Plastic Molding Module (Cat. No.
Important User Information Because of the variety of uses for the products described in this publication, those responsible for the application and use of this control equipment must satisfy themselves that all necessary steps have been taken to assure that each application and use meets all performance and safety requirements, including any applicable laws, regulations, codes and standards.
Table of Contents Important Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . P 1 Manual Objectives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Audience . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Use of Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Related Publications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ii Table of Contents Overview of Remaining Configuration Procedures . . . . . . 4 1 Chapter Objectives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Configuration Concepts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . System Command and Status Blocks . . . . . . . . . . . . . . . . . . . . . . Overview of Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Enter Data Table Values and Download Data Blocks . . . . . . . . . . .
Table of Contents iii Load Initial Profile Setpoints . . . . . . . . . . . . . . . . . . . . . . . 8 1 Chapter Objectives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Use These Worksheets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Determine and Record Setpoints for the Clamp Close Profile (CPC) Determine Bit Selections for Worksheet 8 A . . . . . . . . . . . . . . . . . Determine Word Values for Worksheet 8 A . . . . . . . . . . . . . . . . . .
iv Table of Contents Tune Your Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 1 Chapter Objectives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Closed loop Tuning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Injection Tuning Considerations for Producing Parts . . . . . . . . . . . Tuning Considerations for Clamp and Ejector Operations . . . . . . .
Table of Contents v Troubleshoot with LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . 11 1 Chapter Objectives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Use LEDs to Troubleshoot Your QDC Module . . . . . . . . . . . . . . . . 11 1 11 1 Blank Worksheets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Preface Important Information Manual Objectives Use this preface to familiarize yourself with this manual so you can use it effectively. This manual shows you how to apply the QDC module to your molding machine in a reasonable length of time. Since this manual is task oriented, we recommend that you perform these tasks in the following order: Perform this task: 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 abbreviated catalog numbers when referring to Allen-Bradley equipment: Abbreviated Name: Title: QDC module 1771 QDC Plastic Molding Module PLC 5 processor PLC 5 Programmable Controller T45 or T47 T50 oe T53 termin
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, Clamp, and Eject Mode Chapter Objectives This chapter presents an overview of the 1771-QDC Plastic Molding Module in the inject, clamp, and eject mode. We present a summary of operating features followed by sample applications. Important: This chapter assumes you have already read your Plastic Molding Module Application Guide (publication 1771-4.10) and have chosen inject, clamp, and eject as your QDC module’s mode of operation.
Chapter 1 Overview of Inject, Clamp, and Eject Mode Injection Phase You can vary the velocity of the ram (screw), or the pressure driving it, so the leading edge of the melt moves through the mold cavity at the desired speed. The pattern of velocity or pressure variation during injection is called the injection profile. The QDC module lets you chose from four different injection profiles: velocity vs. position pressure-limited velocity vs. position pressure vs. position pressure vs.
Chapter 1 Overview of Inject, Clamp, and Eject Mode Example Benefits of Profiling an Injection Phase The injection phase should force the melt through the mold as fast as possible without flashing the mold or burning the melt at a mold gate.
Chapter 1 Overview of Inject, Clamp, and Eject Mode Flash Prevention Example - With a velocity profile (Figure 1.4 part 1), the pressure may reach a peak and flash the mold at ram (screw) position segments that correspond to events such as: the initial surge (2.a) when the melt front enters a constriction in the mold cavity (2.b) You can remedy this (part 3) by decreasing the ram (screw) velocity at segments (3.a) and (3.b) that correspond to flash points. Conversely, you can boost velocity at segment (3.
Chapter 1 Overview of Inject, Clamp, and Eject Mode Injection to pack Transition The QDC module ends the injection phase and automatically starts the pack or hold phase when it detects the first of up to three events occurred: Ram (screw) position exceeds a preset limit Ram (screw) pressure exceeds a preset limit Injection phase elapsed time exceeds a preset limit You select which of these events you want monitored for transition by entering the appropriate setpoint, or zero for ignoring the event.
Chapter 1 Overview of Inject, Clamp, and Eject Mode Example Benefit of Profiling the Pack Phase Molten plastic may cool unevenly in the mold causing variations in density with the end result of warpage and distortion as shown in Figure 1.6. Figure 1.
Chapter 1 Overview of Inject, Clamp, and Eject Mode Hold Phase The QDC module controls the hold phase with a pressure vs. time profile. You create the profile based on controlling the hydraulic pressure against the ram (screw). The pressure can be controlled using up to five segments. You determine the pressure setpoints and time durations for the hold profile based on molding requirements.
Chapter 1 Overview of Inject, Clamp, and Eject 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, Clamp, and Eject 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 3rd Open Open Slow 2nd Open 1st Open Clamp Close You may configure three separate clamp close profiles: first close second close third close You may select from these control modes: velocity vs.
Chapter 1 Overview of Inject, Clamp, and Eject Mode You may start these operations between the three clamp close profiles: pick up the 3rd plate of a mold (on a floating 3-plate mold) or set cores program other events for all valves automatically bridge between profiles, or let ladder logic decide when to begin the next profile You can subdivide each clamp close profile into three position segments (Figure 1.11).
Chapter 1 Overview of Inject, Clamp, and Eject Mode Figure 1.12 Example Low Pressure Close Moving Platen L Stationary Platen Pressure Clamp Cylinder Low Pressure Close Segments 1 2 X 0 Position Important: If you need only one low pressure close segment, configure the 1st segment of the low pressure close profile.
Chapter 1 Overview of Inject, Clamp, and Eject Mode You may start these operations between the three clamp open profiles: drop the third plate of a mold (on a floating 3-plate mold) or pull cores program other events for all valves automatically bridge between profiles, or let ladder logic decide when to begin the next profile. Each clamp open profile can be subdivided into three position segments (Figure 1.14).
Chapter 1 Overview of Inject, Clamp, and Eject Mode Figure 1.15 Example Open Slow Moving Platen Stationary Platen Velocity Clamp Cylinder Open Slow Segments 1 L Y 0 2 Position Important: If you need only one open slow motion, configure only the 1st segment of the open slow profile. Ejector Control In this section, we describe the eject operation for expelling molded parts. The operation consists of: ejector advance ejector retract Figure 1.
Chapter 1 Overview of Inject, Clamp, and Eject Mode You may use up to three ejector-advance profile segments, and select from these control modes: velocity vs. position pressure vs. position Figure 1.17 Example Ejector Advance Ejector Advance Segments 1 2 Velocity Velocity Ejector 0 Fully Advanced Position 3 Position Important: If you need only one ejector-advance motion, configure only the 1st advance segment.
Chapter 1 Overview of Inject, Clamp, and Eject Mode Other Eject Features The QDC module gives you the following additional features: Multiple Cycles – the ability to repeat the ejector cycle a number of times, changing from advance to retract determined either automatically or by command from your PLC program Ejector Forward Dwell - the ability to pause after completing the first or last advance stroke.
Chapter 1 Overview of Inject, Clamp, and Eject Mode Because system pressure may change from one phase to the next, we recommend that you: assign pressure control to phases that require pressure profiles (and are hydraulically plumbed to support it) place the system pressure sensor accordingly in the hydraulic circuit configure the remaining phases with velocity profiles We define open-loop pressure control as when the QDC module controls phase pressure without input from the system pressure sensor.
Chapter 1 Overview of Inject, Clamp, and Eject Mode Example 4 valve System with System Pressure Sensor With this hydraulic system, a QDC module in the Inject, Clamp, and Eject mode, has maximum control flexibility. It can control all profiles with: pressure or velocity open or closed loop Figure 1.
Chapter 1 Overview of Inject, Clamp, and Eject Mode Example 3 valve System with Ram (Screw) Pressure Sensor With this hydraulic system, one QDC module in the Inject, Clamp, and Eject mode, can control the following: closed-loop pressure for injection, pack, hold, and plastication profiles closed-loop velocity for injection profiles open-loop pressure for clamp and ejector profiles closed-loop velocity for clamp and ejector profiles Figure 1.
