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 6, 3 11 A 3, A 4 Added the section, Record I/O Ranges 2 1 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Determine Initial Clamp and Ejector Jog Values . . . . . . . . . . . . . . Jog Your Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Configure Jogs for the Screw and Injection Cylinder . . . . . . . . . . .
Table of Contents iii Span Your Clamp and Ejector Valves . . . . . . . . . . . . . . . . . 9 1 Chapter Objectives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Span Your Low Pressure Close Valve . . . . . . . . . . . . . . . . . . . . . Span Your Clamp Close Pressure Valve(s) . . . . . . . . . . . . . . . . . . Span Your Clamp Close Velocity (Flow) Valve(s) . . . . . . . . . . . . . . Span Your Clamp Open Pressure Valve(s) . . . . . . . . . . . . . . . . . .
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 the minimum length of time. Since this manual is task oriented, we recommend that you perform these tasks in the following order: Perform this task: Browse through the entire manual to become familiar with its contents.
Preface Using this Manual Audience Before attempting to apply the QDC module to a molding machine we assume that you are: an injection molding professional an experienced programmer (especially with A-B PLC-5 processors) familiar with hydraulics Use of Terms We use these abbreviations: Abbreviated Name: Item: QDC module 1771 QDC Plastic Molding Module PLC Processor PLC 5 Programmable Controller T47 or T50 terminal 1784 T47 or 1784 T50 Industrial Terminal Pro Set 600 Software Pro Set 600 Inject
Preface Using this Manual Command Blocks Command blocks provide the parameters that control machine operation. Command blocks are transferred from the PLC processor to the QDC module by means of block transfer write (BTW) instructions in software ladder logic.
Preface Using this Manual Word and Bit Numbering The QDC module stores data in command and status blocks. Each word location in a command or status block is identified by an alphanumeric code containing the block acronym and word number. For example, word 09 of the Module Configuration Command Block (MCC) is identified as MCC09. Identify bits in a word location by adding bit numbering to the abbreviated word location.
Preface Using this Manual Reference information for the QDC module is contained in a separate document titled “Plastic Molding Module Reference Manual”. Take time now to familiarize yourself with this reference manual’s content and purpose.
Chapter 1 Overview of the Clamp and Eject Mode Chapter Objectives This chapter presents an overview of the 1771-QDC Plastic Molding Module’s Clamp and Eject Mode. A summary of clamp and eject features is followed by sample applications of the QDC Module in Clamp and Eject Mode. Important: This manual assumes you have already read your Plastic Molding Module Application Guide (pub. no. 1771-4.10) and have chosen Clamp and Eject as your QDC module’s mode of operation.
Chapter 1 Overview of the Clamp and Eject Mode Clamp Control You control clamp operation with these phases: clamp close low pressure close clamp open open slow Figure 1.1 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 the Clamp and Eject Mode Moving Platen Clamp Cylinder L Stationary Platen Velocity Figure 1.
Chapter 1 Overview of the Clamp and Eject Mode Low Pressure Close Use the Low Pressure Close Profile to decelerate closing motion to guard against damaging the mold halves and detect for part obstructions. The pressure setpoint that you select to control low pressure close should prohibit the mold from fully closing if there is an obstruction. Up to two low pressure close profile segments may be used. You will use the pressure vs. position control mode for low pressure close. Figure 1.
Chapter 1 Overview of the Clamp and Eject Mode Clamp Open You can open the mold fast with three profiles of the Clamp Open phase: first open second open third open You may select from these control modes: velocity vs. position pressure vs. position Use Clamp Open to move the platen from the fully closed position (0) to some position Y at a relatively high velocity or pressure. Y is a position relatively close to your fully open position (L), yet far enough away to allow deceleration into Open Slow.
Chapter 1 Overview of the Clamp and Eject Mode Figure 1.6 Example Clamp Open Position Segments Clamp Cylinder Moving Platen Stationary Platen L Y 0 Velocity 3 2 3rd Open Profile 1 Segments 3 2 1 2nd Open Profile 2 1 3 1st Open Profile Position Important: You may use as many or as few profiles and/or segments within profiles as needed. If using a single open motion, use the first segment of the 1st open profile. The Open Slow Profile must follow.
Chapter 1 Overview of the Clamp and Eject Mode Open Slow Use the Open Slow Profile to accurately position the clamp for ejecting the part(s). You may decelerate clamp motion twice with this profile using up to two profile segments. You may select from these control modes: velocity vs. position pressure vs. position Figure 1.
Chapter 1 Overview of the Clamp and Eject Mode Ejector Control In this section, we describe Eject operation for expelling parts from the mold. The operation consists of: ejector advance ejector retract Figure 1.
Chapter 1 Overview of the Clamp and Eject Mode Figure 1.9 Example Ejector Advance Ejector Advance 1 Segments 2 Velocity Velocity Ejector 0 3 Fully Advanced Position Position Important: If you need only one ejector advance motion, configure only the 1st Advance segment. Ejector Retract After the ejector advance is completed, ejector retract is executed. Similar to advancing the ejector, you retract it with up to three profile segments. You may select from these control modes: velocity vs.
Chapter 1 Overview of the Clamp and Eject Mode Other Eject Features The QDC Module gives you the following additional features: the ability to repeat the ejector cycle a number of times, changing from advance to retract determined either automatically or by command from your PLC program Ejector Forward Dwell - the ability to pause after completing the first or last ejector advance stroke.
Chapter 2 Install the QDC Module Chapter Objectives This chapter guides you through the process of installing your QDC module to assure reliable, safe performance. Major topics described in this chapter include how to: set module jumpers key your I/O rack install your module wire I/O devices to your module ground your system plan for E-STOPs and Machine Interlocks 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 Jumpers Before installing the QDC module, you must use jumper plugs to configure the I/O ranges that you selected with Worksheet 2-A. Access and Position the Jumpers Access the jumpers and set them as follows: ATTENTION: To avoid damage to internal circuits, observe handling precautions and rid yourself of any electrostatic charge. Also, this should be done on an anti-static work station. 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 E14 E12 E13 E15 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 relative to the orientation 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 +10V dc with jumper E11, E12, E15, and/or E16 sets the QDC module for bi-directional valve operation. The relationship to percentage output is as follows: 10 8 5 3 0 -3 -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 Your QDC Module To install your QDC module in an I/O chassis, complete the following: 1. First, turn off power to the I/O chassis. ATTENTION: Remove power from the 1771 I/O chassis backplane and wiring arm before removing or installing a QDC module. Failure to remove power from the backplane could cause injury or equipment damage due to possible unexpected operation.
Chapter 2 Install the QDC Module Wire the QDC Module Use the swingarm (1771-WF) supplied with the QDC module to wire I/O devices (Figure 2.3). The field wiring arm lets you install or remove the QDC module from the I/O chassis without rewiring. Swingarm terminals are numbered in descending order, from the top down, starting with terminal 18 (Table 2.B). Figure 2.
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 (or equivalent). For cable distances over 50 ft, use 18-gage cable such as Belden 8760 (or equivalent) Ground the cable shield at one end only; generally at the sensor or amplifier end, not at the I/O chassis (see Figure 2.
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 performing the following system tasks: designing your system assembling mechanical/hydraulic components wiring system components developing system ladder logic ATTENTION: The Electrical Standard for Industrial Machinery (NFPA 79-1987) requires an emergency stop that, when actuated, shall de-energize all electrical power circuits which provide e
Chapter 2 Install the QDC Module Figure 2.
Chapter 3 Configure the QDC Module's Inputs and Outputs Chapter Objectives Your QDC module needs to know the characteristics of your clamp and ejector 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 Inputs and Outputs Command and Status Blocks Used The following table contains a list of command blocks you are to configure throughout the course of this chapter. You may reference these command blocks in sections 1 and 3 of the Plastic Molding Module Reference Manual (pub. no. 1771-6.5.88).
Chapter 3 Configure the QDC Module's Inputs and Outputs 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.
Chapter 3 Configure the QDC Module's Inputs and Outputs 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.
Chapter 3 Configure the QDC Module's Inputs and Outputs Determine Initial Sensor configuration Values To determine initial sensor configuration values, refer to Table 3.A, and to the specifications that accompanied your sensors, valves, and cylinders. Write down applicable values on Worksheet 3-D.
