the QDC Module's I/O Actuate the Ram (screw) and Clamp with Set output Operation 1. Enter values that result in no motion in these DYC words: Output: In Data Word: At Pro Set Address: 1 DYC09 N40:121 2 DYC10 N40:122 3 DYC11 N40:123 4 DYC12 N40:124 600 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. 3.
Chapter 3 Configure the QDC Module's I/O Worksheet 3 E Final Sensor configuration Values Enter Your Final Values Here Input 1 2 3 4 1 Line Control Word Pro Set 600 Addr.
Chapter 3 Configure the QDC Module's I/O 3. Record this position value (normally 0000) on line 1 for MCC09 on Worksheet 3-E. 4. With your programming terminal, read the signal level returned in SYS33 (N40:185) from your position sensor. You may wish to zero your position sensor at this time. 5. Record this value on line 3 for MCC11 (should be at minimum signal if you zeroed your position sensor in step 4). 6. Move the ram (screw) backward to the backpoint mechanical stop. 7.
Chapter 3 Configure the QDC Module's I/O 3. Record this position value (usually 0000) on line 9 for MCC23 on Worksheet 3-E. 4. With your programming terminal, read the signal level returned in SYS35 (N40:187) from your position sensor. You may wish to zero your position sensor at this time. 5. Record this value on line 11 for MCC25 (should be at minimum signal if you zeroed your position sensor in step 4). 6. Move the clamp backward to the mechanical open stop. 7.
Chapter 3 Configure the QDC Module's I/O ATTENTION: Use extreme caution during the next steps because you stress the hydraulic system to its maximum rated pressure. Loose fittings or faulty components could fail, causing possible damage to equipment and/or injury to personnel. 6. Re-torque all hydraulic connections and joints before proceeding. 7. Boost system pressure to obtain maximum ram (screw) pressure.
Chapter 3 Configure the QDC Module's I/O 5. Record this signal level on line 15 for MCC33 (should be at minimum signal if you zeroed your pressure sensor in step 4). ATTENTION: Use extreme caution during the next steps because you stress the hydraulic system to its maximum rated pressure. Loose fittings or faulty components could fail, causing possible damage to equipment and/or injury to personnel. 6. Re-torque all hydraulic connections and joints before proceeding. 7.
Chapter 3 Configure the QDC Module's I/O Select Optional Configurations You also have the option of configuring the following QDC features: Use this Option: For this Benefit: Software Travel Limits to guard against damaging the nozzle assembly or seals Pressure Alarm Time Delay to warn of excessive pressure without nuisance alarms Digital Filter to compensate for noise on position inputs Configure Software Travel Limits You may want to use the software restrictions, Figure 3.
Chapter 3 Configure the QDC Module's I/O Configure the QDC module for SWTL as follows: 1. Determine these SWTL values for ram (screw) and/or clamp travel with respect to the range of physical travel. SWTL deadband Maximum SWTL Minimum SWTL 2. Record non-zero SWTL values on Worksheet 3-F. Zero values disable the corresponding SWTLs. ATTENTION: Leaving your SWTL settings at zero (MCC13, 14, 27, and 28) inhibits the QDC module from performing this safety function.
Chapter 3 Configure the QDC Module's I/O Set Up Maximum Pressure Alarms and Time Delays The QDC module continuously monitors ram (screw) and clamp pressure inputs. When it detects that the process input equals or exceeds a preset alarm setpoint, the QDC module sets an alarm bit. A setpoint of zero disables the associated alarm.
Chapter 3 Configure the QDC Module's I/O Configure Digital Filters for Position Inputs You may enable an optional digital filter on position inputs to reduce electrical noise from a potentiometer-type position sensors or picked up by your input circuits. To determine if you need a digital filter, move the ram (screw) or clamp very slowly.
Chapter 4 Overview of Remaining Configuration Procedures Chapter Objectives This chapter introduces you to the remaining procedures necessary to successfully configure your QDC module. You must follow the procedures in the given order. Please use this chapter as a guide. Configuration Concepts 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.
Chapter 4 Overview of Remaining Configuration Procedures There are two basic types of command blocks. They are presented in the following table: Type of Command Block: Which Contain: Examples: Configuration Blocks Information necessary to configure your Valve spanning module to run a certain portion of a profile. information for the 1st clamp close profile. Profile Blocks Actual process setpoints necessary to produce a desired part. 1st clamp close profile operating setpoints.
Chapter 4 Overview of Remaining Configuration Procedures Overview of Remaining Configuration Procedures Configuration procedures detailed over the next several chapters are outlined below. The procedures are sequential in nature: configuration information determined in initial chapters is needed in later chapters. Step: Procedure: Enter this Information: Refer to: 1 Jog Your Machine Machine jog pressure and flow setpoints are entered into the Jog Configuration (JGC) block.
Chapter 4 Overview of Remaining Configuration Procedures Enter Data Table Values and Download Command Blocks We refer to these procedures throughout this manual whenever you must: enter data table values download command blocks Enter Values into Your PLC Data Table With your programming terminal, enter worksheet values into your PLC-5 data table as follows: 1. Switch the PLC-5 processor to PROGRAM mode. 2. Display your PLC-5 data table 3.
Chapter 4 Overview of Remaining Configuration Procedures Learn the following procedure because you will use it often. 1. For the block you want to download (subject block), get its ID number from Table 4.A and enter it into DYC61. Table 4.A Information Required to Download a Command Block Block to Download: Pro Set 600 Block ID.
Chapter 4 Overview of Remaining Configuration Procedures When you have done all three: 1. Corrected all errors in MCC and DYC blocks 2. Entered the ID of the subject block in DYC61 3. Downloaded the subject block Then: The QDC module immediately reports any programming errors it detected in the subject block 3. Start the download procedure by setting the corresponding download bit (Table 4.A) in your PLC-5 data table. 4.
Chapter 5 Jog Your Machine Chapter Objectives This chapter describes how to: configure jog block values necessary to jog the ram (screw) and clamp test jog values and make changes, if necessary configure values which indirectly affect screw-rotate and ejector jogs About Jogging Jogging your machine is similar to operating it in set-output: You apply percentage values to your QDC module’s outputs to obtain the desired motion.
Chapter 5 Jog Your Machine Determine Initial Jog Values Worksheet 5-A lists all words in which you must enter values to successfully configure your QDC module for jogging the ram (screw) and clamp forward and backward. Use it to record: initial values Enter initial values just sufficient to jog in the desired direction. Keep this information in mind: The numbers you enter are %-signal output. For a range of –10 to +10 Vdc, zero output occurs @ 50% (See Warning on next page.
Chapter 5 Jog Your Machine Worksheet 5. A Ram (screw) and Clamp Jog Configuration Values Enter Your Initial Values Here Control Block Word Pro Set 600 Addr.
Chapter 5 Jog Your Machine ATTENTION: You can connect up to four different valves to your QDC module. Although all four may not directly jog the ram (screw) or clamp, consider their indirect effect when setting jog set-output values. Indirectly, they could cause unexpected machine motion with possible damage to equipment or injury to personnel. ATTENTION: A value of 0 entered in your data table does not necessarily correspond to zero pressure or flow.
Chapter 5 Jog Your Machine Write Ladder Logic Take time now to develop ladder logic (independent of Pro-Set 600 software) to jog the ram (screw) and clamp. You need to monitor switches on your operator control panel, and set corresponding command bits. Use word 1 in the dynamic command block (DYC01) to enable and disable individual jogs. Use word 1 in the system status block (SYS01) to monitor the QDC module’s reaction to jog commands. Tables 5.A and 5.
Chapter 5 Jog Your Machine Figure 5.
Chapter 5 Jog Your Machine Jog Your Ram (Screw) and Clamp Jog your ram (screw) and clamp, one at a time, in forward and reverse directions. Experiment with values you entered in the jog configuration block (JGC) until you obtain the desired jog operation. You must download the JGC to the QDC module each time you change a value in the command block to implement the new value. Refer to the download procedure outlined in chapter 4.
Chapter 5 Jog Your Machine Worksheet 5. B Screw rotate & Eject Jog Configuration Values for Indirect Control Enter Your Initial Values Here Control Block Word Pro Set 600 Addr.
Chapter 5 Jog Your Machine Table 5.C Enable Bits for Screw rotate and Ejector Jogs Command Block Word: Pro Set 600 Address: Description: DYC01 B09 B34/393 Execute Screw rotate Jog DYC01 B14 B34/398 Execute Ejector Jog Advance DYC01 B15 B34/399 Execute Ejector Jog Retract Table 5.
Chapter 5 Jog Your Machine Figure 5.
Chapter 6 Select Command and Status Bits to Sequence Machine Operation Chapter Objectives In this chapter, we provide you with tables of command and status bits that you use to write ladder logic to: implement manual functions such as jog, set outputs, and stop step your QDC module through machine cycles We suggest how to assess your logic requirements and based on those requirements how to use bit tables to write your machine’s sequential ladder logic that depends on your machine’s hydraulic configurat
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.
Chapter 6 Select Command and Status Bits to Sequence Machine Operation Table 6.
Chapter 6 Select Command and Status Bits to Sequence Machine Operation Table 6.D Command Bits To Interrupt Inject and Clamp Movement Between Profiles 6-4 Bit Description: QDC Block Addr.
Chapter 6 Select Command and Status Bits to Sequence Machine Operation Table 6.E Miscellaneous Status Bits To Trigger New Inject and Clamp Action Reason for Using: Bit Description: QDC Block Addr.
Chapter 6 Select Command and Status Bits to Sequence Machine Operation Table 6.F Status Bits Category: Bit Status (when = 1): Pro Set B34/xx: QDC Block Addr.
Chapter 6 Select Command and Status Bits to Sequence Machine Operation Table 6.F (continued) Status Bits Category: Bit Status (when = 1): Pro Set B34/xx: QDC Block Addr.
Chapter 6 Select Command and Status Bits to Sequence Machine Operation Table 6.F (continued) Status Bits 6-8 Category: Bit Status (when = 1): Pro Set B34/xx: QDC Block Addr.
Chapter 6 Select Command and Status Bits to Sequence Machine Operation Table 6.G Command and Configuration Bits Operation: Function Enabled (when = 1): Pro Set B34/xx: QDC Block Addr.
Chapter 6 Select Command and Status Bits to Sequence Machine Operation Table 6.G (continued) Command and Configuration Bits Operation: Function Enabled (when = 1): Pro Set Address: QDC Block Addr.
Chapter 7 Load Initial Configuration Values Chapter Objectives This chapter helps you determine, enter, and download configuration setpoints required to tune the QDC module. You will refer to this chapter frequently when tuning the QDC module in chapter 9.
Chapter 7 Load Initial Configuration Values Use These Worksheets The following table lists command blocks and corresponding worksheets for recording your initial values that you use to configure the QDC module.
Chapter 7 Load Initial Configuration Values This page is purposely blank so that the following 2-page worksheets will be on facing pages.