Chapter 1 Overview of Inject, Clamp, and Eject Mode Example 2 valve System for Injection Control with Clamp and Ejector Position Inputs With this hydraulic system, the QDC module in the Inject, Clamp, and Eject mode sends clamp and ejector position data to the PLC-5 processor.
Chapter 1 Overview of Inject, Clamp, and Eject Mode Summary of Inject, Clamp, and Eject Mode of Operation 1-20 When you select this mode, you can use the following phases of operation: Inject Phase: Description: Injection The ram (screw) injects plastic into the mold. You can vary the velocity of the ram (screw), or the pressure driving it, to fill areas of the mold cavity at different rates to achieve uniform quality of the molded part. This phase can be critical to part quality.
Chapter 2 Install the QDC Module Chapter Objectives This chapter helps you install the QDC module with these procedures: record I/O ranges set module jumpers key the I/O chassis install the QDC module wire I/O devices to the QDC module ground and shield I/O devices plan for E-STOPs and machine interlocks 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 select with jumper plugs the I/O ranges that you recorded on Worksheet 2-A Access and Position the Jumpers Access the jumper plugs and set them as follows: ATTENTION: To avoid damage to internal circuits, observe handling precautions and rid yourself of any electrostatic charge. Use an anti-static work station when setting jumpers. 1. Remove the label-side cover plate by removing the four screws. 2.
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 positions as left, right, top, and bottom. This represents the position of the jumper on the 3-pin connector relative to the orientation of the circuit board shown above.
Chapter 2 Install the QDC Module Table 2.
Chapter 2 Install the QDC Module Key the I/O Chassis Use plastic keying bands, shipped with each I/O chassis, for keying the backplane connector to accept only one type of module. Do this to prevent inadvertent installation of the wrong module into the designated slot location. Important: You must use the following slot location in the I/O chassis for the QDC module because this is the address used by your Pro-Set 600 software to communicate with the QDC module.
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 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 I/O Devices 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 ATTENTION: The QDC module has ESD protection to 20kV, but you can damage the module by accidental application of the wrong voltage to the I/O terminals. Do not exceed: Ground and Shield Your I/O Devices This voltage: On these terminals: When in: +12V dc input (18 thru 10) any mode +12V dc output (09 thru 02) voltage mode +24V dc output (09 thru 02) current mode Analog inputs and outputs are sensitive to electrical noise interference.
Chapter 2 Install the QDC Module Figure 2.5 Shielding Single ended Outputs QDC Module Output Customer Valve Amplifier + 9 – 8 Input Ground Chassis Ground Connect the cable shield to earth ground at the valve amplifier 17182 Ground the cable shields to a low-impedance earth ground of less than 1/8 ohm Do not connect any ground to input common (terminal 14) except as specified in the Exceptions section, below.
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), clamp, and ejector sensors.
Chapter 3 Configure the QDC Module's I/O Select Module Parameters and I/O Ranges You select module parameters and I/O ranges by setting configuration bits in control words.
Chapter 3 Configure the QDC Module's I/O Worksheet 3 B Select Input Ranges for your Sensors Control Word MCC03 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 Determine Initial Sensor configuration Values To determine initial sensor configuration values, refer to Table 3.A, and specifications that accompanied your sensors, valves, and cylinders. Write down applicable values on Worksheet 3-D. Important: You must enter floating-point numbers and percentages as integers, so we recommend that you write them in Worksheet 3-D in the following format: Use an assumed decimal point position that depends on the range value.
Chapter 3 Configure the QDC Module's I/O Worksheet 3 D Determine Initial Sensor configuration Values Record 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 3. Locate the data file for storing the MCC block. PLC-5 data table word addresses are listed on the worksheets. 4. Enter the value for each word and bit. When you enter bit selections in words prefixed with file identifier B (example: B34), the PLC-5 processor automatically switches the radix to binary format so you can conveniently enter binary data.
Chapter 3 Configure the QDC Module's I/O To finish configuring the QDC module, you actuate the ram (screw), clamp, and ejector axes with the QDC module’s set-output operation that applies percentage values to your QDC module’s outputs to move the actuator in a controllable fashion. To do this, you apply a %-output signal to a module output so you can move the actuator over its intended range. ATTENTION: Do not rely on pressure valves connected to the QDC module for pressure relief.
Chapter 3 Configure the QDC Module's I/O Follow this procedure to actuate the ram (screw), clamp, and ejector: 1. 2. Enter values in words DYC09-12 that result in no motion. Output: In Data Word: At Pro Set 600 Address: 1 DYC09 N40:121 2 DYC10 N40:122 3 DYC11 N40:123 4 DYC12 N40:124 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.
Chapter 3 Configure the QDC Module's I/O Worksheet 3 E Final Sensor configuration Values Record 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. Important: If your position sensor has a potentiometer for setting the zero reference, do so now. 5. Record this value on line 3 for MCC11 (should be at minimum signal if you zeroed your position sensor in step 4). 6.
Chapter 3 Configure the QDC Module's I/O 3. Record this position value (usually 0000) on line 9 for MCC23 on Worksheet 3-E. 4. With your programming terminal, read the signal level returned in SYS35 (N40:187) from your position sensor. Important: If your position sensor has a potentiometer to set the zero reference, do so now. 5. Record this value on line 11 for MCC25 (should be at minimum signal if you zeroed your position sensor in step 4). 6. Move the clamp backward to the mechanical open stop.
Chapter 3 Configure the QDC Module's I/O 4. With your programming terminal, read the signal level returned in SYS33 (N40:185) from your position sensor. Important: If your position sensor has a potentiometer for setting the zero reference, do so now 5. Record this value on line 15 for MCC33 (should be at minimum signal if you zeroed your position sensor in step 4). 6. Move the ejector forward to the mechanical advance stop. 7. Remove ejector pressure and/or flow to stop movement. 8.
Chapter 3 Configure the QDC Module's I/O ATTENTION: Use extreme caution during the next steps because you stress the hydraulic system to its maximum rated pressure. Loose fittings or faulty components could fail, causing possible damage to equipment and/or injury to personnel. ATTENTION: If the ram (screw), clamp, and/or ejectors are not disconnected from the hydraulic circuit, be sure that they are fully retracted with their hydraulics aligned in the retract position.
Chapter 3 Configure the QDC Module's I/O Select Optional Configurations You have the option of configuring the following QDC module features: Use this Option: For this Benefit: Software Travel Limits to guard against damaging the nozzle, mold, or ejectors Pressure Alarm Time Delay to warn of excessive pressure without nuisance alarms Digital Filter to compensate for electrical noise on position inputs Configure Software Travel Limits You may want to use software restrictions to stop the travel of
Chapter 3 Configure the QDC Module's I/O Configure the QDC module for SWTL alarms as follows: 1. Determine these SWTL values for ram (screw), clamp, and/or ejector travel with respect to the range of physical travel. SWTL deadband Maximum SWTL Minimum SWTL 2. Record non-zero SWTL values on Worksheet 3-F. Zero values disable the corresponding SWTLs. ATTENTION: Leaving your SWTL settings at zero (MCC13, 14, 27, 28, 41, 42) inhibits the QDC module from performing this safety function.
Chapter 3 Configure the QDC Module's I/O Set Up Maximum Pressure Alarms and Time Delays The QDC module continuously monitors the system pressure input. When it detects that the process input equals or exceeds a preset alarm setpoint, the QDC module sets an alarm bit. A setpoint of zero disables the associated alarm.
Chapter 3 Configure the QDC Module's I/O Configure Digital Filters for Position Inputs You may enable an optional digital filter on position inputs to reduce electrical noise from a potentiometer-type position sensors or picked up by your input circuits. To determine if you need a digital filter, move the ram (screw), clamp, and/or ejector very slowly.
Chapter 4 Overview of Remaining Configuration Procedures Chapter Objectives This chapter gives you and overview of the remaining configuration procedures necessary to successfully configure your QDC module for the inject, clamp, and eject mode Important: You must follow the configuration procedures presented in chapters 5-10 in given order. Please use this chapter as a guide. Configuration Concepts The QDC module communicates with your PLC-5 processor through data “blocks”.