Chapter 3 Configure the QDC Module's Inputs and Outputs Table 3.
Chapter 3 Configure the QDC Module's Inputs and Outputs Download MCC Values to the QDC Module Use this download procedure now and later in this chapter.
Chapter 3 Configure the QDC Module's Inputs and Outputs Important: Pro-Set 600 software downloads all command blocks when your PLC-5 processor enters run mode after a valid MCC block is accepted. All programming errors reported in SYS62 (N40:214) are referenced to the MCC block until SYS01-B08 = 1. Correct Any Data entry (Programming) Errors in MCC Upon receipt of the MCC block, the QDC module tests data for data-entry errors, such as a value out of range.
Chapter 3 Configure the QDC Module's Inputs and Outputs To finish configuring the QDC module, you actuate the clamp and ejector with the QDC module’s set-output operation. Set-output applies percentage output values to your valves to move your clamp or ejector cylinder in a controllable fashion. You apply a percentage output signal to each module output so you can move each 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 Inputs and Outputs ATTENTION: As soon as you enable set-output operation, the QDC module’s outputs drive the connected valves according to the values you entered into DYC09 - DYC12 (Pro-Set 600 words N41:121 - N41:124). Be sure these values RESULT IN NO MOVEMENT until you adjust them one-at-a-time with your programming terminal in the procedures that follow. Actuating the Clamp and Ejector with Set output Operation 1.
Chapter 3 Configure the QDC Module's Inputs and Outputs Complete your Sensor Configuration Complete the procedure for configuring the QDC module to match its sensors by spanning them over their intended range with the machine in operation.
Chapter 3 Configure the QDC Module's Inputs and Outputs Determine Clamp Position Sensor Values Important: The following procedure and subsequent set-up information must be utilized for every different mold used on a hydraulic machine. On a toggle clamp (with die height adjust), it must be completed only once. ATTENTION: Incorrect values entered in DYC09 through DYC12 may result in rapid clamp motion and potential damage to your mold and cylinder seals.
Chapter 3 Configure the QDC Module's Inputs and Outputs 11. Record this value on line 12 of Worksheet 3-E for MCC26. You may now download your adjusted values to the QDC module using the MCC download procedure presented earlier in this chapter. Determine Ejector Position Sensor Values ATTENTION: Make sure your clamp is open sufficiently to allow full ejector travel before proceeding.
Chapter 3 Configure the QDC Module's Inputs and Outputs 12. Return your ejector to the fully retracted position. You may now download your adjusted values to the QDC module using the MCC download procedure presented earlier in this chapter. Determine Values for the Clamp Pressure Sensor (if used) To complete the configuration for your clamp pressure sensor, enter minimum and maximum pressures and corresponding signal levels from manufacturer’s specifications in MCC31 - MCC34.
Chapter 3 Configure the QDC Module's Inputs and Outputs 10. With your programming terminal, read the signal level returned in SYS36 (Pro-Set 600 address N41:188) from your pressure sensor. You may wish to span your pressure sensor at this time. 11. Record this signal level on line 16 of Worksheet 3-E for MCC34. 12. Release pressure. You may now download your adjusted values to the QDC module using the MCC download procedure presented earlier in this chapter.
Chapter 3 Configure the QDC Module's Inputs and Outputs 7. Boost system pressure to obtain maximum pressure at the ejector. Max system pressure may be obtained by positioning the ejector at its fully advanced or retracted position while keeping the valve open that causes motion in that direction. This forces the cylinder to press against the mechanical limits of its travel and builds max system pressure. 8.
Chapter 3 Configure the QDC Module's Inputs and Outputs Optional Configurations Your QDC module also gives the option of configuring the following features: Use this Option: For this Benefit: Software Travel Limits to guard against damaging the mold 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 to stop the trave
Chapter 3 Configure the QDC Module's Inputs and Outputs Configure the QDC module for SWTL as follows: 1. Determine these SWTL values for clamp and/or ejector travel with respect to the range of physical travel. SWTL deadband Maximum SWTL Minimum SWTL 2. Record non-zero SWTL values on Worksheet 3-F. Zero values disable the corresponding SWTLs. ATTENTION: Leaving your SWTL settings at zero (MCC27, MCC28, MCC41, MCC42) inhibits the QDC module from performing this safety function.
Chapter 3 Configure the QDC Module's Inputs and Outputs Set Up Maximum Pressure Alarms and Time Delays The QDC module continuously monitors clamp and ejector pressure inputs. When it detects that the pressure equals or exceeds a preset pressure alarm setpoint, the QDC module sets an alarm bit. A setpoint of zero disables the associated alarm.
Chapter 3 Configure the QDC Module's Inputs and Outputs Configure a Digital Filter for Position Inputs from Clamp and Ejector You can enable an optional digital filter on position inputs. This filter is used to reduce electrical noise from potentiometer-type position sensors or other external noise picked up by your input circuits. To determine if you need a digital filter, move the clamp or ejector 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 “Blocks”. Blocks are made up of several 16-bit words stored in the PLC-5 data table.
Chapter 4 Overview of the Remaining Configuration Procedures There are two basic types of command blocks. They are presented in the following table: Type: Which Contain: Examples: Configuration Blocks Information necessary to configure your module to run a certain portion of a profile Valve spanning information for the 1st clamp close profile Profile Blocks Actual process setpoints necessary to produce a desired part.
Chapter 3 Overview of the Remaining Configuration Procedures Overview of the 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 the 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 3 Overview of the 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 3.A Information Required to Download a Command Block Block to Download: Pro Set 600 Block ID.
Chapter 4 Overview of the Remaining Configuration Procedures 3. Start the download procedure by setting the corresponding download bit (Table 4.A) in your PLC-5 data table. 4. Watch the bit you set in step 3 and wait for Pro-Set 600 software to reset it to zero. This indicates the PLC-5 processor has transferred the block to the QDC module. 5. Observe the value of SYS62 (N40:214) in your PLC-5 data table: If SYS62 = 0, the QDC module detected no errors. Go to step 6.
Chapter 5 Jog Your Machine Chapter Objectives Jogging your machine is similar to operating it in set output; percent output values are applied to your four QDC module outputs in order to obtain the desired motion. The jog configuration block (JGC) allows you to set up jog parameters for your QDC outputs for close and open clamp jogging and advance and retract jogging of the ejector.
Chapter 5 Jog Your Machine Determine Initial Clamp and Ejector Jog Values Worksheet 5-A outlines all values necessary to successfully configure your QDC module for clamp and ejector jogs. Enter initial values to allow minimal actuator motion during jogs. Later in this chapter, we gradually increase these values until we reach the desired jog values. At this time, also enter in jog high pressure setpoints in Worksheet 5-A.
Chapter 5 Jog Your Machine ATTENTION: Up to 4 different valves may be connected to your QDC module for clamp and eject control. Although all 4 may not be directly involved with clamp and eject jogs, consider their indirect effects when setting jog set output values. Output Voltage ATTENTION: A value of 0 entered in your data table does not necessarily correspond to zero pressure or flow. For an output configured + 10VDC, an output of 50% corresponds to zero volts signal output (see the following graph).
Chapter 5 Jog Your Machine Jog Your Machine Word 1 in the Dynamic Command block (DYC01) is used to enable and disable individual jogs. Word 1 in the System Status block (SYS01) may also be used to monitor the QDC module’s reaction to jog commands. Below are two quick cross-reference tables identifying the jog enable and status bits for the clamp and ejector: Table 5.
Chapter 5 Jog Your Machine Figure 5.
Chapter 5 Jog Your Machine Jog your clamp and ejector in both the advance and retract directions. Experiment with the values entered in the Jog Configuration block (JGC) until you obtain the desired jog operation. The JGC must be downloaded to the QDC module each time a value in the command block is changed for the new value to take effect. Refer to the download procedure outlined in chapter 4.
Chapter 5 Jog Your Machine Worksheet 5 B Inject and Screw Rotate Jog Configuration Values (for Clamp and Eject Mode) Enter Your Initial Values Here Control Word Pro Set 600 Addr.
