Manual

ManualsBrandsRockwell Automation ManualsEquipment1771-QI,D17716.5.126 PLASTIC MOLD.MODULE

Allen-Bradley

Reference

Manual

Plastic Molding

Module

(Cat. No. 1771-QI)

Summary of content (153 pages)

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Allen-Bradley Plastic Molding Module (Cat. No.
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Important User Information Solid state equipment has operational characteristics differing from those of electromechanical equipment. “Safety Guidelines for the Application, Installation and Maintenance of Solid State Controls” (Publication SGI-1.1) describes some important differences between solid state equipment and hard-wired electromechanical devices.
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Preface Preface Read this preface to familiarize yourself with the manual. This preface covers the following topics: • the purpose of this manual • Related Publications • Terms • Allen-Bradley support Purpose of this Manual Related Publications This manual provides reference information for the 1771-QI Plastic Molding Module. It provides lists of words, bits, addresses, and error codes needed for all applications. It also describes procedures you use to calibrate the module.
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P–2 Preface Terms Allen-Bradley Support The following terms are specific to this product or commonly used: Term: Definition: BTR BTW Block-transfer Read Block-transfer Write Command Block (MCC) Downloaded from the PLC data table to the QI module to initiate or change machine operation. It must accompany every configuration or profile block transferred to the QI module. Configuration Blocks Data blocks containing machine-specific setpoints.
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Table of Contents Abbreviated Command and Status Block Chapter 1 Command Word/Bit Descriptions Chapter 2 Chapter Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DYC – Dynamic Command Block . . . . . . . . . . . . . . . . . . . . . . . . . HDC – Hold Configuration Block . . . . . . . . . . . . . . . . . . . . . . . . . HPC – Pack/Hold Profile Block . . . . . . . . . . . . . . . . . . . . . . . . . . INC – Injection Configuration Block . . . . . . . . . . . . . . . . . .
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toc–ii Table of Contents HDC – Hold Configuration Block . . . . . . . . . . . . . . . . . . . . . . . . . Bit-mapped Control Words . . . . . . . . . . . . . . . . . . . . . . . . . . Expert Response Compensation (ERC) Percentage . . . . . . . . Unselected Valve Set-output Values . . . . . . . . . . . . . . . . . . . Output Ramp Rates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . End of Profile Set-output Values . . . . . . . . . . . . . . . . . . . . . .
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Table of Contents MCC – Module Configuration Command Block . . . . . . . . . . . . . . . Bit-mapped Control Words . . . . . . . . . . . . . . . . . . . . . . . . . . Ram (Screw) Position Transducer Configuration . . . . . . . . . . . Ram (Screw) Pressure Transducer Configuration . . . . . . . . . . Ram (Screw) Position Transducer Configuration (other injector) Screw RPM Transducer Configuration . . . . . . . . . . . . . . . . . . Cavity Pressure Transducer Configuration . . . . . . . . . . . . . . .
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toc–iv Table of Contents PSC – Post-decompression Configuration Block . . . . . . . . . . . . . . Bit-mapped Control Words . . . . . . . . . . . . . . . . . . . . . . . . . . Movement Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Watchdog Timer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Movement Set-output Values . . . . . . . . . . . . . . . . . . . . . . . . Output Ramp Rates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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Table of Contents PPS – Plastication Profile Status Block . . . . . . . . . . . . . . . . . . . . . Bit-mapped Status Words . . . . . . . . . . . . . . . . . . . . . . . . . . . Plastication Profile Actuals . . . . . . . . . . . . . . . . . . . . . . . . . . Plastication Maximum Pressure . . . . . . . . . . . . . . . . . . . . . . Post-decompression Maximum Pressure . . . . . . . . . . . . . . . . Execution Times . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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toc–vi Table of Contents Sequencing Co-injection Chapter 5 Chapter Objectives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A, Only or B, Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A and B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A then B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Standard Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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Chapter 1 Abbreviated Command and Status Blocks Chapter Contents Use this chapter as a quick reference to word descriptions and Pro-Set addresses of all data blocks used by the QI module. For complete word and bit descriptions of these data blocks, see Chapter 2 (command) and Chapter 3 (status). The following tables list command and status blocks in this chapter by page number. Blocks are presented in abbreviated format.