Chapter 7 Load Initial Configuration Values Worksheet 7 A First Clamp Close Configuration Block (FCC) Control Word FCC01 Bxx 15 14 13 12 11 10 09 08 07 06 05 04 03 02 01 00 Pro Set 600 Addr. B37/bit 15 14 13 12 11 10 09 08 07 06 05 04 03 02 01 00 Value 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1 1 FCC Block Identifier Control Word FCC02 Bxx 15 14 13 12 11 10 09 08 07 06 05 04 03 02 01 00 Pro Set 600 Addr.
Chapter 7 Load Initial Configuration Values Worksheet 7 A (continued) First Clamp Close Configuration Block (FCC) Enter Your Values Here Control Word Pro Set 600 Addr.
Chapter 7 Load Initial Configuration Values Worksheet 7 B Second Clamp Close Configuration Block (SCC) Control Word SCC01 Bxx 15 14 13 12 11 10 09 08 07 06 05 04 03 02 01 00 Pro Set 600 Addr. B37/bit 79 78 77 76 75 74 73 72 71 70 69 68 67 66 65 64 Value 0 0 0 0 0 0 0 0 0 0 0 0 0 1 0 0 SCC Block Identifier Control Word SCC02 Bxx 15 14 13 12 11 10 09 08 07 06 05 04 03 02 01 00 Pro Set 600 Addr.
Chapter 7 Load Initial Configuration Values Worksheet 7 B (continued) Second Clamp Close Configuration Block (SCC) Enter Your Values Here Control Word Pro Set 600 Addr.
Chapter 7 Load Initial Configuration Values Worksheet 7 C Third Clamp Close Configuration Block (TCC) Control Word TCC01 Bxx 15 14 13 12 11 10 09 08 07 06 05 04 03 02 01 00 Pro Set 600 Addr. B37/bit 143 142 141 140 139 138 137 136 135 134 133 132 131 130 129 128 0 0 0 0 0 0 0 0 0 0 0 0 0 1 0 1 Value TCC Block Identifier Control Word TCC02 Bxx 15 14 13 12 11 10 09 08 07 06 05 04 03 02 01 00 Pro Set 600 Addr.
Chapter 7 Load Initial Configuration Values Worksheet 7 C (continued) Third Clamp Close Configuration Block (TCC) Enter Your Values Here Control Word Pro Set 600 Addr.
Chapter 7 Load Initial Configuration Values Worksheet 7 D Clamp Low Pressure Close Configuration Block (LPC) Control Word LPC01 Bxx 15 14 13 12 11 10 09 08 07 06 05 04 03 02 01 00 Pro Set 600 Addr. B37/bit 207 206 205 204 203 202 201 200 199 198 197 196 195 194 193 192 0 0 0 0 0 0 0 0 0 0 0 0 0 1 1 0 Value LPC Block Identifier Control Word LPC02 Bxx 15 14 13 12 11 10 09 08 07 06 05 04 03 02 01 00 Pro Set 600 Addr.
Chapter 7 Load Initial Configuration Values Worksheet 7 D (continued) Clamp Low Pressure Close Configuration Block (LPC) Enter Your Values Here Control Word Pro Set 600 Addr.
Chapter 7 Load Initial Configuration Values Worksheet 7 E Injection Configuration Block (INC) Control Word INC01 Bxx 15 14 13 12 11 10 09 08 07 06 05 04 03 02 01 00 Pro Set 600 Addr. B38/bit 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 Word INC02 Bxx 15 14 13 12 11 10 09 08 07 06 05 04 03 02 01 00 Pro Set 600 Addr.
Chapter 7 Load Initial Configuration Values Worksheet 7 E(continued) Injection Configuration Block (INC) Enter Your Values Here Control Word Pro Set 600 Addr.
Chapter 7 Load Initial Configuration Values Worksheet 7 F Pack Configuration Block (PKC) Control Word PKC01 Bxx 15 14 13 12 11 10 09 08 07 06 05 04 03 02 01 00 Pro Set 600 Addr. B38/bit 143 142 141 140 139 138 137 136 135 134 133 132 131 130 129 128 0 0 0 0 0 0 0 0 0 0 0 0 1 0 1 0 Value PKC Block Identifier Control Word PKC02 Bxx 15 14 13 12 11 10 09 08 07 06 05 04 03 02 01 00 Pro Set 600 Addr.
Chapter 7 Load Initial Configuration Values Worksheet 7 F (continued) Pack Configuration Block (PKC) Enter Your Values Here Control Word Pro Set 600 Addr.
Chapter 7 Load Initial Configuration Values Worksheet 7 G Hold Configuration Block (HDC) Control Word HDC01 Bxx 15 14 13 12 11 10 09 08 07 06 05 04 03 02 01 00 Pro Set 600 Addr. B38/bit 207 206 205 204 203 202 201 200 199 198 197 196 195 194 193 192 0 0 0 0 0 0 0 0 0 0 0 0 1 0 1 1 Value HDC Block Identifier Control Word HDC02 Bxx 15 14 13 12 11 10 09 08 07 06 05 04 03 02 01 00 Pro Set 600 Addr.
Chapter 7 Load Initial Configuration Values Worksheet 7 G (continued) Hold Configuration Block (HDC) Enter Your Values Here Control Word Pro Set 600 Addr.
Chapter 7 Load Initial Configuration Values Worksheet 7 H Plastication Configuration Block (PLC) Control Word PLC01 Bxx 15 14 13 12 11 10 09 08 07 06 05 04 03 02 01 00 Pro Set 600 Addr. B38/bit 399 398 397 396 395 394 393 392 391 390 389 388 387 386 385 384 0 0 0 0 0 0 0 0 0 0 0 0 1 1 1 0 Value PLC Block Identifier Control Word PLC02 Bxx 15 14 13 12 11 10 09 08 07 06 05 04 03 02 01 00 Pro Set 600 Addr.
Chapter 7 Load Initial Configuration Values Worksheet 7 H (continued) Plastication Configuration Block (PLC) Enter Your Values Here Control Word Pro Set 600 Addr.
Chapter 7 Load Initial Configuration Values Worksheet 7 I First Clamp Open Configuration Block (FOC) Control Word FOC01 Bxx 15 14 13 12 11 10 09 08 07 06 05 04 03 02 01 00 Pro Set 600 Addr. B37/bit 335 334 333 332 331 330 329 328 327 326 325 324 323 322 321 320 0 0 0 0 0 0 0 0 0 0 0 1 0 0 0 1 Value FOC Block Identifier Control Word FOC02 Bxx 15 14 13 12 11 10 09 08 07 06 05 04 03 02 01 00 Pro Set 600 Addr.
Chapter 7 Load Initial Configuration Values Worksheet 7 I (continued) First Clamp Open Configuration Block (FOC) Enter Your Values Here Control Word Pro Set 600 Addr.
Chapter 7 Load Initial Configuration Values Worksheet 7 J Second Clamp Open Configuration Block (SOC) Control Word SOC01 Bxx 15 14 13 12 11 10 09 08 07 06 05 04 03 02 01 00 Pro Set 600 Addr. B37/bit 399 398 397 396 395 394 393 392 391 390 389 388 387 386 385 384 0 0 0 0 0 0 0 0 0 0 0 1 0 0 1 0 Value SOC Block Identifier Control Word SOC02 Bxx 15 14 13 12 11 10 09 08 07 06 05 04 03 02 01 00 Pro Set 600 Addr.
Chapter 7 Load Initial Configuration Values Worksheet 7 J (continued) Second Clamp Open Configuration Block (SOC) Enter Your Values Here Control Word Pro Set 600 Addr.
Chapter 7 Load Initial Configuration Values Worksheet 7 K Third Clamp Open Configuration Block (TOC) Control Word TOC01 Bxx 15 14 13 12 11 10 09 08 07 06 05 04 03 02 01 00 Pro Set 600 Addr. B37/bit 463 462 461 460 459 458 457 456 455 454 453 452 451 450 449 448 0 0 0 0 0 0 0 0 0 0 0 1 0 0 1 1 Value TOC Block Identifier Control Word TOC02 Bxx 15 14 13 12 11 10 09 08 07 06 05 04 03 02 01 00 Pro Set 600 Addr.
Chapter 7 Load Initial Configuration Values Worksheet 7 K (continued) Third Clamp Open Configuration Block (TOC) Enter Your Values Here Control Word Pro Set 600 Addr.
Chapter 7 Load Initial Configuration Values Worksheet 7 L Clamp Open Slow Configuration Block (OSC) Control Word OSC01 Bxx 15 14 13 12 11 10 09 08 07 06 05 04 03 02 01 00 Pro Set 600 Addr. B37/bit 527 526 525 524 523 522 521 520 519 518 517 516 515 514 513 512 0 0 0 0 0 0 0 0 0 0 0 1 0 1 0 0 Value OSC Block Identifier Control Word OSC02 Bxx 15 14 13 12 11 10 09 08 07 06 05 04 03 02 01 00 Pro Set 600 Addr.
Chapter 7 Load Initial Configuration Values Worksheet 7 L (continued) Clamp Open Slow Configuration Block (OSC) Enter Your Values Here Control Word Pro Set 600 Addr.
Chapter 7 Load Initial Configuration Values Procedure to Determine and Enter Initial Values Follow this procedure to complete each worksheet: 1. Read the text for the subject parameter. 2. Determine your initial value. Important: If you need additional information when determining your initial values, refer to the same configuration blocks in Section 3 of the Plastic Molding Module Reference Manual, publication 1771-6.5.88. 3.
Chapter 7 Load Initial Configuration Values Selected Valve for Pressure Control (FCC02, SCC02, TCC02, LPC02, INC02, PKC02, HDC02, PLC02, FOC02, SOC02, TOC02, OSC02) The QDC module can control ram (screw) and clamp movement using pressure vs. position (or time vs. ram) algorithms. For the plastication algorithm, the pressure component is backpressure. You must inform the QDC module which valve to use for controlling pressure with these algorithms.
Chapter 7 Load Initial Configuration Values Comparison of Gain Constants Compare dependent and independent gains constants as follows: Dependent Gains Constants: Independent Gains Constants: Controller Gain Kc (dimensionless) Proportional Gain Kp (dimensionless) Reset Term 1/Ti (minutes per repeat) Integral Gain Ki (inverse seconds) Rate Term Td (minutes) Derivative Term Kd (seconds) Other variables used in any algorithm choice include: Output E PV = Percentage of full scale = Error (scaled) SP-PV
Chapter 7 Load Initial Configuration Values Determine Word Selections: Select ERC Values Expert Response Compensation Minimum Percentages (FCC05 06, SCC05 06, TCC05 06, LPC06, INC05 06, PKC06, HDC06, PLC06, FOC05 06, SOC05 06, TOC05 06, OSC05 06) The QDC module uses a proprietary control scheme called Expert Response Compensation. It accounts for changes in your machine, machine hydraulics, raw materials, and other process variables.
Chapter 7 Load Initial Configuration Values Table 7.