Chapter 5 Jog Your Machine Download Jog Configuration Block (JGC) Utilizing the same procedure outlined in chapter 3, enter your initial inject and screw rotate jog values in Worksheet 5-B. To download this block , refer to the download procedure outlined in chapter 4. Word 1 in the Dynamic Command block (DYC01) is used to enable and disable individual jogs. Word 1 in the System Status Block (SYS01) may also be used to monitor the QDC module’s reaction to jog commands.
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: monitor input devices on your Ready Panel or operator station step your QDC module through machine cycles We suggest how to access your logic requirements and how to use bit tables to write your machine’s sequential ladder logic based on those logic requirements.
Chapter 6 Select Command and Status Bits to Sequence Machine Operation Use Bit Tables Table 6.A lists the tables included in this chapter along with specific information found in each: Table 6.A Bit Table Summary Type of Function: What the Table Contains: How You Implement Commands: Table 6.B Manual (non profiled) Command and status bits to control and monitor manual jog, direct set output, and stop To enable: set command bit (0 to 1) To terminate: reset command bit (1 to 0) 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.E Command Bits to Interrupt Clamp Movement Between Profiles Bit Description: QDC Block Addr.
Chapter 6 Select Command and Status Bits to Sequence Machine Operation Table 6.G Command Bits to Enable or Disable Ejector Profiles Bit Description: QDC Block Addr.: 0 = start ejector profile on clamp position 1 = start ejector profile on command EPC03 B08 0 = ejector profile enabled 1 = ejector profile disabled EPC03 B09 0 = run ejector profile without interruption 1 = stop and notify @ end of ejector stroke EPC03 B12 Table 6.
Chapter 6 Select Command and Status Bits to Sequence Machine Operation Table 6.I Status Bits for Clamp and Eject Mode Category: Bit Status (when = 1): QDC Block Addr.: Pro Set Addr.
Chapter 6 Select Command and Status Bits to Sequence Machine Operation Table 6.I (continued) Category: Bit Status (when = 1): QDC Block Addr.: Pro Set Addr.
Chapter 6 Select Command and Status Bits to Sequence Machine Operation Table 6.J Command and Configuration Bits for Clamp and Eject Mode Operation: Function Enabled (when = 1): QDC Block Addr.: Pro Set Addr.
Chapter 6 Select Command and Status Bits to Sequence Machine Operation Table 6.J (continued) Operation: Function Enabled (when = 1): QDC Block Addr.
Chapter 7 Load Initial Configuration Values Chapter Objectives This chapter describes how to prepare the machine to run clamp and ejector control profiles. Major topics include how to: use configuration command block worksheets set your accel/decel ramp rates set pressure control limits set velocity control limits enter and downloading your worksheet values This chapter helps you determine and enter values into the clamp and ejector configuration blocks.
Chapter 7 Load Initial Configuration Values Use Configuration Command Block Worksheets This chapter walks you through a configuration procedure that helps you fill out all of the following configuration block worksheets. Worksheets for each of the command blocks are given followed by the information to fill them in later in this chapter. Configure Clamp and Eject Blocks Ten different blocks need to be configured before you are ready to enter profile setpoint values in chapter 8.
Chapter 7 Load Initial Configuration Values The QDC module incorporates close fast functionality with three separate close profiles (refer to chapter 1 of this manual for more information): First Close (FCC) Second Close (SCC) Third Close (TCC) By allowing up to three separate, segmented profiles, the QDC module increases your mold closing control flexibility. Also, the final clamp close profile, characterized by pressure control, is Low Pressure Close (LPC).
Chapter 7 Load Initial Configuration Values Worksheet 7 A First Clamp Close (FCC) Configuration Block 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 (FCC) Configuration Block Enter Your Values Here Control Word Pro Set 600 Addr.
Chapter 7 Load Initial Configuration Values Worksheet 7 B Second Clamp Close (SCC) Configuration Block 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 (SCC) Configuration Block Enter Your Values Here Control Word Pro Set 600 Addr.
Chapter 7 Load Initial Configuration Values Worksheet 7 C Third Clamp Close (TCC) Configuration Block 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 (TCC) Configuration Block Enter Your Values Here Control Word Pro Set 600 Addr.
Chapter 7 Load Initial Configuration Values Worksheet 7 D Clamp Low Pressure Close (LPC) Configuration Block 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 (LPC) Configuration Block Enter Your Values Here Control Word Pro Set 600 Addr.
Chapter 7 Load Initial Configuration Values Worksheet 7 E First Clamp Open (FOC) Configuration Block 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 E (continued) First Clamp Open (FOC) Configuration Block Enter Your Values Here Control Word Pro Set 600 Addr.
Chapter 7 Load Initial Configuration Values Worksheet 7 F Second Clamp Open (SOC) Configuration Block 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 F (continued) Second Clamp Open (SOC) Configuration Block Enter Your Values Here Control Word Pro Set 600 Addr.
Chapter 7 Load Initial Configuration Values Worksheet 7 G Third Clamp Open (TOC) Configuration Block 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 G (continued) Third Clamp Open (TOC) Configuration Block Enter Your Values Here Control Word Pro Set 600 Addr.
Chapter 7 Load Initial Configuration Values Worksheet 7 H Clamp Open Slow (OSC) Configuration Block 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 H (continued) Clamp Open Slow (OSC) Configuration Block Enter Your Values Here Control Word Pro Set 600 Addr.
Chapter 7 Load Initial Configuration Values Worksheet 7 I Ejector Advance (EAC) Configuration Block Control Word EAC01 Bxx 15 14 13 12 11 10 09 08 07 06 05 04 03 02 01 00 Pro Set 600 Addr. B39/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 1 0 1 1 0 EAC Block Identifier Control Word EAC02 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) Ejector Advance (EAC) Configuration Block Enter Your Values Here Control Word Pro Set 600 Addr.
Chapter 7 Load Initial Configuration Values Worksheet 7 J Ejector Retract (ERC)Configuration Block Control Word ERC01 Bxx 15 14 13 12 11 10 09 08 07 06 05 04 03 02 01 00 Pro Set 600 Addr. B39/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 1 0 1 1 1 ERC Block Identifier Control Word ERC02 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) Ejector Retract (ERC) Configuration Block Enter Your Values Here Control Word Pro Set 600 Addr.
Chapter 7 Load Initial Configuration Values Procedure to Determine and Record Worksheet Values Follow this procedure to complete each worksheet. 1. Decide which profiles you will and will not use. 2. Read the text for the subject parameter. 3. Determine your initial value for that parameter and add it to each corresponding worksheet at the listed configuration word address. Important: Block identifier codes are already recorded for you.
Chapter 7 Load Initial Configuration Values Select the Type of PID Algorithm Pressure Algorithm Selection (FCC02, SCC02, TCC02, LPC02, FOC02, SOC02, TOC02, OSC02, EAC02, ERC02) When executing pressure vs. position profiles, the QDC module can use one of two types of PID algorithms: dependent gains (ISA) or independent gains (Allen-Bradley).
Chapter 7 Load Initial Configuration Values Important: If, after attempting to tune your pressure loops using the procedure in chapter 10, you believe your application requires the use of dependant gain (ISA) pressure algorithms, refer to Section 3 of the Plastic Molding Module Reference Manual (pub. no. 1771-6.5.88) for information on this option.
Chapter 7 Load Initial Configuration Values Tonnage Watchdog Timer Preset (LPC07) The QDC module starts an internal Tonnage watchdog timer every time it completes execution of Low Pressure Close. The QDC module stops this timer when clamp pressure exceeds the tonnage preset (CPC63). You are asked to enter a Watchdog Timer setpoint in word LPC07. Any time the internal timer’s accumulated value is equal to or greater than this value, the QDC module sets the Tonnage Watchdog Timer alarm bit (SYS04-B15).
Chapter 7 Load Initial Configuration Values Determine Unselected Valve Set output Values Unselected Valve Set output Values (FCC09 12, SCC09 12, TCC09 12, LPC09 12, FOC09 12, SOC09 12, TOC09 12, OSC09 12, EAC09 12, ERC09 12) Earlier in this chapter, you told the QDC module which of its four outputs were being used to control pressure and flow profiles.
Chapter 7 Load Initial Configuration Values Table 7.A presents unselected valve setpoints you may wish to use, depending on your machines valve types and the desired profile action. Table 7.