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1–2 Abbreviated Command and Status Blocks DYC – Dynamic Command Block Word Pro-Set Address Bit-mapped Control Words DYC01 B34:24 DYC02 B34:25 DYC03 B34:26 DYC04 B34:27 DYC05-06 B34:28-29 DYC07 B34:30 DYC08 B34:31 Direct Set-output Values DYC09 N40:121 DYC10 N40:122 DYC11 N40:123 DYC12 N40:124 DYC131-16 N40:125-128 Acceleration Ramp Rates DYC17 N40:129 DYC18 N40:130 DYC19 N40:131 DYC20 N40:132 DYC21-24 N40:133-136 Deceleration Ramp Rates DYC25 N40:137 DYC26 N40:138 DYC27 N40:139 DYC28 N40:140 DYC29-32 N
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Abbreviated Command and Status Blocks Acceleration Ramp Rates HDC17 N44:193 HDC18 N44:194 HDC19 N44:195 HDC20 N44:196 HDC21-24 N44:197-200 Deceleration Ramp Rates HDC25 N44:201 HDC26 N44:202 HDC27 N44:203 HDC28 N44:204 HDC29-32 N44:205-208 End of Profile Set-output Values HDC33 N44:209 HDC34 N44:210 HDC35 N44:211 HDC36 N44:212 HDC37-40 N44:213-216 Ram (Screw) Pressure Control Limits HDC41 N44:217 HDC42 N44:218 HDC43 N44:219 HDC44 N44:220 Cavity Pressure Control Limits HDC45 N44:221 HDC46 N44:222 HDC47 N44:2
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1–4 Abbreviated Command and Status Blocks Setpoints for Pack Profile HPC05-08 N44:241-244 HPC09 N44:245 HPC10 N44:246 HPC11 N44:247 HPC12 N44:248 HPC13 N44:249 HPC14 N44:250 HPC15 N44:251 HPC16 N44:252 HPC17 N44:253 HPC18 N44:254 HPC19 N44:255 HPC20 N44:256 HPC21 N44:257 HPC22 N44:258 HPC23 N44:259 Pack Profile Offsets HPC24 N44:260 HPC25 N44:261 Setpoints for Hold Profile HPC26 N44:262 HPC27 N44:263 HPC28 N44:264 HPC29 N44:265 HPC30 N44:266 HPC31 N44:267 HPC32 N44:268 HPC33 N44:269 HPC34 N44:270 HPC35 N44
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Abbreviated Command and Status Blocks 1–5 Expert Response Compensation Percentage INC05 N44:1 ERC % minimum velocity INC06 N44:2 ERC % minimum pressure INC07, 08 N44:3, 4 RFU Set-output Values for Unselected Valves (During Profile) INC09 N44:5 Output #1 INC10 N44:6 Output #2 INC11 N44:7 Output #3 INC12 N44:8 Output #4 INC13-16 N44:9-12 RFU Acceleration Ramp Rates INC17 N44:13 Output #1 INC18 N44:14 Output #2 INC19 N44:15 Output #3 INC20 N44:16 Output #4 INC21-24 N44:17-20 RFU Deceleration Ramp Rates INC25
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1–6 Abbreviated Command and Status Blocks Set-outputs During Suspended Injection INC:61 N44:57 INC:62 N44:58 INC:63 N44:59 INC:64 N44:60 IPC – Injection Profile Block Publication 1771-6.5.
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Abbreviated Command and Status Blocks 1–7 Setpoints for Injection Profile (continued) IPC41 N44:97 Segment 9 velocity IPC42 N44:98 Segment 9 pressure IPC43 N44:99 End of Segment 9 position IPC44 N44:100 Segment 9 time IPC45 N44:101 Segment 10 velocity IPC46 N44:102 Segment 10 pressure IPC47 N44:103 End of Segment 10 position IPC48 N44:104 Segment 10 time IPC49 N44:105 Segment 11 velocity IPC50 N44:106 Segment 11 pressure Profile Offsets IPC51 N44:107 Velocity Profile IPC52 N44:108 Pressure Profile IPC53 N
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1–8 Abbreviated Command and Status Blocks Ram(Screw) Forward-jog Set-output Values JGC17 N40:73 Output #1 JGC18 N40:74 Output #2 JGC19 N40:75 Output #3 JGC20 N40:76 Output #4 JGC21-24 N40:77-80 RFU Ram(Screw) Reverse-jog Set-output Values JGC25 N40:81 Output #1 JGC26 N40:82 Output #2 JGC27 N40:83 Output #3 JGC28 N40:84 Output #4 JGC29-64 N40:85-120 RFU MCC – Module Configuration Command Block Word Pro-Set Address Description Bit-mapped Control Words MCC01 B34:32 MCC02 B34:33 MCC03 B34:34 MCC04 B34:35
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Abbreviated Command and Status Blocks 1–9 Cavity Pressure Sensor Configuration MCC57 N40:53 Minimum pressure MCC58 N40:54 Maximum pressure MCC59 N40:55 Analog signal @ min pressure MCC60 N40:56 Analog signal @ max pressure MCC61 N40:57 High pressure alarm setpoint MCC62 N40:58 Time delay for pressure alarms MCC63 N40:59 Switchover time delay, input 3: cavity pressure/RPM MCC64 N40:60 Number of input samples for loss-of-sensor alarms PKC – Pack Configuration Block Word Pro-Set Address Description Bit-map
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1–10 Abbreviated Command and Status Blocks Profile Tuning Constants PKC49 N44:165 PKC50 N44:166 PKC51 N44:167 PKC52 N44:168 PKC53 N44:169 PKC54 N44:170 Setpoints for Profile Pressure Alarms PKC55-56 N44:171-172 PKC57 N44:173 PKC58 N44:174 PKC59-64 N44:175-180 PLC – Plastication Configuration Block Publication 1771-6.5.