Chapter 4 Overview of Remaining Configuration Procedures There are two types of command blocks, presented in the following table: Type of Command Block: Which Contains: Examples: Configuration Information necessary to configure your Valve spanning module to run a certain portion of a profile. information for the 1st clamp close profile. Profile Actual process setpoints necessary to produce a desired part. 1st clamp close profile operating setpoints.
Chapter 4 Overview of Remaining Configuration Procedures Overview of Procedures Configuration procedures described in the next several chapters are outlined below. They are sequential in nature: configuration information determined in initial chapters is needed in later chapters. Step: Procedure: Description: Refer to: 1 Jog Your Machine You enter machine jog pressure and flow setpoints into the Jog Configuration (JGC) block.
Chapter 4 Overview of Remaining Configuration Procedures Enter Data Table Values and Download Data Blocks We refer to these procedures throughout this manual whenever you must: enter data table values download data blocks Enter Values into Your PLC Data Table With your programming terminal, enter worksheet values into your PLC-5 data table as follows: 1. Switch the PLC-5 processor to PROGRAM mode. 2. Display your PLC-5 data table 3.
Chapter 4 Overview of Remaining Configuration Procedures Table 4.A Information Required to Download a Block Block to Download: Pro Set 600 Block ID.: Pro Set 600 Download Bit B21/ JGC FCC SCC TCC LPC CPC INC IPC PKC HDC HPC PRC PLC PPC PSC FOC SOC TOC OSC OPC EAC ERC EPC 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 2.
Chapter 4 Overview of Remaining Configuration Procedures 3. Start the download procedure by setting the corresponding download bit (Table 4.A) in your PLC-5 data table. 4. Watch the bit you set in step 3 and wait for Pro-Set 600 software to reset it to zero. This indicates the PLC-5 processor has transferred the block to the QDC module. 5. Observe the value of SYS62 (N40:214) in your PLC-5 data table: If SYS62 = 0, the QDC module detected no errors. Go to step 6.
Chapter 5 Jog Your Machine Chapter Objectives This chapter describes how to: configure jog block values necessary to jog the ram (screw), clamp, and ejector test jog values and make changes, if necessary configure values which indirectly affect screw-rotate jogs About Jogging Jogging your machine is similar to operating in set-output mode: You apply percentage values to your QDC module’s outputs to obtain the desired motion.
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), clamp, and ejector in both directions. Use it to record: initial values Enter initial values just sufficient to jog in the desired direction. Keep this information in mind: The numbers you enter are %-signal output. For a range of –10 to +10V dc, zero output occurs @ 50% (See Warning on next page.
Chapter 5 Jog Your Machine Worksheet 5. A Ram (screw), Clamp, and Ejector Jog Configuration Values Record Your Initial Values Here 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), clamp, and/or ejector, consider their indirect effect when setting jog set-output values. Indirectly, they could cause unexpected machine motion with possible damage to equipment or injury to personnel. ATTENTION: A value of 0 entered in your data table does not necessarily correspond to zero pressure or flow.
Chapter 5 Jog Your Machine Write Ladder Logic Take time now to develop ladder logic (independent of Pro-Set 600 software) to jog the ram (screw), clamp, and ejector. You may need to monitor switches on your operator control panel, and set corresponding command bits. Use word 1 in the dynamic command block (DYC01) to enable and disable individual jogs. Use word 1 in the system status block (SYS01) to monitor the QDC module’s reaction to jog commands. Tables 5.A and 5.
Chapter 5 Jog Your Machine Figure 5.
Chapter 5 Jog Your Machine Jog Your Ram (Screw), Clamp, and Ejector Jog your ram (screw), clamp, and ejector, one at a time, in forward and reverse directions. Experiment with values you entered in the jog configuration block (JGC) until you obtain the desired jog operation.
Chapter 5 Jog Your Machine Worksheet 5. B Screw rotate Jog Configuration Values for Indirect Control Enter Your Initial Values Here Block Word Pro Set 600 Addr. Value Description JGC09 N40:65 Set Output Values Output #1 1 JGC10 N40:66 Output #2 1 JGC11 N40:67 Output #3 1 JGC12 N40:68 Output #4 1 Screw Rotate Jog 1 Write Ladder Logic to Assist with Screw rotate Jogs % Signal Output 00.00 to 99.
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.
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.
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.
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.
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.
Chapter 7 Load Initial Configuration Values Chapter Objectives This chapter helps you load the QDC module with machine-specific configuration values by performing four tasks: Determine initial configuration values Record them on worksheets Enter them in PLC-5 data table Download them to the QDC module Initial values that you load include: configuration bits set-output values acceleration and deceleration ramp rates pressure or velocity control limits pressure or velocity gain constants pressure alarm se
Chapter 7 Load Initial Configuration Values Use These Worksheets The following table lists configuration blocks and corresponding worksheets for recording your initial values to configure the QDC module.
Chapter 7 Load Initial Configuration Values Worksheet 7 A Clamp Close Configuration Blocks (FCC, SCC, and TCC) Word FCC01 B15 thru 00 15 14 13 12 11 10 09 08 07 06 05 04 03 02 01 00 Bit Address 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 Word SCC01 B15 thru 00 15 14 13 12 11 10 09 08 07 06 05 04 03 02 01 00 Bit Address B37/Bit 79 78 77 76 75 74 73 72 71 70 69 68 67 66 65 64
Chapter 7 Load Initial Configuration Values Worksheet 7 A (continued) Clamp Close Configuration Blocks (FCC, SCC, and TCC) Enter Your Values Here For these Parameters (footnote = units) Word FCC N43: FCC Value Minimum ERC Percentage - Velocity 8 05 1 1000 Minimum ERC Percentage - Pressure 8 SCC N43: SCC Value TCC N43: TCC Value 61 1000 121 1000 1000 06 2 1000 62 1000 122 Profile Watchdog Timer Preset 1 08 4 0 64 0 124 Output #1 Selected Valve % Output During Profile 4 09 5
Chapter 7 Load Initial Configuration Values Worksheet 7 B Low Pressure Close Configuration Block (LPC) Word LPC01 Bits 15 thru 00 15 14 13 12 11 10 09 08 07 06 05 04 03 02 01 00 Bit Addresses B37/Bxxx 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 Important: Verify block identifier.
Chapter 7 Load Initial Configuration Values Worksheet 7 B (continued) Low Pressure Close Configuration Block (LPC) Enter Your Values Here For these Parameters (footnote = units) Word Minimum ERC Percentage 8 06 182 1000 Tonnage Watchdog Timer Preset 1 07 183 0 Profile Watchdog Timer Preset 1 08 184 #1 Selected Valve Set Output During Profile 4 09 185 * #2 Selected Valve Set Output During Profile 4 10 186 * #3 Selected Valve Set Output During Profile 4 11 187 * 4 * #4 Selected Val
Chapter 7 Load Initial Configuration Values Worksheet 7 C 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 C (continued) Injection Configuration Block (INC) Enter Your Values Here Control Word Pro Set 600 Addr.
Chapter 7 Load Initial Configuration Values Worksheet 7 D 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 D (continued) Pack Configuration Block (PKC) Enter Your Values Here Control Word Pro Set 600 Addr.
Chapter 7 Load Initial Configuration Values Worksheet 7 E 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 E (continued) Hold Configuration Block (HDC) Enter Your Values Here Control Word Pro Set 600 Addr.
Chapter 7 Load Initial Configuration Values Worksheet 7 F 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 F (continued) Plastication Configuration Block (PLC) Enter Your Values Here Control Word Pro Set 600 Addr.