Chapter 7 Load Initial Configuration Values Output Voltage Figure 7.1 Set Output Operations 10 8 5 3 0 -3 -5 -8 -10 0 10 20 30 40 50 60 70 80 90 100 % Output Requested ATTENTION: A value of zero in set-output words does not necessarily correspond to zero pressure or flow. If you have configured jumper E11, E12, E15, and/or E16 for bi-directional valve operation, an output of 0% gives –10V dc, 50% gives 0V dc.
Chapter 7 Load Initial Configuration Values Set your Accel/Decel Ramp Rates As you read the following sections, fill in the values for the mentioned words in the worksheets. Depending on the clamp and ejector profiles required by your application, ramp rates may be necessary to provide smooth actuator motion. The QDC module provides you with multi-stepped profiles to reduce the need for ramp rates.
Chapter 7 Load Initial Configuration Values may also be obtained by referencing Section 3 of the Plastic Molding Module Reference Manual (pub. no. 1771-6.5.88).
Chapter 7 Load Initial Configuration Values Set Pressure Control Limits As you read the following sections, fill in the values for the mentioned words in the worksheets. Setting pressure control limits performs two functions: spanning your selected valve outputs to allow effective open loop and closed loop control allowing users with reverse-acting valves to configure their system accordingly Your injection machine manufacturer typically provides you with all necessary values to configure these limits.
Chapter 7 Load Initial Configuration Values Selected Pressure Valve Output for Minimum (FCC43, SCC43, TCC43, LPC43, FOC43, SOC43, TOC43, OSC43, EAC43, ERC43) This word operates in conjunction with the minimum pressure control limit (word 41). Enter in this word the signal output percentage that the QDC module uses to drive the selected pressure valve to minimum pressure during any pressure vs. position profile or stroke.
Chapter 7 Load Initial Configuration Values Reference the above table and enter one of the following for each Selected Pressure Valve Maximum Output: 9999 (100%) for uni-directional direct acting valves 0 (0%) or 9999 (100%) for bi-directional valves (dependant upon desired direction of motion) 0 (0%) for uni-directional reverse acting valves The valve spanning procedures presented in chapter 9 require these initial values in order to assist you in selecting the correct, final values required by your appli
Chapter 7 Load Initial Configuration Values Selected Velocity Valve Output for Minimum (FCC47, SCC47, TCC47, FOC47, SOC47, TOC47, OSC47, EAC47, ERC47) This word operates in conjunction with the minimum velocity control limit (word 45). Enter in this word the signal output percentage that the QDC module uses to drive the selected velocity valve to minimum velocity during any velocity vs. position profile or stroke.
Chapter 7 Load Initial Configuration Values Selected Velocity Valve Output for Maximum (FCC48, SCC48, TCC48, FOC48, SOC48, TOC48, OSC48, EAC48, ERC48) This word operates in conjunction with the minimum velocity control limit (word 46). Enter in this word the signal output percentage that the QDC module uses to drive the selected velocity valve to maximum velocity during any velocity vs. position profile or stroke.
Chapter 7 Load Initial Configuration Values Profile Pressure Alarm Setpoint (FCC57, SCC57, TCC57, LPC57, FOC57, SOC57, TOC57, OSC57, EAC57) The QDC module compares real-time clamp (or ejector) pressure against this entry when executing the appropriate profile. The QDC module sets an alarm bit (SYS05-B12, B13, B14, B15, SYS06-B09 B10, B11, B12, B13 respectively) any time clamp (or ejector) pressure equals or exceeds this entry during execution of the respective profile. A zero entry inhibits this alarm.
Chapter 8 Load Initial Profile Values for Machine Tuning Chapter Objectives In the previous chapters, you entered information into configuration blocks necessary for your clamp and eject profiles to run properly. This chapter describes how to load actual profile setpoints for clamp and ejector operations.
Chapter 8 Load Initial Profile Values for Machine Tuning Worksheet 8 A Clamp Close (CPC) Profile Block 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.
Chapter 8 Load Initial Profile Values for Machine Tuning Worksheet 8-A (continued) Clamp Close (CPC) Profile Block Enter Your Values Here Control Word CPC09 Pro Set 600 Addr.
Chapter 8 Load Initial Profile Values for Machine Tuning Determine Bit Selections for Worksheet 8 A The following sections describe how to complete Worksheet 8-A. After each section is discussed, fill in values for the mentioned words or bits. Clamp Close Profile Block Identifier (CPC01) The first eight bits of this word are used to identify it as the first word in a series of words used to define the clamp close profile. These first eight bits must be set at 00000111.
Chapter 8 Load Initial Profile Values for Machine Tuning Expert Response and Open/Closed Loop Selections (CPC04) The following BITs of CPC04 determine if expert response is turned on and also selects whether or not the QDC module uses closed-loop control during the clamp close operation. - BITs 15, 13, 12, 11, 10, 09, and 08 are used to select expert response compensation for the different clamp close profiles.
Chapter 8 Load Initial Profile Values for Machine Tuning Start LPC Position Setpoint (CPC61) This clamp position is used by the QDC module as protection against running a Clamp Close Profile into the Mold Protection Zone.
Chapter 8 Load Initial Profile Values for Machine Tuning Velocity Setpoints (CPC09, CPC12, CPC15, CPC18, CPC21, CPC24, CPC27, CPC30, CPC33) Use these words when configuring Velocity vs. Position profiles. Each velocity is used between the last completed clamp segment, and the End-of Segment position setpoint. Enter 0 for each Velocity Setpoint Value. The valve spanning procedures presented in chapter 9 require these initial values.
Chapter 8 Load Initial Profile Values for Machine Tuning Determine and Enter Clamp Open Profile (OPC) The following two pages contain worksheets for the Clamp Open Profile (one worksheet for bit entries and one for word entries). The valve spanning procedure in chapter 9 requires specific values in certain block entries. We have already entered those values for you on your worksheets.
Chapter 8 Load Initial Profile Values for Machine Tuning Worksheet 8-B (continued) Clamp Open (OPC) Profile Block Enter Your Values Here Control Word OPC09 OPC10 OPC11 OPC12 OPC13 OPC14 OPC15 OPC16 OPC17 OPC18 OPC19 OPC20 OPC21 OPC22 OPC23 OPC24 OPC25 OPC26 OPC27 OPC28 OPC29 OPC30 OPC31 OPC32 OPC33 OPC34 OPC35 OPC36 OPC37 OPC38 OPC39 OPC40 OPC61 OPC62 OPC63 Pro Set 600 Addr.
Chapter 8 Load Initial Profile Values for Machine Tuning Determine Bit Selections for Worksheet 8 B The following sections describe how to complete Worksheet 8-B. After each section is discussed, fill in values for the mentioned words or bits. Clamp Open Profile Block Identifier (OPC01) The first eight bits of this word are used to identify it as the first word in a series of words used to define the clamp open profile. These first eight bits must be set at 00010101.
Chapter 8 Load Initial Profile Values for Machine Tuning Expert Response and Open/Closed Loop Selections (OPC04) The following BITs of OPC04 determine if expert response is turned on and also select whether or not the QDC module uses closed-loop control during the clamp open operation. - BITs 15, 14, 13, 12, 11, 10, 09, and 08 are used to select expert response compensation for the different clamp open profiles.
Chapter 8 Load Initial Profile Values for Machine Tuning Start OSC Position Setpoint (OPC61) This clamp position is used by the QDC module as protection against running a Clamp Open Profile into the Open Slow Zone.
Chapter 8 Load Initial Profile Values for Machine Tuning Velocity Setpoints (OPC09, OPC12, OPC15, OPC18, OPC21, OPC24, OPC27, OPC30, OPC33, OPC36, OPC39) Use these words when configuring Velocity vs. Position profiles. Each velocity is used between the last completed clamp segment, and the End-of Segment position setpoint. Enter 0 for each Velocity Setpoint Value. The valve spanning procedures presented in chapter 9 require these initial values.
Chapter 8 Load Initial Profile Values for Machine Tuning Determine and Enter Ejector Profile (EPC) The following two pages contain worksheets for the Ejector Profile (one worksheet for bit entries and one for word entries). The valve spanning procedure in chapter 9 requires specific values in certain block entries. We have already entered those values for you on your worksheets.