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Abbreviated Command and Status Blocks Pressure Control Limits PLC41 N44:397 PLC42 N44:398 PLC43 N44:399 PLC44 N44:400 RPM Control Limits PLC45 N44:401 PLC46 N44:402 PLC47 N44:403 PLC48 N44:404 Profile Tuning Constants PLC49 N44:405 PLC50 N44:406 PLC51 N44:407 PLC52 N44:408 PLC53 N44:409 PLC54 N44:410 PLC55-56 N44:411-412 Setpoint for Profile Pressure Alarm PLC57 N44:413 PLC58-64 N44:414-420 PPC – Plastication Profile Block Word Pro-Set Address Bit-mapped Control Words PPC01 B38:28 PPC02 B38:29 PPC03 B38:3
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1–12 Abbreviated Command and Status Blocks Setpoints for Plastication Profile (continued) PPC29 N044:445 Segment 6 RPM PPC30 N44:446 Segment 6 pressure PPC31 N44:447 End of Segment 6 position PPC32 N44:448 Segment 6 time PPC33 N44:449 Segment 7 RPM PPC34 N44:450 Segment 7 pressure PPC35 N44:451 End of Segment 7 position PPC36 N44:452 Segment 7 time PPC37 N44:453 Segment 8 RPM PPC38 N44:454 Segment 8 pressure PPC39 N44:455 End of Segment 8 position PPC40 N44:456 Segment 8 time PPC41 N44:457 Segment 9 RPM PP
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Abbreviated Command and Status Blocks Acceleration Ramp Rates PRC17 N44:313 PRC18 N44:314 PRC19 N44:315 PRC20 N44:316 Deceleration Ramp Rates PRC25 N44:321 PRC26 N44:322 PRC27 N44:323 PRC28 N44:324 PRC29-32 N44:325-328 End of Movement Set-output Values PRC33 N44:329 PRC34 N44:330 PRC35 N44:331 PRC36 N44:332 PRC37-56 N44:333-352 Setpoint for Movement Pressure Alarm PRC57 N44:353 PRC58-64 N44:354-360 PSC – Post-decompression Configuration Block Word Pro-Set Address Bit-mapped Control Words PSC01 B38:32 PSC0
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1–14 Abbreviated Command and Status Blocks End of Movement Set-output Values PSC33 N44:509 PSC34 N44:510 PSC35 N44:511 PSC36 N44:512 PSC37-56 N44:513-532 Setpoint for Movement Pressure Alarm PSC57 N44:533 PSC58-64 N44:534-40 PTC – Process Trace Configuration Block RLC – Inject ERC Values Block Publication 1771-6.5.
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Abbreviated Command and Status Blocks ERC Values for Hold Profile RLC25 N44:561 RLC26 N44:562 RLC27 N44:563 RLC28 N44:564 RLC29 N44:565 ERC Values for Plastication Profile RLC30 N44:566 RLC31 N44:567 RLC32 N44:568 RLC33 N44:569 RLC34 N44:570 RLC35 N44:571 RLC36 N44:572 RLC37 N44:573 RLC38 N44:574 RLC39 N44:575 RLC40 N44:576 RLC41-64 N44:577-600 HPS – Pack/Hold Profile Status Block Word Pro-Set Address Bit-mapped Status Words HPS01 B34:0 HPS01 B34:0 HPS02 B34:1 HPS03 B34:2 HPS04 B34:3 HPS05-06 B38:44-45 HP
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1–16 Abbreviated Command and Status Blocks Actuals from Hold Profile HPS26 N44:674 Segment 1 cavity pressure HPS27 N44:675 Segment 1 ram (screw) pressure HPS28 N44:676 End of Segment 1 position HPS29 N44:677 Segment 2 cavity pressure HPS30 N44:678 Segment 2 ram (screw) pressure HPS31 N44:679 End of Segment 2 position HPS32 N44:680 Segment 3 cavity pressure HPS33 N44:681 Segment 3 ram (screw) pressure HPS34 N44:682 End of Segment 3 position HPS35 N44:6834 Segment 4 cavity pressure HPS36 N44:684 Segment 4 ra
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Abbreviated Command and Status Blocks Injection Profile Actuals IPS09 N44:601 IPS10 N44:602 IPS11 N44:603 IPS12 N44:604 IPS13 N44:605 IPS14 N44:606 IPS15 N44:607 IPS16 N44:608 IPS17 N44:609 IPS18 N44:610 IPS19 N44:611 IPS20 N44:612 IPS21 N44:613 IPS22 N44:614 IPS23 N44:615 IPS24 N44:616 IPS25 N44:617 IPS26 N44:618 IPS27 N44:619 IPS28 N44:620 IPS29 N44:621 IPS30 N44:622 IPS31 N44:623 IPS32 N44:624 IPS33 N44:625 IPS34 N44:626 IPS35 N44:627 IPS36 N44:628 IPS37 N44:629 IPS38 N44:630 IPS39 N44:631 IPS40 N44:632
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1–18 Abbreviated Command and Status Blocks Transition (Transfer) Actuals IPS61 N44:653 IPS62 N44:654 IPS63 N44:655 IPS64 N44:656 PPS – Plastication Profile Status Block Publication 1771-6.5.