Chapter 7 Load Initial Configuration Values Worksheet 7 G Clamp Open Configuration Blocks (FOC, SOC, TOC, and OSC) Word FOC01 B15 thru 00 15 14 13 12 11 10 09 08 07 06 05 04 03 02 01 00 Bit Address B37/Bit 335 334 333 332 331 330 329 328 327 326 325 324 323 322 321 320 Value 0 0 0 0 0 0 0 0 0 0 0 1 0 0 0 1 Word SOC01 B15 thru 00 15 14 13 12 11 10 09 08 07 06 05 04 03 02 01 00 Bit Address B37/Bit 399 398 397 396 395 394 393 392 391
Chapter 7 Load Initial Configuration Values Worksheet 7 G (continued) Clamp Open Configuration Blocks (FOC, SOC, TOC, and OSC) Enter Your Values Here For these Parameters (footnote = units) Word FOC N43 Minimum ERC Percentage - Velocity 8 05 301 Minimum ERC Percentage - Pressure 8 06 302 1 Profile Watchdog Timer Preset 08 304 #1 Selected Valve Set Output During Profile 4 09 305 #2 Selected Valve Set Output During Profile 4 10 306 4 #3 Selected Valve Set Output During Profile 11 307 #4 Selected Valve Set Ou
Chapter 7 Load Initial Configuration Values Worksheet 7 H Ejector Configuration Blocks (EAC and ERC) 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 Control Word ERC01 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) Ejector Configuration Blocks (EAC and ERC) Enter Your Values Here Description Word 05 EAC @ N45: N45:1 EAC Value 1000 ERC @ N45: N45:61 ERC Value 1000 Minimum ERC Percentage Pressure 8 Profile Watchdog Timer Preset 1 Output #1 Set Output Value during Advance 4 Output #2 Set Output Value during Advance 4 Output #3 Set Output Value during Advance 4 Output #4 Set Output Value during Advance 4 Output #1 Acceleration Ramp Rate during
Chapter 7 Load Initial Configuration Values Procedure to Determine and Record Initial 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. 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.
Chapter 7 Load Initial Configuration Values Selected Valve for Pressure Control (FCC02, SCC02, TCC02, LPC02, INC02, PKC02, HDC02, PLC02, FOC02, SOC02, TOC02, OSC02, EAC02, ERC02) Important: We define system pressure for the Inject, Clamp, and Eject mode as the pressure continuously detected by the single pressure sensor connected to the QDC module at input 2. Depending on machine hydraulics, a single pressure valve may control inject, clamp, and/or eject mode profiles.
Chapter 7 Load Initial Configuration Values Select the Type of PID Algorithm Type of PID Pressure Algorithm (FCC02, SCC02, TCC02, LPC02, INC02, PKC02, HDC02, PLC02, FOC02, SOC02, TOC02, OSC02, EAC02, ERC02) When executing pressure versus position or time profiles, the QDC module can use one of two types of PID algorithms: dependent gains (ISA) or independent gains (Allen-Bradley).
Chapter 7 Load Initial Configuration Values Important: PID gain constants that we entered on worksheets and used in closed-loop tuning procedures in chapter 10 were independent (A-B) gains. If, after attempting to tune your pressure loops in chapter 10, you must use dependent (ISA) gain constants, refer to Section 3 of the Plastic Molding Module Reference Manual (publication 1771-6.5.88) for more information.
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 +10V dc), 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, EAC17 20, ERC17 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.
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. Important: We refer to system pressure during profile or axis movement as: inject pressure clamp pressure ejector pressure All three are the pressure measured at input 2 of the QDC module.
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, EAC45, ERC45) 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 Record initial Output for Minimum values on corresponding worksheets. Selected Velocity Valve, Output for Maximum (FCC48, SCC48, TCC48, INC48, FOC48, SOC48, TOC48, OSC48, EAC48, ERC48) The QDC module uses this word with the Maximum Velocity Control Limit (word 46) above. Enter the %-signal output that the QDC module uses to drive the selected velocity valve for maximum profile velocity.
Chapter 7 Load Initial Configuration Values Profile Pressure Alarm Setpoints (FCC57, SCC57, TCC57, LPC57, INC57, PKC57, HDC57, PLC57, FOC57, SOC57, TOC57, OSC57, EAC57) The QDC module compares real-time clamp pressure against these entries when executing the appropriate profile. The QDC module sets a corresponding alarm bit any time pressure equals or exceeds these entries during the respective profile. A zero entry inhibits each respective alarm.
Chapter 7 Load Initial Configuration Values Enter and Download your Worksheet Values After you determine your initial values and record them on configuration worksheets, you are ready to proceed. Refer to procedures in chapter 4 if necessary. Important: Be sure that you do not alter any setpoints, and that you enter each and every setpoint exactly as on the worksheets. 1. Enter all worksheet values into your PLC-5 data table. 2. Download command blocks to the QDC module.
Chapter 8 Load Initial Profile Setpoints Chapter Objectives In this chapter you load the QDC module with profile setpoints by performing four tasks: Determine initial profile setpoints from text Record them on worksheets Enter them into PLC-5 data table Download profile blocks to the QDC module Initial profile setpoints that you load include: control bits velocity setpoints pressure setpoints position setpoints timer presets Important : Complete all previous chapters before starting this chapter.
Chapter 8 Load Initial Profile Setpoints Determine and Record Setpoints for the Clamp Close Profile (CPC) The following two pages contain Worksheet 8-A for the clamp close profile (one page for bit entries and one for word entries). The valve spanning procedures in chapter 9 require specific values. We have already recorded many setpoints for you on the worksheet. You must determine the remaining setpoints based on your specific machine. Important: You record setpoints for pressure vs.
Chapter 8 Load Initial Profile Setpoints 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.
Chapter 8 Load Initial Profile Setpoints Worksheet 8-A (continued) Clamp Close Profile Block (CPC) Enter Your Values Here Control Word Pro Set 600 Addr.
Chapter 8 Load Initial Profile Setpoints Determine Bit Selections for Worksheet 8-A 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. Pro-Set 600 sets these bits to 00000111. We recorded this value 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 Setpoints 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 recorded a value of 1 for pressure vs. position on Worksheet 8-A. Important: All other bit selections in CPC03 should be zero.
Chapter 8 Load Initial Profile Setpoints Determine Word Values for Worksheet 8-A Velocity Setpoints (CPC09, 12, 15, 18, 21, 24, 27, 30, 33) Use these words to configure velocity vs. position profiles in units per second. Each 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. Record these setpoints into CPC09, 12, and 15 of Worksheet 8-A.
Chapter 8 Load Initial Profile Setpoints Figure 1.1 Example Setpoints for Mold Safe (CPC62) and Start Protection Zone (CPC61) zero Clamp Motion LPC Protection Zone (CPC61) (OPC62) Fully Open (CPC62) Mold Safe We recommend an initial value larger than the start LPC position you would typically use during normal machine operation. Record a value for CPC61 that is a safe distance from mold safe (CPC62) on Worksheet 8-A. The valve spanning procedures in chapter 9 require this initial value.
Chapter 8 Load Initial Profile Setpoints 4. Record your FCC end-of-segment position setpoints for CPC11, 14, and 17 on Worksheet 8-A. We recorded 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 Setpoints Determine and Record Setpoints for the Injection Profile (IPC) The following two pages contain Worksheet 8-B for the injection profile (one page for bit entries and one for word entries). The valve spanning procedures in chapter 9 require specific values. We have already recorded many values for you on the worksheet. You must determine the remaining setpoints based on your specific machine. Important: You record setpoints for a pressure vs. time and a velocity vs.
Chapter 8 Load Initial Profile Setpoints 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 Setpoints 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 N
Chapter 8 Load Initial Profile Setpoints Determine Bit Selections for Worksheet 8-B Block Identifier (IPC01) Bits 07-00 of this word identify it as the first word in a series used to define the injection profile. Pro-Set 600 sets these bits to 00001001. We recorded this value 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 Setpoints 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 recorded a value of 1 (ERC = Off) on Worksheet 8-B.
Chapter 8 Load Initial Profile Setpoints 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 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. Record the initial value of one-half system pressure for all 11 pressure setpoints on Worksheet 8-B.
Chapter 8 Load Initial Profile Setpoints Time Setpoints (IPC12, 16, 20, 24, 28, 32, 36, 40, 44, and 48) Use these words when configuring pressure vs.time profiles 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 recorded 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 Setpoints 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 Setpoints Enter and Download your Worksheet Values After you determine initial values and record them on Worksheet 8-B, you are ready to proceed. Refer to procedures in chapter 4 if necessary. Important: Be sure that you do not alter any setpoints, and that you enter each and every setpoint exactly as on the worksheet. 1. Enter all worksheet values into your PLC-5 data table. 2. Download command blocks to the QDC module. We repeat the IPC block download data.