Chapter 8 Load Initial Profile Values for Machine Tuning Worksheet 8-C (continued) Ejector (EPC) Profile Block Enter Your Values Here Control Word EPC09 Pro Set 600 Addr.
Chapter 8 Load Initial Profile Values for Machine Tuning Determine Bit Selections for Worksheet 8 C The following sections describe how to complete Worksheet 8-C. After each section is discussed, fill in values for the mentioned words or bits. Ejector Profile Block Identifier (EPC01) The first eight bits of this word are used to identify it as the first word in a series of words used to define the ejector profile. These first eight bits must be set at 00011000.
Chapter 8 Load Initial Profile Values for Machine Tuning If the QDC module has control of all the valves in your ejector circuit that are required to change the direction of ejector travel, select 0 for bit 12 (the QDC module has the control capability during the Ejector Profile to initiate each subsequent retract/advance stroke upon completion of the preceding advance/retract stroke).
Chapter 8 Load Initial Profile Values for Machine Tuning - BIT 09 controls the QDC modules ability to perform any profiled ejector movement. 0 = QDC module executes profiled ejector action as required (Ejectors enabled or ON) 1 = QDC module does not execute any profiled ejector action (Ejectors disabled or OFF) At this time, select 0 for bit 09. - BIT 08 controls when the QDC module initiates Ejector Profiles.
Chapter 8 Load Initial Profile Values for Machine Tuning Determine Word Values for Worksheet 8 C Ejector Fully Advanced Position Setpoint (EPC59) The Ejector Fully Advanced Position Setpoint (EPC59) defines to the QDC module the ejector position when fully extended. The QDC module uses this ejector position as the End of Full Advance position setpoint.
Chapter 8 Load Initial Profile Values for Machine Tuning To determine this ejector position, we recommend you jog your clamp closed until the two mold halves mate. Now jog your ejector to its maximum advanced position while being constrained by the closed mold and observe the value in SYS25 (Pro-Set 600 address N41:177). Use this value as an initial EPC63 clamp close enable position.
Chapter 8 Load Initial Profile Values for Machine Tuning End-of Segment Position Setpoints (EPC11, EPC14, EPC23, EPC29, EPC35, EPC38) At this time, we are configuring only the 1st full advance segment and the 1st full retract segment. Since the QDC module uses EPC59 and EPC60 as the End-of Full Advance and End-of Full Retract positions (respectively), all other position setpoints should be set to zero. Enter 0 for all other position setpoints (EPC11, EPC14, EPC23, EPC29, EPC35, EPC38).
Chapter 8 Load Initial Profile Values for Machine Tuning Ejector Forward Dwell Timer Preset (EPC57) The QDC module starts an internal Ejector Forward Dwell Timer dependent upon the state of EPC03-B15. Enter 0 for the Ejector Forward Dwell Timer Preset. For additional information to assist you in selecting the correct, final value required by your application, refer to Section 3 of the Plastic Molding Module Reference Manual (pub. no. 1771-6.5.88).
Chapter 9 Span Your Clamp and Ejector Valves Chapter Objectives This chapter describes how to span your clamp and ejector valves using set-output operation and test out your spanning running simple open-loop profiles. (In previous chapters, you have configured command blocks, entered initial profiles, and programmed PLC command bit interaction as prerequisites to running profiles). ATTENTION: Before proceeding, make sure you have completed configuration procedures in all previous chapters.
Chapter 9 Span Your Clamp and Ejector Valves Command and Status Blocks Used The following table contains a list of command blocks you are to configure throughout the course of this chapter. You may reference these command blocks in sections 1 and 3 of the Plastic Molding Module Reference Manual (pub. no. 1771-6.5.88).
Chapter 9 Span Your Clamp and Ejector Valves Important: Maintain the same initialization values that you entered in previous chapters except where noted in the text. Span Your Low Pressure Close Valve We recommend you first span your Low Pressure Close Pressure Valve.
Chapter 9 Span Your Clamp and Ejector Valves Select Start LPC on Zone Overrun (CPC03-B11 = 0) If current settings do not match our recommended values from previous chapters, we suggest you correct these values now using the download procedure discussed in chapter 4. Span Your Low Pressure Close Pressure Valve Span your Low Pressure Close Pressure vs. Position Profile for smooth operation at the highest desired LPC pressure.
Chapter 9 Span Your Clamp and Ejector Valves pressure attainable. This procedure may be required on a bi-directional valve with a spool offset. If this pressure is zero, marginally adjust the selected LPC valve set-output value until the observed pressure feedback just becomes greater than zero, and then re-adjust the value until you just observe zero again. This procedure may be required on a uni-directional valve with no response at low signal levels. 6.
Chapter 9 Span Your Clamp and Ejector Valves Test Your Low Pressure Close Pressure Valve for Linearity 1. Select a pressure setpoint for Low Pressure Close which is typical of the pressure you would run during machine operation. Enter this setpoint into CPC37 (Pro-Set 600 address N43:273). 2. Download changes to the QDC module (refer to chapter 4 for detailed instructions). 3. Jog your clamp to a position just outside the Low Pressure Close start position (CPC61). 4.
Chapter 9 Span Your Clamp and Ejector Valves What You Have Accomplished The valve spanning procedure you just completed has: defined the range of pressure available during Low Pressure Close informed the QDC module of the signal level needed to drive the selected low pressure close valve for any requested open-loop pressure: % of Signal Level Entered In: Drives the selected valve to produce: LPC43 Pressure (usually 0) in LPC41 LPC44 Pressure in LPC42 Now, for all open-loop Low Pressure Close profiles
Chapter 9 Span Your Clamp and Ejector Valves 4. Align all other machine hydraulics to simulate clamp tonnage. For example, if certain pumps are turned off during tonnage, turn them off at this time. If a certain valve alignment exists during tonnage, line the valves up accordingly at this time. 5. Enable set-output by transitioning DYC01-B08 (Pro-Set 600 address B35/392) from a 0 to a 1. 6.
Chapter 9 Span Your Clamp and Ejector Valves Span Your Clamp Close Pressure Valve(s) We recommend that you next tune the First, Second, and Third Clamp Close for clamp close pressure performance.
Chapter 9 Span Your Clamp and Ejector Valves Identify, all end-of segment position setpoints (CPC11, CPC14, CPC17, CPC20, CPC23, CPC26, CPC29, CPC32, CPC35, CPC38). These should remain unchanged from the initial settings Select start LPC on Zone Overrun (CPC03-B11 = 0) Identify Start LPC Position Setpoint (CPC61) If current settings do not match our recommended values from previous chapters, we suggest you correct these values now using the download procedure discussed in chapter 4.
Chapter 9 Span Your Clamp and Ejector Valves 5. Observe the pressure reported back in SYS28 (Pro-Set 600 address N41:180). If this pressure is greater than zero, marginally adjust the selected Clamp Close valve set-output value in an attempt to obtain zero pressure feedback. Stop the adjustments when you observe the smallest pressure attainable. This procedure may be required on a bi-directional valve with a spool offset.
Chapter 9 Span Your Clamp and Ejector Valves Test Your Clamp Close Pressure Valve(s) for Linearity 1. Select pressure setpoints for Clamp Close that are typical of the pressures you would run during normal machine operation. Enter these setpoints into CPC10, CPC13, and CPC16 (Pro-Set 600 addresses N43:246, N43:249, and N43:252). 2. Download changes to the QDC module (refer to chapter 4 for detailed instructions). 3. Jog your clamp to the full open position. 4.
Chapter 9 Span Your Clamp and Ejector Valves What You Have Accomplished The valve spanning procedure you just completed has: defined the range of pressure available during First, Second and Third Clamp Close informed the QDC module of the signal level needed to drive the selected clamp pressure valve(s) for any requested open-loop pressure: % of Signal Level Entered In: Drives the selected valve to Produce: FCC43, SCC43, TCC43 Pressure (usually 0) in FCC41, SCC41, and TCC41 FCC44, SCC44, TCC44 Pressur
Chapter 9 Span Your Clamp and Ejector Valves Span Your Clamp Close Velocity (Flow) Valve(s) We recommend that you next span the clamp close velocity (flow) valve(s). Do this in three parts: Revise/confirm critical values for velocity valve spanning Span your clamp close velocity (flow) valve(s) Test your values Important: Many injection molding machine OEMs and hydraulic valve manufacturers provide data regarding valve spanning (working range) for a particular valve on their machine.