Chapter 7 Load Initial Configuration Values Output Voltage ATTENTION: A value of zero entered in your set-output words does not necessarily correspond to zero pressure or flow. If you configured for bi-directional valve operation (–10 to +10 Vdc), a set-output value of 50% gives zero volts signal output (see graph) while a set-output value of 0% or 100% gives maximum signal output. Amplifier electronics or spool-null offsets may also allow pressure or flow at zero signal input.
Chapter 7 Load Initial Configuration Values Acceleration Ramp Rates (FCC17 20, SCC17 20, TCC17 20, LPC17 20, INC17 20, PKC17 20, HDC17 20, PLC17 20, FOC17 20, SOC17 20, TOC17 20, OSC17 20) The QDC module uses acceleration ramp rates when moving its outputs to a higher setpoint during execution of a profile. They affect both selected and unselected valves. A ramp rate of zero disables ramping, and the QDC module steps directly from setpoint to setpoint. We entered zero on corresponding worksheets.
Chapter 7 Load Initial Configuration Values Set Pressure Control Limits Control limits let you span your selected valve outputs for effective control with either direct-acting or reverse-acting valves. Your machine manufacturer typically provides you with values to configure these limits. Minimum Pressure Control Limit (FCC41, SCC41, TCC41, LPC41, INC41, PKC41, HDC41, PLC41, FOC41, SOC41, TOC41, OSC41) The value in this word corresponds to the minimum controllable pressure during the respective profile.
Chapter 7 Load Initial Configuration Values Determine Output for Minimum values as follows: 0 (0%) for uni-directional direct acting valves 5000 (50%) for bi-directional valves 9999 (100%) for uni-directional reverse acting valves If your selected pressure valve is: Then the value in word 43 should be: And during the profile, the QDC module does NOT drive the valve with a % output: Direct Acting less than the value in word 44 less than the value in word 43 Reverse Acting greater than the value in wo
Chapter 7 Load Initial Configuration Values Set Velocity Control Limits Minimum Velocity Control Limit (FCC45, SCC45, TCC45, INC45, FOC45, SOC45, TOC45, OSC45,) The value in this word corresponds to the minimum controllable velocity during the respective profile. The QDC module uses this word with the Selected Velocity Valve, Output for Minimum (word 47) below. The QDC module expects this velocity when setting the selected velocity valve to the percentage output you enter in word 47.
Chapter 7 Load Initial Configuration Values Determine Output for Minimum values as follows: 0 (0%) for uni-directional direct acting valves 5000 (50%) for bi-directional valves 9999 (100%) for uni-directional reverse acting valves If your selected velocity valve is: Then the value in word 47 should be: And during the profile or stroke, the QDC module does NOT drive the valve with a % output: Direct Acting less than the value in word 48 less than word 47 Reverse Acting greater than the value in word
Chapter 7 Load Initial Configuration Values Set Profile Gain Constants, Pressure Alarm Setpoints, and Watchdog Timer Presets Profile Gain Constants (FCC49 53, SCC49 53, TCC49 53, LPC49 51, INC49 53, PKC49 51, HDC49 51, PLC49 51, FOC49 53, SOC49 53, TOC49 53, OSC49 53) The QDC module’s PID and velocity feedforward (VelFF) algorithms are different from classic PID and VelFF algorithms.
Chapter 7 Load Initial Configuration Values Enter and Download your Worksheet Values After you determine your initial values and enter them on configuration worksheets, you are ready to proceed. 1. Enter all worksheet values into your PLC-5 data table. Important: Be sure that you have not altered any setpoints, and that you have entered each and every setpoint exactly as on the worksheets. 2. Use the procedure described in chapter 4 to download command blocks to the QDC module.
Chapter 8 Load Initial Profile Values Chapter Objectives This chapter describes how to load profile setpoints for inject and clamp operations. You determine initial values and enter setpoints into PLC-5 data table for the following profiles: Clamp Close Profile (CPC) Injection Profile (IPC) Pack/Hold Profile (HPC) Plastication Profile (PPC) Clamp Open Profile (OPC) Important: This chapter continues the procedure for loading information into the QDC module.
Chapter 8 Load Initial Profile Values Determine and Enter Setpoints for Clamp Close Profile (CPC) Use Worksheet 8-A to enter setpoints for pressure vs. position and velocity vs. position clamp close profiles. The valve spanning procedures in chapter 9 require specific values. We have already entered many values for you, and help you determine other values in the text that follows.
Chapter 8 Load Initial Profile Values Worksheet 8 A (continued) Clamp Close Profile Block (CPC) Enter Your Values Here Control Word Pro Set 600 Addr.
Chapter 8 Load Initial Profile Values Determine Bit Selections for Worksheet 8 A Clamp Close Profile Block Identifier (CPC01) Bits 07-00 of this word identify it as the first word in a series used to define the clamp close profile. These bits must be set to 00000111. We entered these bits on Worksheet 8-A. Velocity Units (CPC03) The following bit determines units of measure for velocity values. - BIT 14 selects units of measure.
Chapter 8 Load Initial Profile Values Profile Algorithm (CPC03) The following bits determine the algorithm for each clamp close profile. - BIT 04 configures third clamp close profile - BIT 02 configures second clamp close profile - BIT 00 configures first clamp close profile 0 = Velocity vs. position algorithm 1 = Pressure vs. position algorithm We set these bits to 1 for pressure vs. position on Worksheet 8-A. Important: All other bit selections in CPC03 should be zero.
Chapter 8 Load Initial Profile Values Determine Word Values for Velocity Setpoints (CPC09, 12, 15, 18, 21, 24, 27, 30, 33) Use these words to configure velocity vs. position profiles. Enter velocity in units per second. Each velocity setpoint controls the velocity of its corresponding segment. Select setpoints for first clamp close segments 1-3 that are typical of velocities you would run during normal machine operation. Enter these setpoints into CPC09, 12, and 15 of Worksheet 8-A.
Chapter 8 Load Initial Profile Values Start LPC Position Setpoint (CPC61) This QDC module uses this position as protection against running the clamp into the mold.
Chapter 8 Load Initial Profile Values 4. Enter your FCC end-of-segment position setpoints for CPC11, 14, and 17 on Worksheet 8-A. We entered zero for the remaining position setpoints on Worksheet 8-A. The valve spanning procedures in chapter 9 require these initial values. We help you select correct final values for your application in chapter 10. For additional information, refer to Section 3 of the Plastic Molding Module Reference Manual (publication 1771-6.5.88).
Chapter 8 Load Initial Profile Values Determine and Enter Setpoints for the Injection Profile (IPC) Use Worksheet 8-B to enter setpoints for pressure vs. time and velocity vs. position injection profiles. The valve spanning procedures in chapter 9 require specific values. We have already entered many values for you, and help you determine other values in the text that follows.
Chapter 8 Load Initial Profile Values Worksheet 8 B Injection Profile Block (IPC) Control Word IPC01 Bxx 15 14 13 12 11 10 09 08 07 06 05 04 03 02 01 00 Pro Set 600 Addr. B38/bit 79 78 77 76 75 74 73 72 71 70 69 68 67 66 65 64 Value 0 0 0 0 0 0 0 0 0 0 0 0 1 0 0 1 IPC Block Identifier Control Word IPC03 Bxx 15 14 13 12 11 10 09 08 07 06 05 04 03 02 01 00 Pro Set 600 Addr.
Chapter 8 Load Initial Profile Values IPC15 IPC16 IPC17 IPC18 IPC19 IPC20 IPC21 IPC22 IPC23 IPC24 IPC25 IPC26 IPC27 IPC28 IPC29 IPC30 IPC31 IPC32 IPC33 IPC34 IPC35 IPC36 IPC37 IPC38 IPC39 IPC40 IPC41 IPC42 IPC43 IPC44 IPC45 IPC46 IPC47 IPC48 IPC49 IPC50 IPC51 IPC52 IPC57 IPC58 IPC59 IPC60 IPC61 IPC62 IPC64 1 N44:71 N44:72 N44:73 N44:74 N44:75 N44:76 N44:77 N44:78 N44:79 N44:80 N44:81 N44:82 N44:83 N44:84 N44:85 N44:86 N44:87 N44:88 N44:89 N44:90 N44:91 N44:92 N44:93 N44:94 N44:95 N44:96 N44:97 N44:98 N44:
Chapter 8 Load Initial Profile Values Determine Bit Selections for Worksheet 8 B Injection Profile Block Identifier (IPC01) Bits 07-00 of this word identify it as the first word in a series used to define the injection profile. These bits must be set to 00001001. We entered these bits on Worksheet 8-B. Velocity Units (IPC03) The following bit determines units of measure for velocity values. - BIT 14 selects units of measure.
Chapter 8 Load Initial Profile Values Expert Response Compensation (IPC04) - BITS 11, 10, 09, and 08 determine whether you apply Expert Response Compensation (ERC) to injection profiles. ERC is an exclusive algorithm that adjusts for changes in your machine, hydraulics, raw materials, and other process variables. It compensates for abrupt upsets and long term deviations. 0 = Expert Response Compensation ON 1 = Expert Response Compensation OFF We set these bits to 1 (ERC = Off) on Worksheet 8-B.
Chapter 8 Load Initial Profile Values Pressure Setpoints (IPC10, 14, 18, 22, 26, 30, 34, 38, 42, 46, and 50) Use these words when configuring pressure vs. position or time profiles. Enter pressure in PSI or Bar. Each pressure setpoint controls the pressure of its corresponding segment. You may use from 1 to 11 segments in your profile. The procedures in chapter 9 require all eleven. Enter the initial value of one-half system pressure for all 11 pressure setpoints on Worksheet 8-B.
Chapter 8 Load Initial Profile Values Time Setpoints (IPC12, 16, 20, 24, 28, 32, 36, 40, 44, and 48) Use these words when configuring pressure vs.time profiles. Enter time in seconds (1 second as 100). Each setpoint controls the time of its own segment. You must use one less time setpoint than pressure setpoints. We entered 1 second (100) for these time setpoints on Worksheet 8-B. The valve spanning procedures in chapter 9 require these initial values.
Chapter 8 Load Initial Profile Values The valve spanning procedures in chapter 9 require these initial values. We help you select correct final values for your application in chapter 10. For additional information, refer to Section 3 of the Plastic Molding Module Reference Manual (publication 1771-6.5.88). Transition Setpoints (IPC60, 61, 62, and 64) Use these words when configuring the type of transition from injection to the pack (or hold) profile.
Chapter 8 Load Initial Profile Values - IPC64 determines the start of zone in which the QDC module allows pressure transitions. A non-zero value measured from the mold end forces the QDC module NOT to transition on pressure until the ram (screw) reaches this position. A zero setpoint forces the QDC module to use any non-zero pressure setpoint in IPC62 over the entire injection profile. We entered zero on Worksheet 8-B to inhibit this function.
Chapter 8 Load Initial Profile Values Worksheet 8 C Pack/Hold Profile Block (HPC) Control Word HPC01 Bxx 15 14 13 12 11 10 09 08 07 06 05 04 03 02 01 00 Pro Set 600 Addr. B38/bit 271 270 269 268 267 266 265 264 263 262 261 260 259 258 257 256 0 0 0 0 0 0 0 0 0 0 0 0 1 1 0 0 Value HPC Block Identifier Control Word HPC03 Bxx 15 14 13 12 11 10 09 08 07 06 05 04 03 02 01 00 Pro Set 600 Addr.