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Abbreviated Command and Status Blocks 1–19 Plastication Profile Actuals (continued) PPS41 N44:745 Segment 9 RPM PPS42 N44:746 Segment 9 pressure PPS43 N44:747 Segment 9 execution time PPS44 N44:748 End of Segment 9 position PPS45 N44:749 Segment 10 RPM PPS46 N44:750 Segment 10 pressure PPS47 N44:751 Segment 10 execution time PPS48 N44:752 End of Segment 10 position PPS49 N44:753 Segment 11 RPM PPS50 N44:754 Segment 11 pressure PPS51 N44:755 Segment 11 execution time PPS52 N44:756 RFU Maximum Plastication
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1–20 Abbreviated Command and Status Blocks Starting Data Points from Injection Profile (continued) PTS20 N132:71 Inject segment 6 start data point PTS21 N132:72 Inject segment 7 start data point PTS22 N132:73 Inject segment 8 start data point PTS23 N132:74 Inject segment 9 start data point PTS24 N132:75 Inject segment 10 start data point PTS25 N132:76 Inject segment 11 start data point Starting Data Points from Pack/Hold Profiles PTS26 N132:77 Pack segment 1 start data point PTS27 N132:78 Pack segment 2 st
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Abbreviated Command and Status Blocks 1–21 ERC Actuals from Injection Profile (continued) RLS14 N44:550 Injection segment 6 RLS15 N44:551 Injection segment 7 RLS16 N44:552 Injection segment 8 RLS17 N44:553 Injection segment 9 RLS18 N44:554 Injection segment 10 RLS19 N44:555 Injection segment 11 ERC Actuals from Pack Profile RLS20 N44:556 Pack segment 1 RLS21 N44:557 Pack segment 2 RLS22 N44:558 Pack segment 3 RLS23 N44:559 Pack segment 4 RLS24 N44:560 Pack segment 5 ERC Actuals from Hold Profile RLS25 N44
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1–22 Abbreviated Command and Status Blocks Bit-Mapped Status Words (continued) SYS23*_0** B34:22* B21:18** SYS24*_0** B34:23* B21:19** *Pro-set 600 **Pro-Set 700 Status of trace data collection in progress Status of process trace data collected For example, MCC05_0 is correct for Pro-Set 700.
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2 Chapter Command Word/Bit Descriptions Alphabetical List of Command Blocks and Block ID Codes Command blocks provide the parameters that control machine operation. Command blocks are transferred from the PLC processor to the QI module by block transfer write (BTW) instructions in software ladder logic.
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2–2 Command Word/Bit Descriptions Bit-mapped Words The first several words in any data block are bit-mapped. For bit-mapped command words, you must set/reset or latch/ unlatch command bits to set QI module operating configurations. Stored-value Words These words establish operating conditions for the QI module, such as: • output values for certain conditions • minimum and maximum pressures, positions, and velocities • alarm setpoints Reserved Words (RFU) These words are Reserved for Future Use.
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Command Word/Bit Descriptions Data Blocks for System Control 2–3 Command Blocks for system level control are: Block Description MCC Module Configuration Command Block JGC Jog Configuration Command Block DYC Dynamic Command Block You must establish the QI module’s I/O configuration before it can decide which command blocks to support.
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2–4 Command Word/Bit Descriptions DYC – Dynamic Command Block The module will not accept or process the Dynamic Command Block unless it has a valid MCC installed. Bit-mapped Control Words Word Bit DYC01 Description Block ID = 00011001 (low byte) Action Execution Commands in high byte Bits DYC01-B08 - DYC01-B15 and all 16 bits in DYC02 are the 24 action execution commands to control the module.
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Command Word/Bit Descriptions 2–5 DYC Word Bit DYC02 Description Action Execution Commands Bits DYC01-B08 - DYC01-B15 and all 16 bits in DYC02 are the 24 action execution commands to control the module. Because the module cannot respond to more than one action execution command at a time, it ceases all action execution and sets its outputs to zero when it decodes a valid Dynamic Command Block with more than one of these SET.
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2–6 Word DYC02 Command Word/Bit Descriptions Bit B07 Description = 0 Normal = 1 Execute Pre-decompression Movement A false-to-true transition of this bit forces the module to do one of the following, attempted in the order listed.
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Command Word/Bit Descriptions 2–7 DYC Word Bit Description DYC02 B15 Stop Command = 0 Outputs Enabled = 1 Outputs Disabled When the module decodes a valid DYC having this bit SET, it halts any ongoing profile or jog movement and set its outputs to zero. The module will not respond to any new jog or profile execution commands as long as this bit remains SET.