Chapter 9 Span Your Clamp and Ejector Valves If current settings do not match our recommended values from previous chapters, we suggest you correct these values now using the download procedure discussed in chapter 4. Span Your Clamp Close Velocity Valve(s) 1. Obtain a copy of the flow rate curves provided by your flow valve manufacturer.
Chapter 9 Span Your Clamp and Ejector Valves Test Your Clamp Close Velocity Valve(s) for Linearity 1. Select velocity vs. position control for the entire Clamp Close operation by resetting (= 0) the following three bits: CPC03-B00 (Pro-Set 600 address B37/288) CPC03-B02 (Pro-Set 600 address B37/290) CPC03-B04 (Pro-Set 600 address B37/292) 2. Select velocity setpoints for Clamp Close that are typical of the velocities you would run during normal machine operation.
Chapter 9 Span Your Clamp and Ejector Valves If the actual velocity is still not representative of your setpoint, your flow valve is not linear over the range of your setpoint If: And your Then: Selected Valve is: CPS12 was less than CPC12 Direct Acting Increase FCC48, SCC48, and TCC48 by 5% Reverse Acting Decrease FCC48, SCC48, and TCC48 by 5% Direct Acting Decrease FCC48, SCC48, and TCC48 by 5% Reverse Acting Increase FCC48, SCC48, and TCC48 by 5% CPS12 was more than CPC12 Repeat steps 3 thro
Chapter 9 Span Your Clamp and Ejector Valves Span Your Clamp Open Pressure Valve(s) We recommend that you next tune the First, Second, and Third Clamp Open, and Open Slow, for clamp open pressure performance.
Chapter 9 Span Your Clamp and Ejector Valves Identify all end-of segment position setpoints (OPC11, OPC14, OPC17, OPC20, OPC23, OPC26, OPC29, OPC32, OPC35, OPC38).
Chapter 9 Span Your Clamp and Ejector Valves ATTENTION: A value of 0 entered in your data table does not necessarily correspond to zero pressure or flow. For example, a bi-directional valve would require a set-output value of 50% (5000) to obtain 0 PSI. Amplifier electronics or valve spools may also be designed such that 0 volts signal input does not correspond to no flow or pressure. Please consult your valve and amplifier specifications for more details. 4.
Chapter 9 Span Your Clamp and Ejector Valves 9. Enter this observed maximum Clamp Open pressure (from SYS28) into FOC42, SOC42, TOC42, and OSC42 (Pro-Set 600 addresses N43:338, N43:398, N43458, and N43:518), the Clamp Open Maximum Pressure Control Limits. 10. While maintaining this maximum Clamp Open pressure, observe the actual valve set-output value in the System Status Block (SYS41-SYS44, Pro-Set 600 addresses N41:193-N41:196) that corresponds to your selected Clamp Open pressure valve.
Chapter 9 Span Your Clamp and Ejector Valves If the observed pressure OPS13 is still not representative of the setpoint (within 20% of OPC13), your pressure valve is not linear over the desired range of operation.
Chapter 9 Span Your Clamp and Ejector Valves Span Your Clamp Open Velocity (Flow) Valve(s) We recommend that you next tune the clamp open velocity (flow) valve(s). Do this in three parts: Revise/confirm critical values for velocity valve spanning Span your clamp open velocity (flow) valve(s) Test your values Important: Many injection molding machine OEMs and hydraulic valve manufacturers provide data regarding valve spanning (working range) for a particular valve on their machine.
Chapter 9 Span Your Clamp and Ejector Valves If current settings do not match our recommended values from previous chapters, we suggest you correct these values now using the download procedure discussed in chapter 4. Span Your Clamp Open Velocity Valve(s) 1. Obtain a copy of the flow rate curves provided by your flow valve manufacturer.
Chapter 9 Span Your Clamp and Ejector Valves 6. Divide the voltage/current corresponding to maximum velocities by the full range of the clamp open valve(s) input level to determine the percent signal outputs for maximum. Enter these values into FOC48, SOC48, TOC48, and OSC48. 7. Download changes to the QDC module (refer to chapter 4 for detailed instructions). Test Your Clamp Open Velocity Valve(s) for Linearity 1. Select velocity vs.
Chapter 9 Span Your Clamp and Ejector Valves If the actual velocity is still not representative of your setpoint, your flow valve is not linear over the range of your setpoint If: And Your Then: Selected Valve is: OPS12 was less than OPC12 Direct Acting Increase FOC48, SOC48, TOC48, and OSC48 by 5% Reverse Acting Decrease FOC48, SOC48, TOC48, and OSC48 by 5% Direct Acting Decrease FOC48, SOC48, TOC48, and OSC48 by 5% Reverse Acting Increase FOC48, SOC48, TOC48, and OSC48 by 5% OPS12 was more tha
Chapter 9 Span Your Clamp and Ejector Valves Span Your Ejector Pressure Valve(s) We recommend that you next tune the Ejector Profile for pressure performance. Do this in four parts: Revise/confirm critical values for pressure valve spanning Span your ejector pressure valve(s) Test your values Set pressure alarm setpoints Important: Many injection molding machine OEMs and hydralic valve manufacturers provide data regarding valve spanning (working range) for a particular valve on their machine.
Chapter 9 Span Your Clamp and Ejector Valves If current settings do not match our recommended values from previous chapters, we suggest you correct these values now using the download procedure discussed in chapter 4. Span Your Ejector Pressure Valve(s) Span your Ejector Pressure vs. Position Profile for smooth operation at the highest desired ejector pressure. Do this by finding the optimum values for EAC41-44 and ERC41-44 using the values given above and the procedure below.
Chapter 9 Span Your Clamp and Ejector Valves If this pressure is zero, marginally adjust the selected Ejector Advance valve set-output value until the observed pressure feedback just becomes greater than zero, and then re-adjust the value until you just observe zero again. This procedure may be required on a uni-directional valve with no response at low signal levels. 6.
Chapter 9 Span Your Clamp and Ejector Valves Ejector Retract 1. Jog your ejectors to the full retracted position. 2. Align all other machine hydraulics to simulate Ejector Retract. For example, if certain pumps are enabled during Ejector Retract, enable them at this time. If a certain valve alignment exists during Ejector Retract, line the valves up accordingly at this time. 3.
Chapter 9 Span Your Clamp and Ejector Valves 7. While maintaining this minimum pressure, observe the actual valve set-output value in the System Status Block (SYS41-SYS44, Pro-Set 600 addresses N41:193-N41:196) that corresponds to your selected Ejector Retract pressure valve. Copy this value into ERC43 (Pro-Set 600 address N45:99), the Selected Ejector Retract Pressure Valve Output for Minimum. 8.
Chapter 9 Span Your Clamp and Ejector Valves Test Your Ejector Pressure Valve(s) for Linearity 1. Select pressure setpoints for Ejector Advance and Ejector Retract that are typical of the pressures you would run during normal machine operation. Enter these setpoints into EPC10 and EPC34 (Pro-Set 600 addresses N45:126 and N45:150). 2. Download changes to the QDC module (refer to chapter 4 for detailed instructions). 3. Jog your ejector to the fully retracted position. 4.
Chapter 9 Span Your Clamp and Ejector Valves What You Have Accomplished The valve spanning procedure you just completed has: defined the range of pressure available during any ejector profile informed the QDC module of the signal level needed to drive the selected ejector pressure valve(s) for any requested open-loop pressure: % of Signal Level Entered In: Drives the Selected Valve to Produce: EAC43 and ERC43 Pressure (usually 0) in EAC41 and ERC41 EAC44 and ERC44 Pressure in EAC42 and ERC42 Now, for
Chapter 9 Span Your Clamp and Ejector Valves Span Your Ejector Velocity (Flow) Valve(s) We recommend that you next span your ejector velocity (flow) valve(s). Do this in three parts: Revise/confirm critical values for velocity valve spanning Span your ejector velocity (flow) valve(s) Test your values Important: Many injection molding machine OEMs and hydraulic valve manufacturers provide data regarding valve spanning (working range) for a particular valve on their machine.