Chapter 8 Load Initial Profile Values Worksheet 8 C (continued) Pack/Hold Profile Block (HPC) Enter Your Values Here Control Word Pro Set 600 Addr.
Chapter 8 Load Initial Profile Values Determine Bit Selections for Worksheet 8 C Pack/Hold Profile Block Identifier (HPC01) Bits 07-00 of this word identify it as the first word in a series used to define the pack/hold profile. These bits must be set to 00001100. We entered these bits on Worksheet 8-C. Profile Offset Sign (HPC03) Profile offsets let you shift the amplitude of entire profiles up or down, if necessary. The offset sign determines the direction of shift.
Chapter 8 Load Initial Profile Values Open loop or Closed loop Control (HPC04) - BITS 03 and 01 determine whether you use open- or closed-loop control of pack and hold profiles. In open loop, a valve position moves the cylinder without sensor feedback . In closed loop, sensor feedback controls the valve regulating pressure. 0 = Closed loop 1 = Open loop We set these bits to 1 for open-loop control on Worksheet 8-C. The valve spanning procedures in chapter 9 require these initial bit settings.
Chapter 8 Load Initial Profile Values Cure Timer Preset (HPC61) Use this word to set the length of cure time that starts at completion of the hold profile. You enter this preset in seconds (000.0 to 999.9). After the QDC module starts the internal cure timer, it: reports the accumulated value of the timer in SYS58 sets bit SYS03-B03 when the timer is timing sets the done bit SYS03-B05 when SYS58 equals or exceeds HPC61 stops this timer when: SYS58 = 999.
Chapter 8 Load Initial Profile Values Determine and Enter Setpoints for Plastication Profile (PPC) Use Worksheet 8-D to enter setpoints for a backpressure vs. position plastication profile. The valve spanning procedures in chapter 9 require specific values. We have already entered many values for you, and help you determine other values in the text that follows.
Chapter 8 Load Initial Profile Values Worksheet 8 D Plastication Profile Block (PPC) Control Word PPC01 Bxx 15 14 13 12 11 10 09 08 07 06 05 04 03 02 01 00 Pro Set 600 Addr. B38/bit 463 462 461 460 459 458 457 456 455 454 453 452 421 450 449 448 0 0 0 0 0 0 0 0 0 0 0 0 1 1 1 1 Value PPC Block Identifier Control Word PPC03 Bxx 15 14 13 12 11 10 09 08 07 06 05 04 03 02 01 00 Pro Set 600 Addr.
Chapter 8 Load Initial Profile Values Worksheet 8 D (continued) Plastication Profile Block (PPC) Enter Your Values Here Control Word Pro Set 600 Addr.
Chapter 8 Load Initial Profile Values Determine Bit Selections for Worksheet 8 D Plastication Profile Block Identifier (PPC01) Bits 07-00 of this word identify it as the first word in a series used to define the plastication profile. These bits must be set to 00001111. We entered these bits on Worksheet 8-D. Profile Offset Sign (PPC03) The profile offset lets you shift the amplitude of the entire profile up or down, if necessary. The offset sign determines the direction of shift.
Chapter 8 Load Initial Profile Values Expert Response Compensation (PPC04) - BITS 09 and 08 determine whether you apply Expert Response Compensation (ERC) to plastication profiles. ERC is an exclusive algorithm that adjusts for changes in your machine, hydraulics, raw materials, and other process variables. It compensates for abrupt upsets and long term deviations. 0 = Expert Response Compensation ON 1 = Expert Response Compensation OFF We set these bits to 1 (ERC = Off) on Worksheet 8-D.
Chapter 8 Load Initial Profile Values End of Segment Position Setpoints (PPC11, 15, 19, 23, 27, 31, 35, 39, 43, and 47) Use these words to configure the backpressure vs. position profile. The procedures in chapter 9 require that you use all 10 position setpoints. Determine end-of-segment position setpoints for your backpressure vs. position profile for use in chapter 9 as follows: 1. Back up the ram (screw) from the mold end to the shot size position as read in SYS25 (N40:177).
Chapter 8 Load Initial Profile Values Cushion Size (PPC61) This word determines the length of molten plastic that should remain in the barrel at the conclusion of the hold profile. The QDC uses this length in computing the 100% shot size. Units are inches or millimeters. We entered zero (no cushion) on Worksheet 8-D. Shot Size (PPC62) This word determines the length of molten plastic drawn during the plastication profile. Use this value to determine segment length in End-of-segment Positions, above.
Chapter 8 Load Initial Profile Values Determine and Enter Setpoints for Clamp Open Profile (OPC) Use Worksheet 8-E to enter setpoints for pressure vs. position and velocity vs. position profiles. The valve spanning procedures in chapter 9 require specific values. We have already entered many values for you, and help you determine other values in the text that follows.
Chapter 8 Load Initial Profile Values Worksheet 8 E (continued) Clamp Open Profile Block (OPC) Enter Your Values Here Control Word Pro Set 600 Addr.
Chapter 8 Load Initial Profile Values Determine Bit Selections for Worksheet 8 E Clamp Open Profile Block Identifier (OPC01) Bits 07-00 of this word identify it as the first word in a series used to define the clamp open profile. These bits must be set to 00010101. We entered these bits on Worksheet 8-E. Velocity Units (OPC03) The following bit determines units of measure for velocity values. - BIT 14 selects units of measure.
Chapter 8 Load Initial Profile Values Profile Algorithm (OPC03) The following bits determine the algorithm for each clamp open profile. - BIT 06 configures the open slow profile BIT 04 configures the third clamp open profile BIT 02 configures the second clamp open profile BIT 00 configures the first clamp open profile 0 = Velocity vs. Position algorithm 1 = Pressure vs. Position algorithm We set these bits to 1 for pressure vs. position on Worksheet 8-E.
Chapter 8 Load Initial Profile Values The valve spanning procedures in chapter 9 require these initial bit settings. Where required, we help you select correct final values for your application in chapter 10. For additional information, refer to the Plastic Molding Module Reference Manual (publication 1771-6.5.88). Determine Word Values for Worksheet 8 E Velocity Setpoints (OPC09, 12, 15, 18, 21, 24, 27, 30, 33, 36, 39) Use these words to configure velocity vs. position profiles.
Chapter 8 Load Initial Profile Values Start OSC Position Setpoint (OPC61) The QDC module uses this position as protection against running a clamp open profile into the open slow zone.
Chapter 8 Load Initial Profile Values 4. Enter your FOC end-of-segment position setpoints for OPC11, 14, and 17 on Worksheet 8-E. We entered zero for the remaining position setpoints on Worksheet 8-E. The valve spanning procedures in chapter 9 require these initial values. We help you select correct final values for your application in chapter 10. for additional information, refer to Section 3 of the Plastic Molding Module Reference Manual (publication 1771-6.5.88).
Chapter 9 Span Your Valves Chapter Objectives This chapter describes how to span your valves using direct-output operation, and verify by running simple open-loop profiles. ATTENTION: Before proceeding, be sure you completed all previous chapters. Failure to do so could result in unpredictable machine motion, with possible equipment damage and/or injury.
Chapter 9 Span Your Valves Referenced Worksheets The following table lists command blocks used in this chapter and in corresponding worksheets from chapters 7 and 8 that contain initial values.
Chapter 9 Span Your Valves Span Your Low Pressure Close Valve We recommend that you first span your low pressure close pressure valve for optimum pressure performance.
Chapter 9 Span Your Valves Span Your Low Pressure Close Pressure Valve(s) Span your clamp pressure valve for smooth operation at the highest desired LPC pressure.
Chapter 9 Span Your Valves 4. Enable set-output by changing DYC01-B08 (B34/392) to 1. This forces the QDC module to apply the values in DYC09-12 directly to its outputs 1-4, respectively. 5. Adjust the set-output value DYC09-12 (N40:121-124) that corresponds to the selected clamp LPC valve, and observe the pressure reported in SYS28 (N40:180). For a bi-directional valve with a spool offset: If this pressure is greater than zero, adjust the set-output value to the clamp LPC valve to obtain zero pressure.
Chapter 9 Span Your Valves 13. Download your final values for LPC41-44 to the QDC module by downloading the LPC block. Important: If downloading from your programming terminal, you must download LPC followed by CPC (chapter 4). To download: Set: B21/ LPC 5 CPC 6 Test Valve Linearity with a Low Pressure Close (LPC) Profile 1. Jog your clamp to a position just inside the LPC start position (CPC61). 2. Enable the LPC profile by setting DYC02-B03 (B34/403) = 1.
Chapter 9 Span Your Valves What You Have Accomplished The valve spanning procedure you just completed has defined the: range of pressure available during low pressure close end-of-range maximum and minimum signal levels for linear control of the clamp LPC valve in open-loop control For this range limit When trying to obtain the pressure in: The QDC module drives the selected pressure valve to % output signal in: Minimum LPC41 LPC43 Maximum LPC42 LPC44 Now for the open-loop LPC profile, the QDC mod
Chapter 9 Span Your Valves 5. Enable set-output by transitioning DYC01-B08 (B34/392) to 1. 6. Change the set-output word DYC09-12 (N40:121-124) corresponding to your clamp tonnage (lock-up) pressure valve in 5% increments while observing clamp pressure (SYS28, N40:180). Stop changing it when the observed clamp pressure equals the desired tonnage pressure. If you cannot reach the desired pressure, verify that the other three set-output values are correct. 7.
Chapter 9 Span Your Valves Span Your Clamp Close Pressure Valve(s) Span your clamp close pressure valve(s) for optimum performance. Do this in four parts: Confirm critical values Span your clamp close pressure valve(s) Test valve linearity Set pressure alarm setpoints Important: You may omit the next three parts of this section if you have the right information on valve spanning.
Chapter 9 Span Your Valves Span Your Clamp Close Pressure Valve(s) Span your clamp close pressure valve(s) for smooth operation at highest desired clamp pressure.
Chapter 9 Span Your Valves 4. Enable set-output by changing DYC01-B08 (B34/392) from 0 to 1. This forces the QDC module to apply the values in DYC09-12 directly to its outputs 1-4, respectively. 5. Adjust the set-output value DYC09-12 (N40:121-124) that corresponds to the selected clamp close pressure valve, and observe the pressure reported in SYS28 (N40:180).
Chapter 9 Span Your Valves 11. Lower the set-output value in DYC09-12 corresponding to the selected clamp close pressure valve to a safe level. 12. Disable set-output operation. Toggle DYC01-B08 (B34/392) to 0. 13. Download your changes in FCC, SCC, and TCC to the QDC module. Important: If downloading from your programming terminal, download FCC, SCC, TCC, and CPC in that order (chapter 4). To download Set B21/ FCC 2 SCC 3 TCC 4 CPC 6 Test Valve Linearity with a Clamp Close Pressure Profile 1.