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2–8 Command Word/Bit Descriptions DYC04 Y 4 Status Request Commands Bits DYC04-B00 - DYC04-B07 are the eight command bits available to request the Status Blocks that the module returns with the next BTR to the PLC processor. The module does not respond to any bit associated with an unsupported status block (based on Module I/O configuration).
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Command Word/Bit Descriptions 2–9 DYC Word Bit DYC07 Description Process Trace Commands B00 Process trace data collection inhibited (examined at beginning of injection phase) B01 Return injection position trace data in next PTS block B02 Return trace #1 data in next PTS block B03 Return trace #2 data in next PTS block B04 Return trace #3 data in next PTS block B05 Return trace #4 data in next PTS block B06-14 RFU B15 DYC08 Return phase/segment start information in next PTS block Process T
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2–10 Command Word/Bit Descriptions Word DYC61 Description Programming Error Return Request [29] When the module has a valid MCC and DYC installed, it responds to any non-zero command block ID to the lower byte of this word by returning the identical command block ID in SYS61. In SYS62, it also returns the existing programming error code associated with the command block.
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Command Word/Bit Descriptions 2–11 HDC Unselected Valve Set-output Values When the module starts the Hold Profile, it: • ignores the unselected value of the selected output • uses ramp rates HDC17-20 and HDC25-28 to ramp unselected outputs • sets its unselected outputs to the values listed below Word Description HDC09 Output #1 Set-output Value during Profile [19] HDC10 Output #2 Set-output Value during Profile [19] HDC11 Output #3 Set-output Value during Profile [19] HDC12 Output #4 Set-output
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2–12 Command Word/Bit Descriptions Ram (Screw) Pressure Control Limits Word Description HDC41 Ram (Screw) Pressure Minimum Control Limit [01] Minimum controllable ram (screw) pressure attainable during any Ram Press/ Time Hold Profile. The module expects this ram (screw) pressure when setting its selected ram (screw) pressure valve to the %-output in HDC43.
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Command Word/Bit Descriptions HPC HPC – Pack/Hold Profile Block Word Bit-mapped Control Words Bit Description HPC01 Block ID = 00001100 (Low byte). High byte reserved for the module. Do not use.
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2–14 Command Word/Bit Descriptions Bit Word HPC04 B04-07 Description RFU ERC Enabled/Disabled Selection B08 B09 B10 B11 B12-15 HPC05 - 08 = 0 = 1 = 0 = 1 = 0 = 1 = 0 = 1 RFU Ram Press/Time Pack Profiles ERC On Ram Press/Time Pack Profiles ERC Off Cav Press/Time Pack Profiles ERC On Cav Press/Time Pack Profiles ERC Off Ram Press/Time Hold Profiles ERC On Ram Press/Time Hold Profiles ERC Off Cav Press/Time Hold Profiles ERC On Cav Press/Time Hold Profiles ERC Off RFU Pack Profile Setpoints Word HPC09
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Command Word/Bit Descriptions 2–15 HPC Hold Profile Setpoints Word HPC26 HPC27 HPC28 HPC29 HPC30 HPC31 HPC32 HPC33 HPC34 HPC35 HPC36 HPC37 HPC38 HPC39 HPC40 Description Hold Segment 1 Cavity Pressure Setpoint [04] If you select Cav Press/Time profile execution, the module controls cavity pressure to this setpoint after starting the Hold Profile for time period specified by HPC28.
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2–16 Command Word/Bit Descriptions INC – Injection Configuration Block Word Bit-mapped Control Words Bit INC01 Description Block ID = 00001000 (Low byte). High byte reserved for the module. Do not use. INC02 Configuration Selections B00-02 Selected Velocity Control Valve The module uses its algorithm to drive the following output during any Vel/Pos or LimVel/Pos Injection Profile.
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Command Word/Bit Descriptions 2–17 INC Output Ramp Rates The module uses the following ramp rates when moving its outputs from setpoint to setpoint during the Injection Profile. The module interprets a ramp rate of zero as a step function ramp (ramp disable).
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2–18 Command Word/Bit Descriptions Velocity Control Limits Word INC45 INC46 INC47 INC48 Description Velocity Minimum Control Limit [06] Minimum controllable ram (screw) velocity attainable during any Vel/Pos Injection Profile. The module expects this ram (screw) velocity when setting its selected velocity valve to the %-output in INC47. Velocity Maximum Control Limit [06] Maximum controllable ram (screw) velocity attainable during any Vel/Pos Injection Profile.
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Command Word/Bit Descriptions 2–19 IPC IPC – Injection Profile Block Bit-mapped Control Words Word Bit IPC01 IPC02 P 2 Description Block ID = 00001001 (Low byte). High byte reserved for the module. Do not use. B00-07 B08 B09 B10 B11, B12 B13-15 IPC03 B00-01 Co-injection Parameters RFU Selection bit IPC02:B08 for QI(A) IPCB02:B08 for QI(B) Select whether to inhibit or allow bridging from injection to pack 0 = bridge from injection to pack 1 = disabled bridging.