Chapter 9 Span Your Clamp and Ejector Valves If current settings do not match our recommended values from previous chapters, we suggest you correct these values now using the download procedure discussed in chapter 4. Span Your Ejector Velocity Valve(s) 1. Obtain a copy of the flow rate curves provided by your flow valve manufacturer. The flow rate curves graphically illustrate the flow through a valve at different voltage or input current levels and at different pressure drops across the valve’s spool.
Chapter 9 Span Your Clamp and Ejector Valves Test Your Ejector Velocity Valve(s) for Linearity 1. Select velocity vs. position control for the Ejector profile by EPC03-B00 = 0 (Pro-Set 600 address B39/160). 2. Select velocity setpoints for Ejector Advance and Ejector Retract that are typical of the velocities you would run during normal machine operation. Enter these setpoints into EPC09 and EPC33 (Pro-Set 600 addresses N45:125 and N45:149). 3.
Chapter 9 Span Your Clamp and Ejector Valves What You Have Accomplished The valve spanning procedure you just completed has: defined the range of velocity available during any ejector profile informed the QDC module of the signal level needed to drive the selected ejector velocity valve(s) for any requested open-loop velocity: % of Signal Level Entered In: Drives the Selected Valve to Produce: EAC47 and ERC47 Velocity (usually 0) in EAC45 and ERC45 EAC48 and ERC48 Pressure in EAC46 and ERC46 Now, for
Chapter 10 Tune Your Machine Chapter Objectives In the previous chapter, rough open loop profiles were run as part of the valve spanning process. This chapter presents guidelines to assist you in refining your configuration and profile block values to optimize machine performance for actual production runs.
Chapter 10 Tune Your Machine High speed clamp operation. Molders wish to achieve minimal machine cycle time while achieving repeatable mold positioning and precise Low Pressure Close control. Smooth clamp operation. Jerky, abrupt clamp movements can cause damage to clamp mechanisms as well as accelerate wear on machine hydraulics. Ejector Control Objectives Most molders share the following objectives when tuning their ejector operation: High certainty of parts ejection.
Chapter 10 Tune Your Machine What to do Next The remainder of this chapter is presented in two major sections: In Closed-loop Tuning we discuss the use and effect of the QDC module’s closed-loop tuning constants and present a procedural discussion on how to determine their proper settings for your plastic molding process. If your application does not require operating in closed-loop, you do not need to refer to this section, and may proceed to the section entitled Other Tuning Considerations.
Chapter 10 Tune Your Machine Important: Never use FeedForward and ERC conjunctively to control the same velocity loop. The QDC module’s pressure control algorithm differs from classic PID algorithms. For this reason, the loop integral term should generally be larger than the loop proportional term upon completion of the tuning process. Disable ramping and ERC during tuning procedures. Reset the QDC module’s internal ERC values before attempting to modify closed-loop profile (stroke) tuning constants.
Chapter 10 Tune Your Machine We assume the same objective in tuning a pressure loop utilizing a scope as without it. Maximum control is desired without introducing so much gain that the machine hydraulics hammer and wear. If an oscilloscope is available, connect it to your selected clamp (ejector) pressure control valve at this time and proceed to the section in this chapter on Tuning pressure loops with an oscilloscope.
Chapter 10 Tune Your Machine If: Then: Observed actuals are consistently well below profile setpoints Increase proportional term(s) Observed actuals are consistently well above Decrease proportional term(s) profile setpoints Excessive hammering and vibration is observed in the cylinder's hydraulic lines Decrease proportional term(s) Important: Each change to a tuning constant requires you to download your changes to the QDC module. Refer to the Download Procedure outlined in chapter 4.
Chapter 10 Tune Your Machine Enter an operational profile representative of the movement characteristics you desire for your production cycle. Zero the appropriate integral and derivative term(s) associated with the profile(s), leaving the proportional term(s) at the default settings you entered in chapter 7. Run several cycles of the profile(s) while observing the oscilloscope trace.
Chapter 10 Tune Your Machine Tune Closed loop Velocity Control Important: Only those clamp and ejector profiles which you run using closed-loop velocity vs. position control require velocity loop tuning. If you never run a profile under closed-loop velocity control (you are utilizing pressure control instead), velocity tuning constants do not need to be adjusted.
Chapter 10 Tune Your Machine Enter an operational profile representative of the movement characteristics you desire for your production cycle. Zero the appropriate velocity feedforward term(s) associated with the profile(s), leaving the proportional term(s) at the default settings you entered in chapter 7. Run several cycles of the profile(s) while observing the profile actuals returned in the appropriate status block. Also pay attention to the hydraulic hoses leading to the cylinder being controlled.
Chapter 10 Tune Your Machine Tune velocity loops with an oscilloscope Before you begin tuning your velocity loops, confirm the following: Velocity vs.
Chapter 10 Tune Your Machine If you cannot alter your velocity proportional term(s) such that observed oscilloscope traces quickly level off without any bouncing or chattering, verify your Unselected Valve Set-output Values are correct for your application (Refer to chapter 7 and the discussion later in this chapter).
Chapter 10 Tune Your Machine Important: When controlling the clamp and ejectors, we do not recommend enabling ERC control unless extreme adherence to velocity or pressure setpoints is absolutely required. Enable ERC when: Strict adherence to velocity or pressure (not position) setpoints is required. One example of when ERC may be of great value is during closed-loop Low Pressure Close control, when it is absolutely undesirable to exceed the pressure setpoint.
Chapter 10 Tune Your Machine Expert Response Compensation Minimum Percentages Expert Response Compensation minimum percentages are utilized by the QDC module only when ERC is enabled. Leave these entries at the default values recommended in chapter 7 if you have decided not to enable ERC control. The ERC percentage minimum percentage tells the QDC module to what extent to utilize ERC from machine cycle to cycle.
Chapter 10 Tune Your Machine If you believe your Unselected Valve Set-output Values are adversely affecting your ability to obtain quality closed-loop control: If your Selected valve controls: And you observe: Then: Pressure Profile segment pressures substantially greater than setpoint Decrease the flow available during the profile by appropriately modifying the set output value driving the flow valve.
Chapter 10 Tune Your Machine Decreasing available ejector circuit volume after your clamp is fully open Adjusting flow through a variable pump after clamp operations are complete Configuring your ejector hydraulic circuit to a “rest” or “pre-load” state prior to switching directional valves through the PLC processor and continuing the Ejector Profile When configuring End-of Profile (Stroke) Set-output Values, remember: The QDC module ignores End-of Profile (Stroke) Set-output Values on all profiles (stroke
Chapter 10 Tune Your Machine Figure 10.1 Example Clamp Close Profiles with Acc/Dec ramps Decel. Ramp Decel. Ramp Accel. Ramp Decel. Ramp Accel. Ramp Accel. Ramp Velocity Decel. Ramp 1st Close Profile 2nd Close Profile 3rd Close Profile Low Pressure Close Position Programmed 1st Close Profile Programmed 3rd Close Profile Programmed 2nd Close Profile Programmed Low Pressure Close Accel/Decel Ramp used durring Profile Velocity Figure 10.
Chapter 10 Tune Your Machine You can configure clamp and ejector ramp rates in order to: Smooth out jerky motion present during large increases or decreases in clamp/ejector pressure or flow Decelerate the clamp during a close profile prior to Low Pressure Close. This may prevent possible mold or machinery damage or excessive wear when your application requires moving toward the Mold Protection Zone at relatively high velocities during the clamp close operation.
Chapter 10 Tune Your Machine End of Segment Position Setpoints End-of Segment Position Setpoints are dictated by the particular mold, clamp, and ejector configuration on your plastic molding machine. In general: You are not required to enter any clamp or ejector End-of Segment Position Setpoints. If your profile setpoint entries are configured without End-of Segment Position Setpoints, the following are observed during all clamp and ejector movements.
Chapter 10 Tune Your Machine During normal operation, the only required Clamp End-of Segment Position Setpoints are a single End-of-Segment Position Setpoint for First Clamp Close to identify the operational Start Low Pressure Close position and a single End-of Segment Position Setpoint for First Clamp Open to identify the operational Start Open Slow position.