Chapter 9 Span Your Valves To do this: change FCC44, download the FCC and CPC blocks, and repeat steps 1-3. Repeat as necessary. Important: If downloading from your programming terminal, download FCC followed by CPC with download bits B21/2 and 6 (chapter 4). 4. Copy final FCC44 (N43:40) into SCC44 and TCC44 (N43:100 and 160) and download these changes to the QDC module.
Chapter 9 Span Your Valves Span Your Clamp Close Velocity (Flow) Valve(s) Span your clamp close velocity (flow) valve(s) for optimum velocity performance. Do this in three parts: Confirm critical values Span your clamp close velocity (flow) valve(s) Test valve linearity with a velocity vs. position profile Important: You may omit this section if you have the right information on valve spanning.
Chapter 9 Span Your Valves Span Your Clamp Close Velocity Valve(s) Span your clamp close velocity valve(s) for smooth operation at highest desired clamp velocity.
Chapter 9 Span Your Valves 3. Convert the minimum and maximum flow obtained from your flow curve to clamp cylinder velocity. This is done by: Clamp Cylinder Velocity (in/sec) = Flow (in3/sec) Area (in2) - where area is the inside diameter of the cylinder. This area may be different for the rod and piston ends of the cylinder: Area (no Rod) = π I.D. of cylinder Area for Rod End = π I.D. of cylinder 2 2 2 2 π Rod diameter 2 2 - The flow assumes no restrictions on the cylinder exhaust port. 4.
Chapter 9 Span Your Valves Test Valve Linearity with a Velocity Profile 1. Select velocity vs. position control for the entire clamp close operation by resetting the following bits to zero: CPC03-B00 (B37/288) CPC03-B02 (B37/290) CPC03-B04 (B37/292) 2. Download the CPC block to the QDC module. Important: If downloading from your programming terminal, download CPC by setting B21/6 (chapter 4). 3. Jog your clamp to the full open position. 4.
Chapter 9 Span Your Valves Important: If downloading from your programming terminal, download FCC, SCC, and/or TCC followed by CPC (chapter 4). To download: Set B21/ FCC 2 SCC 3 TCC 4 CPC 6 What You Have Accomplished The valve spanning procedure you just completed has defined the: range of velocity available during any clamp close profile end-of-range maximum and minimum signal levels for linear control of the clamp velocity valve in open-loop control.
Chapter 9 Span Your Valves Span Your Injection Pressure Valve Span your injection pressure valve for optimum pressure performance. You do this in four parts: Confirm critical values Span your injection pressure valves Test valve linearity with a pressure vs. time injection profile Set profile pressure alarms Important: You may omit the next three parts of this section if you have the right information on valve spanning.
Chapter 9 Span Your Valves If these are not your current values, we suggest that you correct them now using the download procedure discussed in chapter 4. Span Your Injection Pressure Valve Span your injection valve for smooth operation at highest desired pressure.
Chapter 9 Span Your Valves 4. Enable set-output by changing DYC01-B08 (B34/392) from 0 to 1. This forces the QDC module to apply the values in DYC09-12 directly to its outputs 1-4, respectively. 5. Adjust the set-output value DYC09-12 (N40:121-124) that corresponds to the selected ram (screw) pressure valve, and observe actual pressure reported in SYS26 (N40:178).
Chapter 9 Span Your Valves Test Valve Linearity with a Pressure vs. Time Injection Profile 1. Confirm that your pressure setpoints are equal to one-half system pressure in IPC10, 14, 18, 22, 26, 30, 34, 38, 42, 46, and 50 (N44:66, 70, 74, 78, 82, 86, 90, 94, 98, 102, 106). If not, correct them and download them to the QDC module. For instructions, refer to chapter 4. 2. Check that the ram (screw) is still at the mold-end position. 3. Run a pressure vs.
Chapter 9 Span Your Valves What You Have Accomplished The open-loop tuning procedure you just completed has defined the: range of ram (screw) backpressure during plastication end-of-range maximum and minimum signal levels for linear control of the injection pressure valve in open-loop control For this range limit When trying to obtain the pressure in: The QDC module drives the selected pressure valve to % output signal in: Minimum INC41 INC43 Maximum INC42 INC44 Now, for all open-loop injection pr
Chapter 9 Span Your Valves Span Your Injection Velocity Valve Span your flow valve for optimum velocity performance in three parts: Confirm critical values Span your injection flow valve Test valve linearity with a velocity vs. position profile Important: You may omit the rest of this section if you have the right information on valve spanning. Many injection molding machine OEMs and hydraulic valve manufacturers provide data on spanning the working range of valves used on their machines.
Chapter 9 Span Your Valves Set New Values for the Velocity vs. Position Profile If necessary, refer to chapter 8 for when you determine the following: 8 B Velocity vs.
Chapter 9 Span Your Valves Find optimum values for INC46, 48 1. Jog the ram (screw) all the way to the backpoint position. 2. Set machine hydraulics to simulate injection. Enable pumps and align valves to their normal state during injection. 3. Run an open-loop velocity vs. position injection profile by toggling DYC02-B04 (B34/404) from 0 to 1 to 0. 4. The QDC module automatically runs the injection, pack, and hold profiles in succession.
Chapter 9 Span Your Valves Determine Optimum Value for INC47 11. Enter new velocity setpoints equal to 1/10 maximum velocity (0.10 times the velocity in INC48) in these words: IPC09, 13, 17, 21, 25, 29, 33, 37, 41, 44, and 49 (N44:65, 69, 73, 77, 81, 85, 89, 93, 97, 101, and 105) 12. Download the INC and IPC blocks to the QDC module. Important: If downloading from your programming terminal, download INC followed by IPC (chapter 4). To download Set B21/ INC 7 IPC 8 13.
Chapter 9 Span Your Valves Test Valve Linearity with a Velocity vs. Position Profile 1. Change your velocity setpoints to one-half maximum velocity (0.5 times the velocity in INC48) in these words: IPC09, 13, 17, 21, 25, 29, 33, 37, 41, 45, and 49 (N44:65, 69, 73, 77, 81, 85, 89, 93, 97, 101, 105). Important: Be sure the correct pump adders are set for this velocity. 2. Download the INC and IPC data blocks to the QDC module.
Chapter 9 Span Your Valves What You Have Accomplished The valve-spanning procedure you just completed has defined the: range of ram (screw) velocity during any injection profile end-of-range maximum and minimum signal levels for linear control of the injection velocity valve in open-loop control For this range limit When trying to obtain the velocity in: The QDC module drives the selected velocity valve to % output signal in: Minimum INC45 INC47 Maximum INC46 INC48 Now for all open-loop injection
Chapter 9 Span Your Valves Span Your Pack and Hold Pressure Valves We recommend that you span your pack and hold pressure valves for optimum pressure performance in four parts: Confirm critical values Span your pack and hold pressure valves Test valve linearity with a pressure vs. time profile Set profile pressure alarms Important: You may omit the next three parts of this section if you have the right information on valve spanning.
Chapter 9 Span Your Valves On Worksheet Confirm Your Configuration With These Words or Bits for Hold Pressure Pro Set Addr 7 G QDC module output to which you connected your pressure control valve HDC02 B06, B05, B04 B38/212 214 Set output values for unselected valves HDC09 12 = your values N44:185 188 All ramping is disabled with zero ramp rates HDC17 20 = 0 HDC25 28 = 0 N44:193 196 N44:201 204 End of profile set output values HDC33 36 for zero output N44:209 212 Pressure limits: Minimum P
Chapter 9 Span Your Valves Span Your Pack and Hold Pressure Valves Span your pack valve for smooth operation at the highest desired pressure.
Chapter 9 Span Your Valves 4. Enable set-output by changing DYC01-B08 (B34/392) from 0 to 1. This forces the QDC module to apply the values in DYC09-12 directly to its outputs 1-4, respectively. 5. Adjust the value of DYC09-12 (N40:121-124) that corresponds to the selected ram (screw) pressure valve, and observe actual pressure reported in SYS26 (N40:178).
Chapter 9 Span Your Valves 12. Download your final values for PKC41-44 and HDC41-44 to the QDC module by downloading the PKC, HDC, and HPC blocks. Important: If downloading from your programming terminal, download PKC and HDC, followed by HPC (chapter 4). To download Set B21/ PKC 9 HDC 10 HPC 11 Test Valve Linearity with a Pressure vs. Time Profile After you span the pressure valve for ram (screw) pack and hold, test linearity for pack and hold profiles with this procedure: 1.
Chapter 9 Span Your Valves 6. If the observed pressure HPS16 for pack and HPS33 for hold are still not within 20% of setpoints HPC16 and HPC33, your pressure valve is not linear over the desired range.
Chapter 9 Span Your Valves Span Your Plastication Pressure Valve We recommend that you span your plastication pressure valve for optimum plastication performance in four parts: Confirm critical values Span your plastication pressure valve Test valve linearity with a plastication backpressure vs. position profile Set the profile pressure alarm Important: You may omit the next three parts of this section if you have the right information on valve spanning.
Chapter 9 Span Your Valves Before proceeding, observe these warnings: ATTENTION: As with any machine start-up, install a test mold. Programming errors, configuration errors, or hydraulic problems could lead to machine damage or injury to personnel. ATTENTION: Be sure all machine guards and shields are in place before proceeding. ATTENTION: Load the hopper with plastic before starting this procedure.
Chapter 9 Span Your Valves 3. While observing actual pressure in SYS26 (N40:178) and the output in SYS41-44 (N40:193-196) that corresponds to the selected plastication valve, run a plastication backpressure vs. position profile. Do this by toggling DYC04-B08 (B34/408) from 0 to 1 to 0. 4.
Chapter 9 Span Your Valves 9. Observe and record actual backpressures reported by the QDC module for all profile segments in PPS10, 14, 18, 22, 26, 30, 34 etc. (N44:714, 718, 722, 726, 730, 734, 738, 742, 746, 750, 754). 10. Compare actual backpressures with your setpoints in PPC10, 14, 18, 22, 26, 30, 34, 38, 42, 46, 50 as follows: If Then Actuals are greater than setpoints by 20% or more 1. 2. 3. 4. Decrease PLC44 by 10%. Enter this new value into PLC data table. Repeat the profile with steps 7 9.
Chapter 9 Span Your Valves To do this: change PLC41 and/or PLC43, download the PLC and PPC blocks, and repeat steps 2-4. Repeat as necessary. Important: If downloading from your programming terminal, download PLC followed by PPC with download bits B21/13 and 14 (chapter 4).
Chapter 9 Span Your Valves Span Your Clamp Open Pressure Valve(s) Span your clamp open pressure valve(s) for optimum performance. Do this in four parts: Confirm critical values Span your clamp open pressure valve(s) Test valve linearity Set profile pressure alarms Important: You may omit the next three parts of this section if you have the right information on valve spanning.
Chapter 9 Span Your Valves On Worksheet: Confirm Your Configuration: With These Words or Bits: Pro set Addr: 8 E Mold Protection - start open slow on overrun OPC03 B11 = 0 B37/619 Logical bridge - start next profile OPC03 B10 = B09 = B08 = 0 B37/618, 617, 616 Pressure vs.