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2–20 Command Word/Bit Descriptions Bit Word IPC04 Description Selections to Inhibit Closed Loop Up To Shot Size B04 = 0 Allow Closed Loop Vel/Pos During Entire Profile = 1 Inhibit Closed Loop Vel/Pos Until 100% Shot Size if: then the module: SET when IPC04-B00 is SET inhibits closed-loop control of all Vel/Pos Injection Profiles until ram (screw) position equals or is less than the 100% shot size position RESET when IPC04-B00 is SET B05 If IPC04-B00 is RESET ignores the state of this bit.
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Command Word/Bit Descriptions 2–21 IPC Injection Profile Setpoints Word IPC09 IPC10 Description Segment 1 Velocity Setpoint [05] or [06] if: then the module: you select Vel/Pos controls ram (screw) forward speed to this setpoint after starting the Injection Profile until ram profile execution (screw) position reaches IPC11 (or until transition if sooner) IPC03-B14 is RESET reads this parameter in percent velocity IPC03-B14 is SET reads it in in.
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2–22 Command Word/Bit Descriptions Description Word IPC22 Segment 4 Pressure Setpoint [01] if: then the module: you select Press/Pos controls ram (screw) pressure to this setpoint from ram (screw) position IPC19 until ram (screw) profile execution position reaches IPC23 (or until transition if sooner) you select Press/Time profile execution controls ram (screw) pressure to this setpoint at completion of Segment 3 for time period IPC24 (or until transition if sooner) IPC23 End of Segment 4 Position Set
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Command Word/Bit Descriptions 2–23 IPC IPC37 IPC38 Segment 8 Velocity Setpoint [05] or [06] if: then the module: you select Vel/Pos controls ram (screw) forward speed to this setpoint from ram (screw) position IPC35 until ram profile execution (screw) position reaches IPC39 (or until transition if sooner) IPC03-B14 is RESET reads this parameter in percent velocity IPC03-B14 is SET reads it in in.
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2–24 IPC49 IPC50 Command Word/Bit Descriptions Segment 11 Velocity Setpoint [05] or [06] if: then the module: you select Vel/Pos controls ram (screw) forward speed to this setpoint from ram (screw) position IPC47 until transition profile execution IPC03-B14 is RESET reads this parameter in percent velocity IPC03-B14 is SET reads it in in.
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Command Word/Bit Descriptions 2–25 JGC Word IPC58 IPC59 Description Ram (Screw) Position for Pressure Limiting Inhibit [12] A non-zero entry forces the module to ignore the magnitude of ram (screw) pressure during a Pressure Limited Vel/Pos Injection Profile until ram (screw) position is equal to or less than this entry. A zero entry forces the module to pressure limit the entire Injection Profile if you have selected Pressure Limited Vel/Pos as the profile mode.
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2–26 Command Word/Bit Descriptions Screw Rotate Jog Set-output Values The module sets its outputs to these values when DYC01-B09 = 1.
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Command Word/Bit Descriptions 2–27 MCC Word MCC022 M Bit B04-05 4- 5 B06 Description Input Configuration Conf gurat on Inject n ect Control ontrol (both bits bit must u t be zero) ero) Input #1 # Input #2 # Input #3 # Input #4 # Ram (Screw) Position Ram (Screw) Pressure Screw RPM Cavity Pressure MCC02.B06 for QI(A) MCCB02.
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2–28 Command Word/Bit Descriptions Ram (Screw) Position Transducer Configuration (own injection head) The module accesses data in MCC09-16 if bit patterns in MCC02, 03 indicate that the module is connected to a ram (screw) position sensor.
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Command Word/Bit Descriptions 2–29 MCC Ram (Screw) Position Transducer Configuration (other injection head) The module accesses data in MCC09-16 if bit patterns in MCC02, 03 indicate that the module is connected to a ram (screw) position sensor.
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2–30 Command Word/Bit Descriptions Other Word Description MCC63 MCC63 for QI(A) MCCB63 for QI(B) Switch-over time delay required to switch the mode of input 3 from screw RPM to cavity pressure (or vice versa) before processing data or setting alarms. Units of 0.01 sec. MCC64 Number of Input Samples for Loss-of-sensor Alarms [29] Range of 0-200. The module monitors sensor inputs for out-of-range signals. To avoid nuisance alarms caused by electrical noise, enter a non-zero value.
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Command Word/Bit Descriptions 2–31 PKC Word Description PKC09 Output #1 Set-output Value during Profile [19] PKC10 Output #2 Set-output Value during Profile [19] PKC11 Output #3 Set-output Value during Profile [19] PKC12 Output #4 Set-output Value during Profile [19] PKC13–16 RFU Output Ramp Rates The module uses the following ramp rates when moving its outputs from setpoint to setpoint during the Pack Profile. The module interprets a ramp rate of zero as a step function ramp (ramp disable).