Chapter 8 Load Initial Profile Setpoints 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 Setpoints Worksheet 8-C (continued) Pack/Hold Profile Block (HPC) Enter Your Values Here Control Word Pro Set 600 Addr.
Chapter 8 Load Initial Profile Setpoints Determine Bit Selections for Worksheet 8-C 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. Pro-Set 600 sets these bits to 00001100. We recorded this value 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 Setpoints 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 recorded a value of 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 Setpoints Cure Timer Preset (HPC61) Use this word to set the length of cure time that starts at completion of the hold profile. You record 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 Setpoints Determine and Record Setpoints for the Plastication Profile (PPC) The following two pages contain Worksheet 8-D for the plastication profile (one page for bit entries and one for word entries). The valve spanning procedures in chapter 9 require specific values. We have already recorded many setpoints for you on the worksheet. You must determine the remaining setpoints based on your specific machine. Important: You enter setpoints for a backpressure vs.
Chapter 8 Load Initial Profile Setpoints 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 Setpoints Worksheet 8-D (continued) Plastication Profile Block (PPC) Enter Your Values Here Control Word Pro Set 600 Addr.
Chapter 8 Load Initial Profile Setpoints Determine Bit Selections for Worksheet 8-D Block Identifier (PPC01) Bits 07-00 of this word identify it as the first word in a series used to define the plastication profile. Pro-Set 600 sets these bits to 00001111. We recorded this value 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 Setpoints 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 recorded a value of 1 (ERC = Off) on Worksheet 8-D.
Chapter 8 Load Initial Profile Setpoints 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 Setpoints Profile Offset (PPC52) The profile offset lets you shift the amplitude of the backpressure profile up or down, if necessary. You record this setpoint in PSI or Bar. We recorded zero (no offset) on Worksheet 8-D. 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.
Chapter 8 Load Initial Profile Setpoints Determine and Record Setpoints for the Clamp Open Profile (OPC) The following two pages contain Worksheet 8-E for the clamp open profile (one worksheet for bit entries and one for word entries). The valve spanning procedures in chapter 9 require specific values. We have already recorded many values for you on the worksheet. You must determine the remaining setpoints based on your specific machine. Important: You enter setpoints for pressure vs.
Chapter 8 Load Initial Profile Setpoints 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.
Chapter 8 Load Initial Profile Setpoints Worksheet 8-E (continued) Clamp Open Profile Block (OPC) Enter Your Values Here Control Word Pro Set 600 Addr.
Chapter 8 Load Initial Profile Setpoints Determine Bit Selections for Worksheet 8-E 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. Pro-Set 600 sets these bits to 00010101. We recorded this value 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 Setpoints 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 recorded the value of 1 for pressure vs. position on Worksheet 8-E.
Chapter 8 Load Initial Profile Setpoints 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 in units per second.
Chapter 8 Load Initial Profile Setpoints Start Overrun Zone Setpoint (OPC61) The QDC module uses this position as protection against opening the clamp too far. If the clamp reaches this position during any of the first three clamp open profiles ( FOC, SOC, or TOC), the QDC module immediately terminates the ongoing profile and either: begins the open slow profile (OSC) sets its outputs to zero (depending on the state of OPC03-B11, the overrun zone bit) Figure 1.
Chapter 8 Load Initial Profile Setpoints zero Clamp Travel Range Fully Open (OPC62) 4. FOC Seg 3 (OPC17) (OPC61) FOC Seg 2 (OPC14) FOC Seg 1 (OPC11) Mold Safe (CPC62) Record your FOC end-of-segment position setpoints for OPC11, 14, and 17 on Worksheet 8-E. We recorded 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.
Chapter 8 Load Initial Profile Setpoints Determine and Record Setpoints for the Ejector Profile (EPC) The following two pages contain Worksheet 8-F for the ejector profile (one worksheet for bit entries and one for word entries). The valve spanning procedure in chapter 9 requires specific values. We have already entered those values for you on the worksheet. You must determine the remaining setpoints based on your specific machine. Important: You enter setpoints for a pressure vs.
Chapter 8 Load Initial Profile Setpoints Worksheet 8 F Ejector Profile Block (EPC) 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.
Chapter 8 Load Initial Profile Setpoints Worksheet 8-F (continued) Ejector Profile Block (EPC) Enter Your Values Here Control Word EPC09 Pro Set 600 Addr.
Chapter 8 Load Initial Profile Setpoints Determine Bit Selections for Worksheet 8 F Block Identifier (EPC01) Bits 07-00 of this word identify it as the first word in a series used to define the ejector profile. Pro-set 600 sets these bits to 00011000. We recorded this value on Worksheet 8-F. Ejector Forward Dwell (EPC03) Forward dwell stops the ejector in its full advance position to let a robot remove a part when ejectors are fully extended.
Chapter 8 Load Initial Profile Setpoints Continue Stroking or Stop and Notify (EPC03) Set this bit only if you your QDC module does NOT have control of all valves required to change direction of ejector travel after each stroke. - BIT 12 controls QDC module reaction when it completes any advance or retract stroke during the ejector profile.
Chapter 8 Load Initial Profile Setpoints Enable/Disable Ejectors (EPC03) - BIT 09 controls whether the QDC module performs any profiled ejector movement. The QDC module: 0 = Executes profiled ejector movement 1 = Inhibits any profiled ejector movement We recorded zero to enable ejector movement on Worksheet 8-F.
Chapter 8 Load Initial Profile Setpoints Open loop or Closed loop Control (EPC04) - BITs 01 and 00 determine whether you use open- or closed-loop control of ejector profiles. In open loop, a valve position moves the cylinder without sensor feedback. In closed loop, sensor feedback controls the valve regulating the pressure or velocity. 0 = Closed loop 1 = Open loop We recorded a value of 1 for open-loop control on Worksheet 8-A. Important: All other bit selections in EPC04 should be zero.
Chapter 8 Load Initial Profile Setpoints End of segment Position Setpoints (EPC11, 14, 23, 29, 35, 38) Use these words to configure pressure vs. position or velocity vs. position ejector profiles. Record positions in inches or millimeters. Measure each position setpoint from the ejector minimum software travel limit. We recorded zero for EPC11, 14, 23, 29, 35, and 38 end-of-segment position setpoints on Worksheet 8-F.
Chapter 8 Load Initial Profile Setpoints Ejector Fully Retracted Position Setpoint (EPC60) This setpoint defines the ejector position when fully retracted. The QDC module uses this position as the end-of-full-retract position setpoint. If reached while the QDC module is executing a full retract ejector stroke, the QDC module immediately terminates the retract stroke and checks EPC03-B12 (continue or stop/notify) to determine its next action.
Chapter 8 Load Initial Profile Setpoints To determine this clamp position, jog the clamp open and measure the gap between the two mold halves. When the gap equals the ejector-fullyadvanced position setpoint (EPC 59), observe the position reported in SYS27 (N40:179). Record this observed position (N40:179) as your initial setpoint for EPC62. The valve spanning procedures in chapter 9 require this initial value. We help you select a correct final value for your application in chapter 10.
Chapter 8 Load Initial Profile Setpoints Record 1 for one ejector stroke. The valve spanning procedures in chapter 9 require this initial value. We help you select a correct final value for your application in chapter 10. For additional information, refer to the Plastic Molding Module Reference Manual (publication 1771-6.5.88) Enter and Download Your Worksheet Values After you determine initial values and record them on Worksheet 8-F, you are ready to proceed.
Chapter 9 Span Your Valves Chapter Objectives This chapter describes how to span your valves using set-output operation, and verify valve linearity by running simple open-loop profiles. The procedures in this chapter require the values and setpoints that you recorded on worksheets in chapters 7 and 8. ATTENTION: Do not attempt this chapter unless you completed all previous chapters. The results could be unpredictable machine motion, with possible personal injury and/or equipment damage.