Chapter 9 Span Your Valves ATTENTION: Be sure all machine guards and shields are in place before proceeding. 1. Jog your clamp to the full open position. 2. Align all other machine hydraulics to simulate clamp open motion. For example, enable required pumps and align required valves. 3.
Chapter 9 Span Your Valves 7. While maintaining this minimum pressure, observe the actual pressure in SYS41-44 (N40:193-196) that corresponds to your selected clamp open pressure valve. Copy this value into FOC43, SOC43, TOC43, and OSC43 (N43:339, 399, 459, and 519), the selected pressure valve output for minimum. 8. Change the set-output value in DYC09-12 (N40:121-124) that corresponds to the clamp open pressure valve by 50%, and then in 5% steps while observing the clamp pressure in SYS28 (N40:180).
Chapter 9 Span Your Valves Test Valve Linearity with a Clamp Open Pressure Profile 1. Jog your clamp to the full open position. 2. Enable first clamp open by setting DYC02-B10 (B34/410) = 1. The clamp should move from its start position through the first clamp open and open slow profiles. If no motion, verify that: - no overtravel alarms are set. The QDC module inhibits clamp open if SYS07-B00 through SYS07-B05 are set - no programming error codes exist in SYS61 and SYS62 3.
Chapter 9 Span Your Valves What You Have Accomplished The valve spanning procedure you just completed has defined the: range of pressure available during any clamp open profile end-of-range maximum and minimum signal levels for linear control of the clamp open pressure valve in open-loop control.
Chapter 9 Span Your Valves Span Your Clamp Open Velocity (Flow) Valve(s) Span your clamp open velocity (flow) valve(s) for optimum velocity performance. Do this in three parts: Confirm critical values Span your clamp open velocity (flow) valve(s) Test valve linearity Important: You may omit the next two parts of this section if you have information on valve spanning.
Chapter 9 Span Your Valves Span Your Clamp Open Velocity Valve(s) Span your clamp open velocity valve(s) for smooth operation at highest velocity.
Chapter 9 Span Your Valves Important: If the pressure during clamp open slow differs from that during clamp open fast, complete the calculations for both pressures. Be sure to record words with correct prefixes: open slow values with the OSC prefix clamp open fast values with FOC, SOC and TOC prefixes 3. Convert the minimum and maximum flow obtained from your flow curve to clamp cylinder velocity.
Chapter 9 Span Your Valves Test Valve Linearity with a Velocity vs. Position Profile 1. Select velocity vs. position control for the entire clamp open operation by resetting the following bits to zero: OPC03-B00 (B37/608) OPC03-B02 (B37/610) OPC03-B04 (B37/612) OPC03-B06 (B37/614) 2. Download this change to the QDC module. Important: If downloading from your programming terminal, download OPC by setting download bit B21/20 (chapter 4). 3. Jog your clamp to the full close position (mold halves mated).
Chapter 9 Span Your Valves 6. Copy final FOC48 (N43:344) into SOC48, TOC48 and OSC48 (N43:404, 464, and 524), and download these changes. Important: If downloading from your programming terminal, download FOC, SOC, TOC and/or OSC followed by OPC (chapter 4).
Chapter 10 Tune Your Machine Chapter Objectives In chapter 9 you ran simple open-loop profiles to span your valves. This chapter presents guidelines to help you adjust parameters in configuration and profile blocks to optimize machine performance for production runs.
Chapter 10 Tune Your Machine Closed loop Control So far, you ran open-loop profiles with the QDC module’s PID and VelFF control algorithms disabled. We suggest that you use open-loop control: for spanning valves for troubleshooting machine performance when the machine has no pressure sensors for feedback Important: You can achieve considerably better consistency of finished parts when the QDC module operates in closed-loop control.
Chapter 10 Tune Your Machine Use only proportional and integral control. Use the highest possible P and I gain constants for inject-mode profiles for precise performance without hammering your hydraulics but Use the lowest possible P and I gain constants for clamp-mode profiles for repeatable performance. First tune your proportional gain. Then add integral gain. Typically, the integral term will be larger than the proportional term. The QDC module’s pressure algorithm differs from classic PID algorithms.
Chapter 10 Tune Your Machine 3. Downloaded all setpoint changes to the QDC module. 4. Run several cycles of the profile while comparing profile actuals (returned in the corresponding status block) with profile setpoints. Also look for abnormal flexing or pulsing of hydraulic hoses leading to the controlled cylinder.
Chapter 10 Tune Your Machine 1. Enter an operational profile representative of the characteristics you desire for your production cycle. 2. Check that you zeroed the profile’s integral and derivative terms. Leave the proportional term at the value you recorded in chapter 7. 3. Downloaded all setpoint changes to the QDC module. 4. Connect an oscilloscope to your selected pressure control valve 5. Run several profile cycles while observing the oscilloscope trace.
Chapter 10 Tune Your Machine Tune Closed loop Velocity Control General Guidelines for Velocity Tuning If your machine will never run velocity profiles, skip this section. In this section we present two procedures: Tune Pressure Loops without an Oscilloscope Tune Pressure Loops with an Oscilloscope Repeat either one of these procedures as needed for tuning closed-loop control of these velocity vs.
Chapter 10 Tune Your Machine Tune Velocity Loops Without An Oscilloscope Before you begin tuning your velocity loop, confirm that you: selected the velocity vs. position algorithm selected closed-loop control zeroed the VelFF term disabled ERC reset ERC values disabled ramping ATTENTION: Verify that you have correctly set the following words and bits in CPC and OPC that control zone overrun to guard against damaging the clamp or mold.
Chapter 10 Tune Your Machine 5. If you are satisfied with your unselected valve set-output values and still cannot match velocity actuals to desired setpoints, your control may require a small feedforward gain. 6. If necessary, slowly increase the feedforward term while running machine cycles until velocity actuals satisfactorily match entered setpoints. Important: If you must use feedforward gain to adequately tune your velocity profile, do NOT enable ERC for this profile.
Chapter 10 Tune Your Machine Ideally for each step of a multi-stepped profile, the oscilloscope trace should rise or fall quickly to a controlled level and then flatten out. Bounce or chatter when rising or falling is undesirable.
Chapter 10 Tune Your Machine Injection Tuning Considerations for Producing Parts In this section, we discuss the usage and effect of the following items as they apply to the inject operation: Profile Requirements Cushion, Shot Size, and Transition Setpoints Unselected Valve Set-output Values Logical Bridges and End-of-profile Set-output Values Decompression Pullback Acceleration and Deceleration Ramp Rates Watchdog Timer and Profile Offsets Pressure Alarm Setpoints Pressure-limited Velocity vs.
Chapter 10 Tune Your Machine Important: The injection velocity profile requires one additional velocity setpoint beyond the last non-zero end-of position setpoint, so you must program one more velocity setpoint than position setpoint, such that total velocity setpoints = total position setpoints + 1 If not, the ram (screw) stops at the final end-of-position setpoint (if it does not see a pressure transition beforehand).
Chapter 10 Tune Your Machine End of segment Position Setpoints Shot size is subdivided into profile segments, the lengths of which are determined by your end-of-segment position setpoints. Each segment has its velocity or pressure setpoint for controlling the ram (screw). Important: Avoid multiple adjacent segments having the same velocity or pressure setpoint. For better control, use a constant velocity or pressure over a single equivalent length segment.
Chapter 10 Tune Your Machine Minimum Profile Requirements We present minimum requirements for inject-mode profiles. Use this as a starting point for developing your own part-specific profiles. Profile End of Segment Position Setpts Time Setpoints Velocity Setpoints Pressure Setpoints Other Velocity vs. Time None required N/A IPC09 N/A one of IPC60, 61, 62, or 63 Pressure limited Vel/Time None required N/A IPC09 N/A one of IPC60, 61, 62, or 63. IPC57, 58, and 59 Pressure vs.
Chapter 10 Tune Your Machine Shot Size (PPC61) Shot size (measured from cushion) is the amount of molten plastic needed to fill the mold (figure 10.3). Determine it with these general steps: 1. Start with a shot size you know will NOT fill the mold. 2. Enter a ram(screw) transition position about 1/2” from ram bottom. 3. Run a shot with transition on position. The end-of-hold position will be at ram bottom, because mold cavities continue to fill during pack and hold. 4.
Chapter 10 Tune Your Machine Ram (Screw) Pressure for Transition (IPC62) If actual ram (screw) pressure during injection exceeds this setpoint, the QDC module transitions to the pack phase. Typically you enter a value less than mold flash pressure. Start of Zone for Pressure Transition (IPC64) A non-zero value (measured from mold end) forces the QDC module NOT to transition on pressure until the ram (screw) reaches this position (figure 10.3).
Chapter 10 Tune Your Machine In chapter 7, you determined the signal output percentages required to drive the unselected valves during respective profiles. These values should allow desired ram (screw) control. Although different part set-ups and other process considerations may require that you modify them during a particular profile, you should adjust them only if you are unable to obtain desired closed-loop control by modifying profile gain constants.
Chapter 10 Tune Your Machine Important: The QDC module always logically bridges the injection, pack and hold phases as a single integrated machine movement.
Chapter 10 Tune Your Machine Post-decompression guards against drooling molten plastic into the open mold when the clamp is opening. The QDC module applies postdecompression pullback to the ram (screw) after plastication. When configuring pre- and post-decompression: Enter values into PRC05 and PSC05 only after you have tested shot size and cushion (PPC61 and PPC62).
Chapter 10 Tune Your Machine Figure 10.1 Example Injection, Pack, and Hold Profiles with Accl/Decel Ramps Injection Profile Selected Valve Accel. Ramps Pack Profile Selected Valve Accel & Decel. Ramps Hold Profile Selected Valve Decel Ramps Velocity Pressure Pack Profile Hold Profile Time Injection Profile Position Important: When enabled, the QDC module applies ramp rates at the beginning of each profile segment.
Chapter 10 Tune Your Machine You enter ramp rates in units of 0 to 9999 percent signal output per second (note that there is no decimal point). A ramp rate of 9999 lets the output move full range in 10 milliseconds, while a ramp rate of 99 requires a full second to go full range. Lower values = slower ramps. Watchdog Timer and Profile Offsets Profile Watchdog Timer Preset (PLC08) Set your plastication profile watchdog timer preset after your machine is running repeatable, quality parts.
Chapter 10 Tune Your Machine Pressure limited Velocity vs. Position Injection Pressure-limited velocity vs. position differs from both velocity and pressure injection control. During normal operation, pressure-limited velocity control acts the same as velocity vs. position control. However, when ram (screw) pressure exceeds a preset, the QDC module changes from velocity to pressure control to guard against flashing the mold. Use pressure-limited velocity vs.
Chapter 10 Tune Your Machine You control the maximum pressure of the pressure-limited velocity vs. position profile with this setpoint: IPC57 – Ram Pressure Limit for Pressure-limited Velocity Control. When ram (screw) pressure reaches this limit and IPC58 and 59 allow it, the QDC module switches control from velocity to pressure control. Consider the following when determining this setpoint.