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2–32 Command Word/Bit Descriptions Profile Tuning Constants Word Description PKC49 Proportional Gain for Ram Press Control [30] PKC50 Integral Gain for Ram Press Control [27] or [28] PKC51 Derivative Gain for Ram Press Control [26] or [21] PKC52 Proportional Gain for Cav Press Control [30] PKC53 Integral Gain for Cav Press Control [27] or [28] PKC54 Derivative Gain for Cav Press Control [26] or [21] PKC55 - 56 RFU Profile Pressure Alarm Setpoint Word Description PKC57 Profile High Ram (S
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Command Word/Bit Descriptions 2–33 PLC Expert Response Compensation (ERC) Percentage Word Description PLC05 Minimum RPM Control ERC Percentage [31] PLC06 Minimum Pressure Control ERC Percentage [31] Although error coding allows range of 00000 to 09999, the module limits it to a minimum of 01000.
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2–34 Command Word/Bit Descriptions End of Profile Set-output Values When module completes Plastication Profile and PPC03-B08 is set, it: • sets status bit SYS22-B08 • uses ramp rates PLC17-20 and PLC25-28 when changing outputs • sets its outputs to the following values Word Description PLC33 Output #1 Set-output Value at End of Profile [19] PLC34 Output #2 Set-output Value at End of Profile [19] PLC35 Output #3 Set-output Value at End of Profile [19] PLC36 Output #4 Set-output Value at End of Pro
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Command Word/Bit Descriptions 2–35 PPC Profile Pressure Alarm Setpoint Word Description PLC57 Profile High Pressure Alarm Setpoint [01] The module compares real-time ram (screw) pressure against this entry when executing the Plastication Profile. The module sets alarm status bit SYS06-B07 when ram (screw) pressure equals or exceeds this entry during the Plastication Profile. A zero entry inhibits SYS06-B07.
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2–36 Command Word/Bit Descriptions Bit Word B10 B11 B12-B15 PPC05 - 08 Description = 0 = 1 = 0 = 1 RFU RPM/Pos Plastication ERC On RPM/Pos Plastication ERC Off RPM/Time Plastication ERC On RPM/Time Plastication ERC Off RFU Plastication Profile Setpoints Word PPC09 PPC10 PPC11 PPC12 PPC13 PPC14 PPC15 PPC16 PPC17 PPC18 PPC19 PPC20 PPC21 PPC22 PPC23 PPC24 PPC25 PPC26 Description Segment 1 RPM Setpoint [25] If you select RPM/Pos profile execution, the module controls RPM to this setpoint after
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Command Word/Bit Descriptions 2–37 PPC Word Description PPC27 End of Segment 5 Position Setpoint [12] PPC28 Segment 5 Time Setpoint [21] If you select RPM/Time or Press/Time profile execution, the module controls RPM to PPC25 or ram (screw) backpressure to PPC26 for this time period (or until 100% shot size if sooner) beginning at completion of Segment 4.
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2–38 Command Word/Bit Descriptions Description Word PPC49 Segment 11 Ram (Screw) RPM Setpoint [25] If you select RPM/Pos profile execution, the module controls RPM to this setpoint from ram (screw) position PPC47 until 100% shot size. If you select RPM/Time profile execution, the module controls RPM to this setpoint at completion or segment 10 until 100% shot size.
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Command Word/Bit Descriptions 2–39 PRC Movement Set-output Values When the module starts the Pre-decompression Movement, it: • uses ramp rates PRC17-20 and PRC25-28 to ramp outputs • sets its outputs to the values listed below Word Description PRC09 Output #1 Set-output Value during Movement [19] PRC10 Output #2 Set-output Value during Movement [19] PRC11 Output #3 Set-output Value during Movement [19] PRC12 Output #4 Set-output Value during Movement [19] PRC13-16 RFU Output Ramp Rates The mo
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2–40 Command Word/Bit Descriptions PSC – Post-decompression Configuration Block Word Bit-mapped Control Words Bit Description PSC01 Block ID = 00010000 (Low byte). High byte reserved for the module. Do not use. PSC02 - 04 RFU Movement Length Word PSC05 Description Incremental Movement Length [17] When the module starts the Post-decompression Movement, it adds this entry to the sum of cushion size (PPC61) + shot size (PPC62) to establish the End of Post-decompression ram (screw) position.
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Command Word/Bit Descriptions 2–41 PTC End of Movement Set-output Values When the module completes the Post-decompression Movement, it: • sets status bit SYS22-B09 • uses ramp rates PSC17-20 and PSC25-28 when changing outputs • sets its outputs to the following values Use these values for-pulling cores if applied before starting the first clamp open profile.
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2–42 Word Command Word/Bit Descriptions Bit PTC09 Description Trace #2 selection B01 Injection position B02 Injection pressure B03 Injection velocity The module will return unscaled injection position data if injection velocity is selected. The process trace screen uses this position information to calculate and display velocity. B04 Cavity pressure B05 Screw RPM B06 Injection flow valve output B07 Injection pressure valve output B08-15 Reserved Do not use.