Chapter 9 Span Your Valves For this Phase If Using Only this Control Then Skip the Section(s) Titled: clamp close velocity FCC, SCC, TCC Profiles - Pressure Valves pressure: and your valve configuration is the same for all four profiles FCC, SCC, TCC, LPC LPC Profile - Low Pressure Valve and FCC, SCC, TCC Profiles - Velocity Valve velocity INC Profile - Pressure Valve pressure INC Profile - Velocity Valve velocity FOC, SOC, TOC, OSC Profiles - Pressure Valve pressure FOC, SOC, TOC, OSC Profil
Chapter 9 Span Your Valves Profile Pressure Velocity Closed Loop Open Loop Not Used SOC TOC OSC EAC ERC If necessary, review system pressure, hydraulic circuits and corresponding control options presented in chapter 2 under the sections System Pressure and Example Hydraulic Circuits, to verify that your application is hydraulically correct. Referenced Worksheets The following table lists worksheets containing initial values from chapters 7 and 8 that you will use in this chapter.
Chapter 9 Span Your Valves LPC Profile Low Pressure Valve We recommend that you first span for optimum performance your low pressure valve used for the LPC profile.
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 SYS26 (N40:178). 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 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 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 in SYS26 (N40:178). 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. Copy the resultant set-output values from DYC09-12 (N40:121-124) into LPC33-36 (N43:209-212).
Chapter 9 Span Your Valves FCC, SCC, TCC Profiles Pressure Valve(s) Span your clamp close pressure valve(s) for optimum performance.
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 SYS26 (N40:178).
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 block, 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 FCC, SCC, TCC Profiles 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.
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 INC Profile Pressure Valve Span your injection pressure valve for optimum pressure performance. You do this in four parts: Confirm critical values Span your injection pressure valve(s) Test valve linearity with a pressure vs.
Chapter 9 Span Your Valves 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 pressure during injection 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 pressure profiles, th
Chapter 9 Span Your Valves INC Profile 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 procedure Span your injection flow valve in this section if the recorded valve spanning data from the manufacturer in velocity control limits INC45-48 (chapter 7) are adequate for your application.
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 the 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 PKC and HDC Profiles 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.
Chapter 9 Span Your Valves On Worksheet Confirm Your Configuration With These Words or Bits for Hold Pressure Pro Set Addr 8 C Pressure vs Time algorithm for Pack and Hold HPC03 B02 = B00 = 0 B38/288, 290 Logical bridge to stop and set outputs before: pre decompression plastication HPC03 B08 = 1 HPC03 B09 = 1 B38/296 B38/297 Open loop control HPC04 B03, B02, B01, B00 = 1 B38/304 307 Expert Response Compensation (ERC) = Off HPC04 B11, B10, B09, B08 = 1 B38/312 315 Pressure setpoints HPC10,
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 pressure valve, and observe actual pressure reported in SYS26 (N40:178). For a bi-directional valve with a spool offset: If this pressure is greater than zero, adjust the set-output value to the pressure valve to obtain zero pressure.
Chapter 9 Span Your Valves 12. Download your final values for PKC41-44 and HDC41-44 to the QDC module by downloading the PKC block. 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 PLC Profile 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.
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 personal injury and/or machine damage. ATTENTION: Be sure all machine guards and shields are in place before proceeding to guard against personal injury. 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 block, 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 FOC, SOC, TOC, OSC Profiles - Pressure Valve(s) Span your clamp open pressure valve(s) for optimum performance.
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 Clamp Open Pressure Valve(s) Span your clamp pressure valve for smooth operation at highest desired clamp open pressure.
Chapter 9 Span Your Valves Important: Enter a value corresponding to zero pressure into the word DYC09-12 for output 1, 2, 3, or 4 that drives the selected clamp pressure valve. ATTENTION: A value of 0 does not always correspond to zero pressure or flow. For example, a bi-directional valve requires a set-output value of 50% (5000) to obtain 0 PSI. Valve spools or amplifier electronics may also allow pressure or flow at 0 volts. 4. Enable set-output by transitioning DYC01-B08 (B34/392) to 1.
Chapter 9 Span Your Valves 9. Copy this observed maximum pressure from SYS26 (N40:178) into FOC42, SOC42, TOC42, and OSC42 (N43:338, 398, 458, and 518), the maximum pressure control limits. 10. While maintaining this maximum pressure, observe the actual set-output value in the SYS41-44 (N40:193-196) that corresponds to your selected clamp open pressure valve. Copy this value into FOC44, SOC44, TOC44, and OSC44 (N43:340, 400, 460, and 520), the selected pressure valve, output for maximum. 11.
Chapter 9 Span Your Valves If: And Your Selected Then change FOC44 Valve is: (N43:340) as follows: OPS13 was less than OPC13 Direct Acting Increase in 5% steps Reverse Acting Decrease in 5% steps Direct Acting Decrease in 5% steps Reverse Acting Increase in 5% steps OPS13 was more than OPC13 To do this: change FOC44, download the FOC block, and repeat steps 1-3. Do this as necessary.
Chapter 9 Span Your Valves Set Profile Pressure Alarms For clamp open profiles, set the maximum pressure alarm (FOC57, SOC57, TOC57, OSC57) to a pressure value that should: not be exceeded during the clamp profile not exceed the max pressure control limit FOC42, SOC42, TOC42, and OSC42 Entering a value of zero disables these alarms. Download new values to the QDC module.
Chapter 9 Span Your Valves FOC, SOC, TOC, OSC Profiles Velocity (Flow) Valve(s) Span your clamp open velocity (flow) valve(s) for optimum velocity performance.
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 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 Important: If downloading from your programming terminal, download FOC followed by OPC with download bits B21/16 and 20 (chapter 4). 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 9 Span Your Valves EAC, ERC Profiles Pressure Valve(s) Span your ejector pressure valve(s) for optimum pressure performance.
Chapter 9 Span Your Valves Span Your Ejector Pressure Valve(s) Span your ejector valve(s) for smooth operation at highest desired pressure.
Chapter 9 Span Your Valves 5. Observe the pressure reported in SYS26 (N40:178). For a bi-directional valve with a spool offset: If this pressure is greater than zero, adjust the selected valve set-output value to obtain zero pressure. Stop adjusting it when you observe the smallest pressure attainable. For a uni-directional valve with no response at low signal level: If this pressure is zero, adjust the selected valve set-output value until the observed pressure just exceeds zero.
Chapter 9 Span Your Valves 12. Disable set-output by transitioning DYC01-B08 (B34/392) to 0. 13. Download your changes in EAC to the QDC module. Important: If downloading from your programming terminal, download EAC followed by EPC with download bits B21/21 and 23 (chapter 4). Test Valve Linearity with an Ejector Pressure Profile 1. Jog your ejector to the fully retracted position. 2. Enable the ejector profile by setting DYC02-B14 (B34/414) to 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 any ejector profile end-of-range minimum and maximum signal levels for linear control of the ejector 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 EAC41, ERC41 EAC43,.
Chapter 9 Span Your Valves EAC, ERC Profiles Velocity (Flow) Valve(s) Span your ejector velocity (flow) valve(s) for optimum velocity performance. Do this in three parts: Confirm critical values Span your ejector velocity (flow) valve(s) Test valve linearity with an ejector velocity profile Important: Omit the procedure Span your ejector velocity (flow) valve(s) in this section if the recorded manufacturer’s valve spanning data for pressure control limits EAC45-48 and ERC45-48 are adequate.
Chapter 9 Span Your Valves Span Your Ejector Velocity Valve(s) Span your ejector valve(s) for smooth operation at highest desired velocity.
Chapter 9 Span Your Valves 3. Convert the min and max flows obtained from your flow curve to ejector cylinder velocities. This is done by: Ejector 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 5. Enable the ejector profile by setting DYC02-B14 (B34/414) to 1. The ejector should move through its advance and retract stroke. If no motion, verify that:: - none of your overtravel alarms are set. The QDC module inhibits ejector profiles if SYS07-B00 through SYS07-B05 are set - there are no programming error codes in SYS61 and SYS62 6.