Chapter 10 Tune Your Machine Profile Velocity Setpoints In general, you choose velocity setpoints to move the clamp as quickly as possible without damaging the machine, mold, or parts. Because of the nature of the large dynamic load on the clamp, configuring the clamp to operate at extremely high speeds should be approached with extreme caution. The moving platen/mold combination, once accelerated to high speeds, is extremely difficult to slow down in a short period of time.
Chapter 10 Tune Your Machine Start Clamp Low Pressure Close Position Setpoint (CPC61) This clamp position is used by the QDC module as protection against running a Clamp Close profile into the Mold Protection Zone. Although it can be used as an operational setpoint when CPC03-B11 = 0 (see discussion of End-of-Segment Position Setpoints above), it is intended for use as an absolute protection position to guard against profile entry errors.
Chapter 10 Tune Your Machine Ideally, this position should be calculated by determining: With the clamp opening at its maximum configurable velocity and pressure, what minimal distance is required for the QDC module to safely assume control prior to the mold reaching the full open position By setting this clamp position as stated, you can virtually eliminate the possibility of damaging your clamp mechanism when clamp open velocity, pressure, or position setpoints are changed This parameter should be re-adj
Chapter 10 Tune Your Machine Clamp Position for Start of Ejector Profile (EPC61) If “start on position” (EPC03-B08 = 0) is selected for ejector profile execution rather than “start on command” (EPC03-B08 = 1), the QDC module immediately begins execution of the Ejector Profile once this position is reached during its execution of any Clamp Open Profile.
Chapter 10 Tune Your Machine Pressure Alarm Setpoints The QDC monitors process pressures and compare them against two different types of high pressure alarm setpoints. Pressures are compared to absolute pressure alarm setpoints (configured in the MCC - refer to chapter 4) on a continuous basis and without regard to current machine mode or operational cycle.
Chapter 11 Troubleshoot with LED's Chapter Objectives This chapter gives you information on how to: troubleshoot your QDC module using LED indicators calibrate your QDC module Use LED's to Troubleshoot Your QDC Module The front panel of the QDC module contains three Light Emitting Diodes (LEDs). These LED’s can be used to troubleshoot some basic 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 LED's Figure 11.
Chapter 11 Troubleshoot with LED's The following table shows the meaning of the QDC module’s LEDs. The QDC module monitors its own operation and reports detected conditions by illuminating its LED’s in the following combinations: Table 11.A LED Indicator Conditions ACTIVE FAULT COMM Condition: We recommend that you: Flashing Off Off Power up.
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 D Determining Initial Sensor configuration Values Enter Your Initial Values Here Input 1 2 3 4 Control Word Pro Set 600 Addr.
Appendix A Blank Worksheets Worksheet 3 E Final Sensor configuration Values Enter Your Final Sensor configuration Values Here Input 1 2 3 4 Control Word Pro Set 600 Addr.
Appendix A Blank Worksheets Worksheet 3 F SWTL Configuration Values Enter Your SWTL Configuration Values Here Control Word Pro Set 600 Addr.
Appendix A Blank Worksheets Worksheet 5 A Initial Clamp and Eject Jog Configuration Values Enter Your Initial Values Here Control Block Word Pro Set 600 Addr.
Appendix A Blank Worksheets Worksheet 5 B Inject and Screw Rotate Jog Configuration Values (for Clamp and Eject mode) Enter Your Initial Values Here Control Word Pro Set 600 Addr.
Appendix A Blank Worksheets Worksheet 7 A First Clamp Close (FCC) Configuration Block 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 (FCC) Configuration Block Enter Your Values Here Control Word Pro Set 600 Addr.
Appendix A Blank Worksheets Worksheet 7 B Second Clamp Close (SCC) Configuration Block 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 (SCC) Configuration Block Enter Your Values Here Control Word Pro Set 600 Addr.
Appendix A Blank Worksheets Worksheet 7 C Third Clamp Close (TCC) Configuration Block 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 (TCC) Configuration Block Enter Your Values Here Control Word Pro Set 600 Addr.
Appendix A Blank Worksheets Worksheet 7 D Clamp Low Pressure Close (LPC) Configuration Block 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 (LPC) Configuration Block Enter Your Values Here Control Word Pro Set 600 Addr.
Appendix A Blank Worksheets Worksheet 7 E First Clamp Open (FOC) Configuration Block 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-E (continued) First Clamp Open (FOC) Configuration Block Enter Your Values Here Control Word Pro Set 600 Addr.
Appendix A Blank Worksheets Worksheet 7 F Second Clamp Open (SOC) Configuration Block 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-F (continued) Second Clamp Open (SOC) Configuration Block Enter Your Values Here Control Word Pro Set 600 Addr.
Appendix A Blank Worksheets Worksheet 7 G Third Clamp Open (TOC) Configuration Block 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-G (continued) Third Clamp Open (TOC) Configuration Block Enter Your Values Here Control Word Pro Set 600 Addr.
Appendix A Blank Worksheets Worksheet 7 H Clamp Open Slow (OSC) Configuration Block 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-H (continued) Clamp Open Slow (OSC) Configuration Block Enter Your Values Here Control Word Pro Set 600 Addr.
Appendix A Blank Worksheets Worksheet 7 I Ejector Advance (EAC) Configuration Block Control Word EAC01 Bxx 15 14 13 12 11 10 09 08 07 06 05 04 03 02 01 00 Pro Set 600 Addr. B39/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 1 0 1 1 0 EAC Block Identifier Control Word EAC02 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) Ejector Advance (EAC) Configuration Block Enter Your Values Here Control Word Pro Set 600 Addr.
Appendix A Blank Worksheets Worksheet 7 J Ejector Retract (ERC)Configuration Block Control Word ERC01 Bxx 15 14 13 12 11 10 09 08 07 06 05 04 03 02 01 00 Pro Set 600 Addr. B39/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 1 0 1 1 1 ERC Block Identifier Control Word ERC02 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) Ejector Retract (ERC) Configuration Block Enter Your Values Here Control Word Pro Set 600 Addr.
Appendix A Blank Worksheets Worksheet 8 A Clamp Close (CPC) Profile Block 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 (CPC) Profile Block Control Word CPC09 Pro Set 600 Addr.
Appendix A Blank Worksheets Worksheet 8 B Clamp Open (OPC) Profile Block 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 Control Word OPC09 OPC10 OPC11 OPC12 OPC13 OPC14 OPC15 OPC16 OPC17 OPC18 OPC19 OPC20 OPC21 OPC22 OPC23 OPC24 OPC25 OPC26 OPC27 OPC28 OPC29 OPC30 OPC31 OPC32 OPC33 OPC34 OPC35 OPC36 OPC37 OPC38 OPC39 OPC40 OPC61 OPC62 OPC63 Pro Set 600 Addr.
Appendix A Blank Worksheets Worksheet 8 C Ejector (EPC) Profile Block Control Word EPC01 Bxx 15 14 13 12 11 10 09 08 07 06 05 04 03 02 01 00 Pro Set 600 Addr. B39/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 1 1 0 0 0 Value EPC Block Identifier Control Word EPC03 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-C (continued) Ejector (EPC) Profile Block Control Word EPC09 Pro Set 600 Addr.
Index C Clamp and Ejector actuating with set-output operation, 3 10 initial jog value determination, 5 2 initial jog values entering and downloading, 5 3 using set-output to move, 3 9 Clamp Pressure Sensor, determining values, 3 14 Clamp-Sensor Position, determining values, 3 12 Command Blocks, 3 2 Complex Applications clamp and eject mode, 1 1 ejector advance, 1 8 ejector retract, 1 9 other eject features, 1 10 inject and clamp mode clamp-open, 1 5 low-pressure close, 1 4 open-slow, 1 7 configuration proc
I–2 Index K keying, 2 5 L LED's, troubleshooting with, 11 1 M Machine Interlocks, planning for, 2 11 Module Parameters, 3 2 O Optional Configurations digital filter, 3 20 configuring, 3 20 maximum pressure alarms, 3 19 software travel limits, 3 17 time delays, 3 19 Q QDC Module complete sensor configuration, 3 11 grounding, 2 9 inputs and outputs, 3 1 installing, 2 1 jogging your machine, 5 1, 5 4 optional configurations, 3 17 sensor-configuration values, determining initial, 3 5 setting jumper plugs
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