Chapter 10 Tune Your Machine Expert Response Compensation The QDC module uses a proprietary, enhanced control scheme called Expert Response Compensation (ERC). It compensates for changes in your machine dynamics, machine hydraulics, raw materials, and other process variables. It also adjusts the open-loop and closed-loop control algorithms to compensate for abrupt upsets and long term deviations to your process. In previous chapters, you ran profiles with the QDC module’s ERC algorithm disabled.
Chapter 10 Tune Your Machine Tuning Considerations for Clamp Operation In this section, we discuss the usage and effect of the following items as they apply to clamp operation: Clamp-control Objectives Profile Requirements Unselected Valve Set-output Values Logical Bridges and End-of-profile Set-output Values Acceleration and Deceleration Ramp Rates Pressure Alarm Setpoints Watchdog Timer Expert Response Compensation We assume you are familiar with conventions, terminology, and procedures used in the Inje
Chapter 10 Tune Your Machine Profile Requirements A profile is a series of position and pressure (or velocity) setpoints which uniquely define a phase of clamp motion. The complexity of the profile depends on your mold and clamp mechanism. Velocity Setpoints In general, choose velocity setpoints to move the clamp quickly without damaging the machine, mold, or parts.
Chapter 10 Tune Your Machine End of segment Position Setpoints These setpoints depend on the particular mold and clamp configurations of your plastic molding machine. In general, you are not required to enter any end-of-segment position setpoints for the clamp.
Chapter 10 Tune Your Machine Figure 10.3 Better Control from Fewer and Longer Steps Rather than using a profile with multiple steps at the same velocity or pressure... Use fewer, longer steps Clamp Close Profiles Start Clamp LPC Position Setpoint (CPC61) The QDC module uses this clamp position as protection against running a clamp close profile into the mold protection zone.
Chapter 10 Tune Your Machine Start Clamp Open Slow Position Setpoint (OPC61) The QDC module uses this clamp position to guard against running a clamp-open profile into the open-slow zone. Although you can use it as an operational setpoint OPC03-B11 = 0 (see discussion of End-of Segment Position Setpoints below), it purpose is to maintain precision clamp positioning in regardless of profile entry errors.
Chapter 10 Tune Your Machine Logical Bridges, and End of profile Set output Values Logical Bridges In chapter 8, you configured your QDC module to logically bridge all your clamp profiles. This forced the QDC module to start each successive profile at completion of the previous one.
Chapter 10 Tune Your Machine End-of-profile set-output values have uses including: setting cores between clamp close profiles pulling cores between clamp open profiles third plate drop-off and pick-up building tonnage/holding pressure on the clamp prior to injection adjusting flow with a variable pump after clamping or between profiles initializing valves for the next profile or movement re-aligning solenoid valves by PLC-5 processor before starting the next profile or movement When configuring end-of-prof
Chapter 10 Tune Your Machine Figure 10.4 Example Clamp Close Profiles with Acc/Dec ramps 2nd Close Profile Decel. Ramp 1st Close Profile 2nd Close Profile Decel. Ramp Accel. Ramp 1st Close Profile Accel. Ramp 3rd Close Profile Decel. Ramp 3rd Close Profile Accel. Ramp Velocity Low Pressure Close Decel.
Chapter 10 Tune Your Machine You can configure ramp rates to decelerate the clamp: at the beginning of low pressure close. This may avoid possible damage to mold or machinery when moving toward the mold protection zone at high velocities during the clamp close operation. at the beginning of open slow. This may help achieve consistent repeatability of the full open position when moving toward the open slow zone at high velocities during the clamp open operation.
Chapter 10 Tune Your Machine In general: When using this alarm to detect this condition You set the alarm setpoint and Program ladder logic to Absolute pressure Dangerously high pressure • Well above normal operating level • Below the level that could result in machine damage or personal injury • Stop the QDC module • Place the machine in a safe condition Profile pressure Abnormally high pressure • Just above the highest pressure expected for the profile of movement • Low enough to detect problem
Chapter 10 Tune Your Machine ERC is not required for: repeatable clamp positioning. Without ERC, the QDC module may force the clamp to overshoot by a constant repeatable amount (relative to cylinder speed and QDC module 2 ms scan time). Landing the clamp precisely on the position you programmed is unimportant. Do NOT use ERC when: spanning your valves using velocity feedforward gain using slow (low value) profile ramp rates to smooth clamp operation.
Chapter 11 Troubleshoot with LEDs Chapter Objectives This chapter gives you information on how to: troubleshoot your QDC module using LED indicators calibrate your QDC module Use LEDs to Troubleshoot Your QDC Module The front panel of the QDC module contains three Light Emitting Diodes (LEDs). Use them to troubleshoot problems that may occur during integration or operation of the QDC module. Each LED is a different color for easy identification.
Chapter 11 Troubleshoot with LEDs Figure 11.
Chapter 11 Troubleshoot with LED's Table 11.A shows how to interpret QDC module LEDs. The QDC module monitors its own operation and reports detected conditions by illuminating its LEDs in the following combinations: Table 11.A LED Indicator Conditions ACTIVE FAULT COMM Condition: We recommend that you: Flashing Off Off Power up. The QDC module has completed its power up diagnos tics, the QDC module hardware and firmware are OK, and the QDC module is awaiting download of the MCC block.
Appendix A Blank Worksheets Worksheet 3 A Selecting Module Parameters Control Word MCC02 Bxx 15 14 13 12 11 10 09 08 07 06 05 04 03 02 01 00 Pro Set 600 Addr.
Appendix A Blank Worksheets Worksheet 3 C Selecting Output Ranges for your Valves Control Word MCC04 Bxx 15 14 13 12 11 10 09 08 07 06 05 04 03 02 01 00 Pro Set 600 Addr.
Appendix A Blank Worksheets Worksheet 3 E Final Sensor configuration Values Enter Your Final Values Here Input 1 2 3 4 1 Line Control Word Pro Set 600 Addr.
Appendix A Blank Worksheets Worksheet 3 G Pressure alarm and Time delay Setpoints Enter Your Pressure alarm and Time delay Values Here Control Word Pro Set 600 Addr.
Appendix A Blank Worksheets Worksheet 5 B Screw rotate & Eject Jog Configuration Values for Indirect Control Enter Your Initial Values Here Control Block Word Pro Set 600 Addr.
Appendix A Blank Worksheets Worksheet 7 A First Clamp Close Configuration Block (FCC) Control Word FCC01 Bxx 15 14 13 12 11 10 09 08 07 06 05 04 03 02 01 00 Pro Set 600 Addr. B37/bit 15 14 13 12 11 10 09 08 07 06 05 04 03 02 01 00 Value 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1 1 FCC Block Identifier Control Word FCC02 Bxx 15 14 13 12 11 10 09 08 07 06 05 04 03 02 01 00 Pro Set 600 Addr.
Appendix A Blank Worksheets Worksheet 7 A (continued) First Clamp Close Configuration Block (FCC) Enter Your Values Here Control Word Pro Set 600 Addr.
Appendix A Blank Worksheets Worksheet 7 B Second Clamp Close Configuration Block (SCC) Control Word SCC01 Bxx 15 14 13 12 11 10 09 08 07 06 05 04 03 02 01 00 Pro Set 600 Addr. B37/bit 79 78 77 76 75 74 73 72 71 70 69 68 67 66 65 64 Value 0 0 0 0 0 0 0 0 0 0 0 0 0 1 0 0 SCC Block Identifier Control Word SCC02 Bxx 15 14 13 12 11 10 09 08 07 06 05 04 03 02 01 00 Pro Set 600 Addr.
Appendix A Blank Worksheets Worksheet 7 B (continued) Second Clamp Close Configuration Block (SCC) Enter Your Values Here Control Word Pro Set 600 Addr.
Appendix A Blank Worksheets Worksheet 7 C Third Clamp Close Configuration Block (TCC) Control Word TCC01 Bxx 15 14 13 12 11 10 09 08 07 06 05 04 03 02 01 00 Pro Set 600 Addr. B37/bit 143 142 141 140 139 138 137 136 135 134 133 132 131 130 129 128 0 0 0 0 0 0 0 0 0 0 0 0 0 1 0 1 Value TCC Block Identifier Control Word TCC02 Bxx 15 14 13 12 11 10 09 08 07 06 05 04 03 02 01 00 Pro Set 600 Addr.
Appendix A Blank Worksheets Worksheet 7 C (continued) Third Clamp Close Configuration Block (TCC) Enter Your Values Here Control Word Pro Set 600 Addr.
Appendix A Blank Worksheets Worksheet 7 D Clamp Low Pressure Close Configuration Block (LPC) Control Word LPC01 Bxx 15 14 13 12 11 10 09 08 07 06 05 04 03 02 01 00 Pro Set 600 Addr. B37/bit 207 206 205 204 203 202 201 200 199 198 197 196 195 194 193 192 0 0 0 0 0 0 0 0 0 0 0 0 0 1 1 0 Value LPC Block Identifier Control Word LPC02 Bxx 15 14 13 12 11 10 09 08 07 06 05 04 03 02 01 00 Pro Set 600 Addr.
Appendix A Blank Worksheets Worksheet 7 D (continued) Clamp Low Pressure Close Configuration Block (LPC) Enter Your Values Here Control Word Pro Set 600 Addr.
Appendix A Blank Worksheets Worksheet 7 E Injection Configuration Block (INC) Control Word INC01 Bxx 15 14 13 12 11 10 09 08 07 06 05 04 03 02 01 00 Pro Set 600 Addr. B38/bit 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 Word INC02 Bxx 15 14 13 12 11 10 09 08 07 06 05 04 03 02 01 00 Pro Set 600 Addr.
Appendix A Blank Worksheets Worksheet 7 E (continued) Injection Configuration Block (INC) Enter Your Values Here Control Word Pro Set 600 Addr.
Appendix A Blank Worksheets Worksheet 7 F Pack Configuration Block (PKC) Control Word PKC01 Bxx 15 14 13 12 11 10 09 08 07 06 05 04 03 02 01 00 Pro Set 600 Addr. B38/bit 143 142 141 140 139 138 137 136 135 134 133 132 131 130 129 128 0 0 0 0 0 0 0 0 0 0 0 0 1 0 1 0 Value PKC Block Identifier Control Word PKC02 Bxx 15 14 13 12 11 10 09 08 07 06 05 04 03 02 01 00 Pro Set 600 Addr.
Appendix A Blank Worksheets Worksheet 7 F (continued) Pack Configuration Block (PKC) Enter Your Values Here Control Word Pro Set 600 Addr.
Appendix A Blank Worksheets Worksheet 7 G Hold Configuration Block (HDC) Control Word HDC01 Bxx 15 14 13 12 11 10 09 08 07 06 05 04 03 02 01 00 Pro Set 600 Addr. B38/bit 207 206 205 204 203 202 201 200 199 198 197 196 195 194 193 192 0 0 0 0 0 0 0 0 0 0 0 0 1 0 1 1 Value HDC Block Identifier Control Word HDC02 Bxx 15 14 13 12 11 10 09 08 07 06 05 04 03 02 01 00 Pro Set 600 Addr.