Chapter 9 Span Your Valves What You Have Accomplished The valve spanning procedure you just completed has defined the: range of velocity available during any ejector profile end-of-range minimum and maximum signal levels for linear control of the ejector velocity valve in open-loop control.
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 Tuning Closed loop Control So far, you have run open-loop profiles with the QDC module’s PID and VelFF 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 Important: In most cases, adding a derivative term to pressure control algorithms makes it too sensitive and does not enhance loop stability. 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 and eject profiles for repeatable performance. First tune your proportional gain.
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 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 If: Then: Your scope trace for any given profile step never levels off (it is either rising or falling for the entire step) Increase the proportional term Your scope trace for any given profile step rises (or falls) quickly and then bounces" or chatters" around a voltage/current Decrease the proportional term Excessive hammering and vibration is observed in the cylinder's hydraulic lines Decrease the proportional term Important: Each time you change a gain constant, y
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 End-of-profile Set-output Values Pre- and Post-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 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. For injection velocity or pressure profiles, you must always program one final velocity or pressure setpoint without an associated end-of-position setpoint that the QDC module uses until it reaches transition (for injection) or 100% shot size (for plastication).
Chapter 10 Tune Your Machine Cushion, Shot Size, and Transition Setpoints Shot Size is the amount of molten plastic injected into the mold. Cushion is the amount of molten plastic that remains in the barrel after injection.The sum of shot size (PPC61) plus cushion (PPC62) tells the QDC module where to terminate the Plastication profile. During injection, the QDC module does NOT terminate the shot at cushion, but continues injecting until one of the three injection transition conditions occurs.
Chapter 10 Tune Your Machine Ram (Screw) Position for Transition (IPC61) This position setpoint (measured from mold end) determines where injection ends and pack (or hold) begins (figure 10.3). Enter a position value equal to or slightly greater than the top-of-cushion position, depending on whether your part requires additional plastic compressed into the mold during pack and hold.
Chapter 10 Tune Your Machine Unselected Valve Set output Values We presented guidelines to assist you in determining unselected valve set-output values (words 09 through 12 in configuration command blocks) in chapter 7 prior to spanning your machine valves in chapter 9. The value in these words is the signal level sent to all outputs not selected for control by the QDC module’s algorithm during a profile.
Chapter 10 Tune Your Machine Logical Bridges In chapter 8, you configured your hold and plastication profiles to stop and set outputs for no flow or pressure at completion.
Chapter 10 Tune Your Machine After the QDC module sets them, they remain set until the QDC module is commanded to start another movement or profile, or until the stop command is asserted Pre and Post decompression Pullback (for pre decompression PRC05) (for post decompression PSC05) Pre-decompression separates plastic solidifying in the sprue from the molten cushion remaining in the barrel. The QDC module applies predecompression pullback to the ram (screw) after hold, before plastication.
Chapter 10 Tune Your Machine Figure 10.1 Example Injection, Pack, and Hold Profiles with 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 Profile Watchdog Timer and Profile Offsets Profile Watchdog Timer (PLC08) Set your plastication profile watchdog timer preset after your machine is running repeatable, quality parts. Set it just longer than the repetitive duration of the profile to warn that a process problem may be developing. For example, warn of a low feed level from the hopper.
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 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 and Ejector Operations In this section, we discuss the usage and effect of the following items as they apply to clamp operation: Control Objectives for Clamp and Ejector Operations Profile Requirements Logical Bridges End-of-profile (-stroke) Set-output Values Unselected Valve Set-output Values Acceleration and Deceleration Ramp Rates Pressure Alarm Setpoints Watchdog Timer Expert Response Compensation We assume you are familiar with conventions
Chapter 10 Tune Your Machine High speed ejector operation while meeting the above objectives. Molders want to achieve minimal machine cycle time while insuring part quality, achieving repeatable ejector advance positioning, and positive part ejection. Profile Requirements A profile is a series of position and pressure (or velocity) setpoints which uniquely define a phase of clamp or ejector motion. The complexity of the profile depends on your mold, clamp, and ejector mechanism.
Chapter 10 Tune Your Machine End-of-segment Position Setpoints for Clamp and Ejector These setpoints depend on the mold, clamp, and ejector configurations of your molding machine. In general, you are not required to enter any end-of-segment position setpoints for the clamp or ejector.
Chapter 10 Tune Your Machine Important: Fast segment velocities or high segment pressures may cause the clamp to overshoot the start low pressure close or start open-slow position. If you increase a velocity or pressure setpoint in a fast clamp close (or open) movement, we recommend that you increase the distance to the start LPC position (or decrease the distance to the open-slow position) at least temporarily to assure a successful low pressure close (or open slow) movement and mold closure (or opening).
Chapter 10 Tune Your Machine Figure 10.1 Example Setpoints for Mold Safe (CPC62) and Start Protection Zone (CPC61) zero Clamp Motion LPC Protection Zone (CPC61) (OPC62) Fully Open (CPC62) Mold Safe By setting this clamp position as stated, you minimize the possibility of mold damage that could result from changing clamp-close velocity, pressure, or position setpoints.
Chapter 10 Tune Your Machine By setting this clamp position as stated, you guard against the possibility of damaging your clamp mechanism that could result from changing clamp-open velocity, pressure, or position setpoints. Important: Re-adjust this value each time you install a new mold.
Chapter 10 Tune Your Machine Important: If you change tooling or set-up which results in changing either of these two distances, you must recalculate clamp position EPC62. Clamp Position for Start of Ejector Profile (EPC61) If you select to start the ejector profile on position (EPC03-B08 = 0) rather than on command (EPC03-B08 = 1), the QDC module immediately begins executing the ejector profile once the clamp reaches this position during any clamp open profile.
Chapter 10 Tune Your Machine Bridging machine phases has benefits such as: reduced cycle time smoother control less chance of hydraulic pressure transients End of profile ( stroke) Set output Values If required by your application, you may configure the QDC module to stop at the completion of any profile (or stoke) and provide a constant signal to each of its four outputs while awaiting further commands from your PLC-5 processor.
Chapter 10 Tune Your Machine When configuring end-of-profile (-stroke) set-output values, remember: The QDC module ignores these values on all profiles (or strokes) that are logically bridged to the next profile or movement After the QDC module sets them, they remain in set until the QDC module is commanded to start another movement or profile, or until the stop command is asserted Unselected Valve Set output Values Refer to this title in Injection Tuning Considerations for Producing Parts.
Chapter 10 Tune Your Machine Figure 10.3 Example Clamp Close Profiles with Accel/Decel Ramps 2nd Close Profile Decel. Ramp Accel. Ramp 1st Close Profile Decel. Ramp Accel. Ramp 3rd Close Profile Accel. Ramp Decel. 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 or ejector positioning. Without ERC, the QDC module will still force the clamp or ejector to overshoot by a constant repeatable amount (relative to cylinder speed and QDC module’s 2 ms scan time). Do NOT use ERC when: spanning your valves using velocity feedforward gain using profile ramp rates to smooth the operation.
Chapter 11 Troubleshoot with LEDs Chapter Objectives This chapter tells you how to troubleshoot your QDC module using LED indicators. 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 The LEDs are located on the front panel of the module (Figure 11.1). 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 4 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 4 B Selecting Input Ranges for your Sensors Control Word MCC03 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 4 D Determining Initial Sensor configuration Values Enter Your Initial Values Here Input 1 2 3 4 1 Line Control Word Pro Set 600 Addr.