Appendix A Blank Worksheets Worksheet 7 G (continued) Hold Configuration Block (HDC) Enter Your Values Here Control Word Pro Set 600 Addr.
Appendix A Blank Worksheets Worksheet 7 H Plastication Configuration Block (PLC) Control Word PLC01 Bxx 15 14 13 12 11 10 09 08 07 06 05 04 03 02 01 00 Pro Set 600 Addr. B38/bit 399 398 397 396 395 394 393 392 391 390 389 388 387 386 385 384 0 0 0 0 0 0 0 0 0 0 0 0 1 1 1 0 Value PLC Block Identifier Control Word PLC02 Bxx 15 14 13 12 11 10 09 08 07 06 05 04 03 02 01 00 Pro Set 600 Addr.
Appendix A Blank Worksheets Worksheet 7 H (continued) Plastication Configuration Block (PLC) Enter Your Values Here Control Word Pro Set 600 Addr.
Appendix A Blank Worksheets Worksheet 7 I First Clamp Open Configuration Block (FOC) Control Word FOC01 Bxx 15 14 13 12 11 10 09 08 07 06 05 04 03 02 01 00 Pro Set 600 Addr. B37/bit 335 334 333 332 331 330 329 328 327 326 325 324 323 322 321 320 0 0 0 0 0 0 0 0 0 0 0 1 0 0 0 1 Value FOC Block Identifier Control Word FOC02 Bxx 15 14 13 12 11 10 09 08 07 06 05 04 03 02 01 00 Pro Set 600 Addr.
Appendix A Blank Worksheets Worksheet 7 I (continued) First Clamp Open Configuration Block (FOC) Enter Your Values Here Control Word Pro Set 600 Addr.
Appendix A Blank Worksheets Worksheet 7 J Second Clamp Open Configuration Block (SOC) Control Word SOC01 Bxx 15 14 13 12 11 10 09 08 07 06 05 04 03 02 01 00 Pro Set 600 Addr. B37/bit 399 398 397 396 395 394 393 392 391 390 389 388 387 386 385 384 0 0 0 0 0 0 0 0 0 0 0 1 0 0 1 0 Value SOC Block Identifier Control Word SOC02 Bxx 15 14 13 12 11 10 09 08 07 06 05 04 03 02 01 00 Pro Set 600 Addr.
Appendix A Blank Worksheets Worksheet 7 J (continued) Second Clamp Open Configuration Block (SOC) Enter Your Values Here Control Word Pro Set 600 Addr.
Appendix A Blank Worksheets Worksheet 7 K Third Clamp Open Configuration Block (TOC) Control Word TOC01 Bxx 15 14 13 12 11 10 09 08 07 06 05 04 03 02 01 00 Pro Set 600 Addr. B37/bit 463 462 461 460 459 458 457 456 455 454 453 452 451 450 449 448 0 0 0 0 0 0 0 0 0 0 0 1 0 0 1 1 Value TOC Block Identifier Control Word TOC02 Bxx 15 14 13 12 11 10 09 08 07 06 05 04 03 02 01 00 Pro Set 600 Addr.
Appendix A Blank Worksheets Worksheet 7 K (continued) Third Clamp Open Configuration Block (TOC) Enter Your Values Here Control Word Pro Set 600 Addr.
Appendix A Blank Worksheets Worksheet 7 L Clamp Open Slow Configuration Block (OSC) Control Word OSC01 Bxx 15 14 13 12 11 10 09 08 07 06 05 04 03 02 01 00 Pro Set 600 Addr. B37/bit 527 526 525 524 523 522 521 520 519 518 517 516 515 514 513 512 0 0 0 0 0 0 0 0 0 0 0 1 0 1 0 0 Value OSC Block Identifier Control Word OSC02 Bxx 15 14 13 12 11 10 09 08 07 06 05 04 03 02 01 00 Pro Set 600 Addr.
Appendix A Blank Worksheets Worksheet 7 L (continued) Clamp Open Slow Configuration Block (OSC) Enter Your Values Here Control Word Pro Set 600 Addr.
Appendix A Blank Worksheets Worksheet 8 A Clamp Close Profile Block (CPC) Control Word CPC01 Bxx 15 14 13 12 11 10 09 08 07 06 05 04 03 02 01 00 Pro Set 600 Addr. B37/ bit 271 270 269 268 267 266 265 264 263 262 261 260 259 258 257 256 0 0 0 0 0 0 0 0 0 0 0 0 0 1 1 1 Value CPC Block Identifier Control Word CPC03 Bxx 15 14 13 12 11 10 09 08 07 06 05 04 03 02 01 00 Pro Set 600 Addr.
Appendix A Blank Worksheets Enter Your Values Here Worksheet 8 A (continued) Clamp Close Profile Block (CPC) Control Word Pro Set 600 Addr.
Appendix A Blank Worksheets Worksheet 8 B Injection Profile Block (IPC) Control Word IPC01 Bxx 15 14 13 12 11 10 09 08 07 06 05 04 03 02 01 00 Pro Set 600 Addr. B38/bit 79 78 77 76 75 74 73 72 71 70 69 68 67 66 65 64 Value 0 0 0 0 0 0 0 0 0 0 0 0 1 0 0 1 IPC Block Identifier Control Word IPC03 Bxx 15 14 13 12 11 10 09 08 07 06 05 04 03 02 01 00 Pro Set 600 Addr.
Appendix A Blank Worksheets Enter Your Values Here IPC17 IPC18 IPC19 IPC20 IPC21 IPC22 IPC23 IPC24 IPC25 IPC26 IPC27 IPC28 IPC29 IPC30 IPC31 IPC32 IPC33 IPC34 IPC35 IPC36 IPC37 IPC38 IPC39 IPC40 IPC41 IPC42 IPC43 IPC44 IPC45 IPC46 IPC47 IPC48 IPC49 IPC50 IPC51 IPC52 IPC57 IPC58 IPC59 IPC60 IPC61 IPC62 IPC63 IPC64 1 N44:73 N44:74 N44:75 N44:76 N44:77 N44:78 N44:79 N44:80 N44:81 N44:82 N44:83 N44:84 N44:85 N44:86 N44:87 N44:88 N44:89 N44:90 N44:91 N44:92 N44:93 N44:94 N44:95 N44:96 N44:97 N44:98 N44:99 N44:
Appendix A Blank Worksheets Worksheet 8 C Pack/Hold Profile Block (HPC) Control Word HPC01 Bxx 15 14 13 12 11 10 09 08 07 06 05 04 03 02 01 00 Pro Set 600 Addr. B38/bit 271 270 269 268 267 266 265 264 263 262 261 260 259 258 257 256 0 0 0 0 0 0 0 0 0 0 0 0 1 1 0 0 Value HPC Block Identifier Control Word HPC03 Bxx 15 14 13 12 11 10 09 08 07 06 05 04 03 02 01 00 Pro Set 600 Addr.
Appendix A Blank Worksheets Worksheet 8 C (continued) Pack/Hold Profile Block (HPC) Enter Your Values Here Control Word Pro Set 600 Addr.
Appendix A Blank Worksheets Worksheet 8 D Plastication Profile Block (PPC) Control Word PPC01 Bxx 15 14 13 12 11 10 09 08 07 06 05 04 03 02 01 00 Pro Set 600 Addr. B38/bit 463 462 461 460 459 458 457 456 455 454 453 452 421 450 449 448 0 0 0 0 0 0 0 0 0 0 0 0 1 1 1 1 Value PPC Block Identifier Control Word PPC03 Bxx 15 14 13 12 11 10 09 08 07 06 05 04 03 02 01 00 Pro Set 600 Addr.
Appendix A Blank Worksheets Worksheet 8 D (continued) Plastication Profile Block (PPC) Enter Your Values Here Control Word Pro Set 600 Addr.
Appendix A Blank Worksheets Worksheet 8 E Clamp Open Profile Block (OPC) Control Word OPC01 Bxx 15 14 13 12 11 10 09 08 07 06 05 04 03 02 01 00 Pro Set 600 Addr. B37/bit 591 590 589 588 587 586 585 584 583 582 581 580 579 578 577 576 0 0 0 0 0 0 0 0 0 0 0 1 0 1 0 1 Value OPC Block Identifier Control Word OPC03 Bxx 15 14 13 12 11 10 09 08 07 06 05 04 03 02 01 00 Pro Set 600 Addr.
Appendix A Blank Worksheets Enter Your Values Here Worksheet 8-E (continued) Clamp Open Profile Block (OPC) Control Word Pro Set 600 Addr.
Index A alarm, pressure setpoint for clamp close profile, 9 13 clamp-mode profiles, 10 32 inject-mode profiles, 10 20 injection profile, 9 23 LPC profle, 9 8 pack and hold profile, 9 35 plastication profile, 9 40 alarm, profile pressure, 3 16, 7 39 algorithm select for profile, 8 5, 8 12, 8 26, 8 33 select gain constants, 7 29 audience, P 2 Auxiliary analog inputs, 2 1 B cushion, 8 29, 10 14 diagram, 10 15 D decompression, 10 17 digital filter, 3 17 download procedures correct data entry errors, 4 6 dat
I–2 Index H hold phase, overview, 1 8 I I/O auxiliary analog inputs, 2 1 record ranges, 2 1 I/O config procedures (optional) digital input filter, 3 17 max pressure alarms, 3 16 software travel limits, 3 14 time delays, 3 16 I/O configuration procedures, 3 1 clamp position sensor, 3 10 clamp pressure sensor, 3 12 correct program errors, 3 6 download config values, 3 6 move screw and clamp, 3 7, 3 8 screw position sensor, 3 9 screw pressure sensor, 3 11 select I/O ranges, 3 2 select module parameters, 3 1
Index OSC start position, 8 35, 10 28 outputs select ranges, 3 3 set-output, end of profile, 7 34 to selected valve pressure control, 7 29 velocity control, 7 28 to unselected valves, set output values, 7 31, 10 15 overview of manual, P 1 P pack phase, example benefits, 1 7 pack profile initial values, 8 17 overview, 1 6 plastication example benefits, 1 9 initial profile values, 8 23 overview, 1 8 post-decompress movement, 1 9 power distribution, 2 12 pre-decompress movement, 1 8 pressure setpoints, 8 14
I–4 Index for producing parts, 10 10 for profiles, 7 39 wiring, QDC module I/O, 2 7 V valve-linearity procedures, for clamp close pressure, 9 12 clamp close velocity, 9 17 injection pressure, 9 22 injection velocity, 9 28 low pressure close, 9 6 pack and hold pressure, 9 34 plastication backpressure, 9 39 valve-spanning procedures, for clamp close pressure, 9 9 clamp close velocity, 9 14 clamp open pressure, 9 41, 9 42, 9 48 injection pressure, 9 19 injection velocity, 9 24 low pressure close, 9 3 pack
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