Appendix A Blank Worksheets Worksheet 4 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 4 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 A Ram (screw) and Clamp Jog Configuration Values Enter Your Initial Values Here Control Block 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 Clamp Close Configuration Blocks (FCC, SCC, and TCC) Word FCC01 B15 thru 00 15 14 13 12 11 10 09 08 07 06 05 04 03 02 01 00 Bit Address 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 Word SCC01 B15 thru 00 15 14 13 12 11 10 09 08 07 06 05 04 03 02 01 00 Bit Address B37/Bit 79 78 77 76 75 74 73 72 71 70 69 68 67 66 65 64 Value 0 0 0
Appendix A Blank Worksheets Worksheet 7 A (continued) Clamp Close Configuration Blocks (FCC, SCC, and TCC) Enter Your Values Here For these Parameters (footnote = units) Word FCC N43: FCC Value Minimum ERC Percentage - Velocity 8 05 1 1000 Minimum ERC Percentage - Pressure 8 SCC N43: SCC Value TCC N43: TCC Value 61 1000 121 1000 1000 06 2 1000 62 1000 122 Profile Watchdog Timer Preset 1 08 4 0 64 0 124 Output #1 Selected Valve % Output During Profile 4 09 5 * 65 * 125 *
Appendix A Blank Worksheets Worksheet 7 B Low Pressure Close Configuration Block (LPC) Word LPC01 Bits 15 thru 00 15 14 13 12 11 10 09 08 07 06 05 04 03 02 01 00 Bit Addresses B37/Bxxx 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 Block Identifier Word LPC02 Bits 15 thru 00 15 14 13 12 11 10 09 08 07 06 05 04 03 02 01 00 Bit Addresses B37/Bxxx 223 222 221 220 219 218 217 216
Appendix A Blank Worksheets Worksheet 7 B (continued) Low Pressure Close Configuration Block (LPC) Enter Your Values Here For these Parameters (footnote = units) Word Tonnage Watchdog Timer Preset 1 07 183 Profile Watchdog Timer Preset 1 LPC N43: LPC Value 0 08 184 #1 Selected Valve Set Output During Profile 4 09 185 * #2 Selected Valve Set Output During Profile 4 10 186 * 4 11 187 * #4 Selected Valve Set Output During Profile 4 12 188 * 5 17 193 0 Output #2 Acceleration Ramp
Appendix A Blank Worksheets Worksheet 7 C 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 C (continued) Injection Configuration Block (INC) Enter Your Values Here Control Word Pro Set 600 Addr.
Appendix A Blank Worksheets Worksheet 7 D 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 D (continued) Pack Configuration Block (PKC) Enter Your Values Here Control Word Pro Set 600 Addr.
Appendix A Blank Worksheets Worksheet 7 E 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 E (continued) Hold Configuration Block (HDC) Enter Your Values Here Control Word Pro Set 600 Addr.
Appendix A Blank Worksheets Worksheet 7 F 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 F (continued) Plastication Configuration Block (PLC) Enter Your Values Here Control Word Pro Set 600 Addr.
Appendix A Blank Worksheets Worksheet 4 G Clamp Open Configuration Blocks (FOC, SOC, TOC, and OSC) Word FOC01 B15 thru 00 15 14 13 12 11 10 09 08 07 06 05 04 03 02 01 00 Bit Address B37/Bit 335 334 333 332 331 330 329 328 327 326 325 324 323 322 321 320 Value 0 0 0 0 0 0 0 0 0 0 0 1 0 0 0 1 Word SOC01 B15 thru 00 15 14 13 12 11 10 09 08 07 06 05 04 03 02 01 00 Bit Address B37/Bit 399 398 397 396 395 394 393 392 391 390 389 388
Appendix A Blank Worksheets Worksheet 7 G (continued) Clamp Open Configuration Blocks (FOC, SOC, TOC, and OSC) Enter Your Values Here For these Parameters (footnote = units) Word FOC N43 Minimum ERC Percentage - Velocity 8 05 301 Minimum ERC Percentage - Pressure 8 06 302 1 Profile Watchdog Timer Preset 08 304 #1 Selected Valve Set Output During Profile 4 09 305 #2 Selected Valve Set Output During Profile 4 10 306 4 #3 Selected Valve Set Output During Profile 11 307 #4 Selected Valve Set Output During Prof
Appendix A Blank Worksheets Worksheet 7 H Ejector Configuration Blocks (EAC and ERC) 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 Control Word ERC01 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) Ejector Configuration Blocks (EAC and ERC) Enter Your Values Here Description Word 05 EAC @ N45: N45:1 EAC Value 1000 ERC @ N45: N45:61 ERC Value 1000 Minimum ERC Percentage Pressure 8 Profile Watchdog Timer Preset 1 Output #1 Set Output Value during Advance 4 Output #2 Set Output Value during Advance 4 Output #3 Set Output Value during Advance 4 Output #4 Set Output Value during Advance 4 Output #1 Acceleration Ramp Rate during Advance 5 Output
Appendix A Blank Worksheets Worksheet 8 A Clamp Close Profile Command 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 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 Command Block (CPC) Control Word Pro Set 600 Addr.
Appendix A Blank Worksheets Worksheet 8 B Injection Profile Command 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 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 Command 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 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 Command Block (HPC) Enter Your Values Here Control Word Pro Set 600 Addr.
Appendix A Blank Worksheets Worksheet 8 D Plastication Profile Command 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 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 Command Block (PPC) Enter Your Values Here Control Word Pro Set 600 Addr.
Appendix A Blank Worksheets Worksheet 8 E Clamp Open Profile Command 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 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 Command Block (OPC) Control Word Pro Set 600 Addr.
Index A alarm, pressure setpoint for clamp close profile, 9 14 clamp LPC profle, 9 9 clamp open profiles, 9 47 ejector profile, 9 57 inject-mode profiles, 10 19 injection profile, 9 24 pack and hold profile, 9 36 plastication profile, 9 41 profile vs absolute, 10 33 alarm, profile pressure, 7 30 alarm, system pressure, 3 16 algorithm select for profile, 8 6, 8 13, 8 27, 8 35, 8 44 select gain constants, 7 21 audience, P 2 Auxiliary analog inputs, 2 1 B determine initial values, 7 19 overview of, 4 3 cont
I–2 Index inject-mode, 10 11 ERC clamp and eject mode, 10 34 initial values, 7 22 inject-mode, 10 22 select on/off, 8 6, 8 14, 8 21, 8 28, 8 35, 8 44 error correction for, data entry in data blocks, 4 6 MCC block, 3 6 F flash prevention, 1 4 G gain constants, 7 21 for profiles, 7 29 P and VelFF, 10 6 PID for pressure control, 10 3 glossary, P 2, 1 20 grounding, QDC module, 2 9 H hold phase, overview, 1 7 I I/O auxiliary analog inputs, 2 1 record ranges, 2 1 I/O config procedures (optional) digital inp
Index logical bridges clamp and ejector, 10 29 inject mode, 10 16 select, 8 21, 8 27 selection of, 8 5, 8 34, 8 44 loop control closed loop, 10 2 open loop, 10 2 select open/closed, 8 6, 8 14, 8 22, 8 28, 8 35, 8 45 low pressure close, overview, 1 10 LPC start position, 10 26 M machine cycle, clamp, 1 9 machine cycle, inject, 1 1 machine interlocks, 2 11 mold open dwell timer preset, 8 38 position setpoint, 8 36 mold protection diagram, 8 8 LPC start position, 8 7 selection of, 8 5 mold safe diagram, 8 8,
I–4 Index profiles, initial values clamp close, 8 2 clamp open, 8 31 ejector, 8 39 injection, 8 10 pack and hold, 8 18 plastication, 8 24 publications, related, P 5 pullback, decompression, 10 17 Q QDC module digital input filter, 3 17 ground, 2 9 I/O ranges, 3 2 I/O terminal designations, 2 8 install, 2 6 optional configurations, 3 14 rack address, 2 5 select parameters, 3 2 sensor config values, initial, 3 4 sensor configuration, final, 3 8 set jumper plugs, 2 2 troubleshoot, 11 1 wire I/O, 2 7 QH modu
Index clamp open velocity, 9 48 ejector pressure, 9 53 ejector velocity, 9 58 injection pressure, 9 20 injection velocity, 9 25 pack and hold pressure, 9 31 plastication backpressure, 9 37 Valve spanning procedures, for, clamp low pressure close, 9 4 velocity setpoints clamp, 10 24 CPC, 8 7 EPC, 8 45 injection, 10 10 IPC, 8 14 OPC, 8 36 velocity units, selection of, 8 5, 8 13, 8 34, 8 42 W watchdog timer, 10 19 for profiles, 7 30, 10 34 wiring, QDC module I/O, 2 7 word numbering, P 4 worksheets configurat
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