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Command Word/Bit Descriptions 2–43 RLC Word Description RLC14 Injection Segment 6 RLC15 Injection Segment 7 RLC16 Injection Segment 8 RLC17 Injection Segment 9 RLC18 Injection Segment 10 RLC19 Injection Segment 11 Pack Profile ERC Values Word Description RLC20 Pack Segment 1 RLC21 Pack Segment 2 RLC22 Pack Segment 3 RLC23 Pack Segment 4 RLC24 Pack Segment 5 Hold Profile ERC Values Word Description RLC25 Hold Segment 1 RLC26 Hold Segment 2 RLC27 Hold Segment 3 RLC28 Hold
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2–44 Command Word/Bit Descriptions Notes: Notes: For [ ] engineering units, see page 2. Publication 1771-6.5.
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3 Chapter - Status Word/Bit Descriptions List of Status Blocks and Block ID Codes Status blocks report current status of molding machine operation. They are returned from the QI module to the PLC processor by means of block transfer read (BTR) instructions in software ladder logic.
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3–2 Status Word/Bit Descriptions Data Blocks Require I/O Configuration The QI module decodes its own I/O configuration based on parameters that you provide in the Module Configuration Command Block (MCC). I/O configuration determines which of the command and status blocks the module supports. For the module to support command and status blocks, you must establish the following position input: • Connect a ram (screw) position sensor to input 1.
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Status Word/Bit Descriptions HPS – Pack/Hold Profile Status Block Word HPS01 HPS02 HPS03 HPS04 HPS05, 06 HPS07 HPS08 3–3 HPS Bit-mapped Status Words Bit Description Block ID = 00000100 (Low byte). High byte identical to SYS01 See SYS02 See SYS03 See SYS04 RFU CV High Limit Alarms For Pack Phase The module latches each bit when executing the subject profile segment in closed loop, and drives its algorithm CV to maximum (100%) in an attempt to control the profile setpoint.
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3–4 Word Status Word/Bit Descriptions Bit Description For Hold Phase The module latches each bit when executing the subject profile segment in closed loop, and drives its algorithm CV to minimum (0%) in an attempt to control the profile setpoint. The module unlatches each bit when it completes execution of the subject profile segment in open loop, or in closed loop without driving its algorithm CV to minimum (0%).
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Status Word/Bit Descriptions 3–5 IPS Pack Maximum Pressures Word HPS51 HPS52 Description Maximum Ram (Screw) Pressure During Pack [01] Maximum instantaneous ram (screw) pressure during last profile. Maximum Cavity Pressure During Pack [04] Maximum instantaneous cavity pressure during last profile. Hold Maximum Pressures Word HPS53 HPS54 Description Maximum Ram (Screw) Pressure During Hold [01] Maximum instantaneous ram (screw) pressure during last profile.
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3–6 Word Status Word/Bit Descriptions Bit B05 B06 B07 B08 B09 B10 B11-B15 IPS06 B00 Description Segment 6 Segment 7 Segment 8 Segment 9 Segment 10 Segment 11 RFU Injection Transition Status = 0 Normal = 1 Injection Transition on Time The module sets this bit when the Transition Time Setpoint (IPC60) triggered completion of last Injection Profile.
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Status Word/Bit Descriptions 3–7 IPS Word Bit B06 B07 B08 B09 B10 B11-B15 Description Segment 7 Segment 8 Segment 9 Segment 10 Segment 11 RFU Injection Profile Actuals Word IPS09 Description Actual Segment 1 Velocity [05] or [06] Average ram (screw) velocity during last Segment 1. If IPC03-B14 is RESET, the module reports this average in percent velocity. If IPC03-B14 is SET, it reports it in in.(mm)/s.
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3–8 Status Word/Bit Descriptions Word IPS37 Description Actual Segment 8 Velocity [05] or [06] Average ram (screw) velocity during last Segment 8. If IPC03-B14 is RESET, the module reports this average in percent velocity. If IPC03-B14 is SET, it reports it in in.(mm)/s. IPS38 IPS39 IPS40 IPS41 Actual Segment 8 Pressure [01] Average ram (screw) pressure during last Segment 8. Actual Segment 8 Execution Time [21] Time required for last Segment 8.
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Status Word/Bit Descriptions 3–9 PPS Word PPS07 PPS08 Bit Description CV High Limit Alarms The module latches each bit when executing the subject profile segment in closed loop, and drives its algorithm CV to maximum (100%) in an attempt to control the profile setpoint. The module unlatches each bit when it completes execution of the subject profile segment in open loop, or in closed loop without driving its algorithm CV to maximum (100%).
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3–10 Word PPS17 PPS18 PPS19 PPS20 PPS21 PPS22 PPS23 PPS24 PPS25 PPS26 PPS27 PPS28 PPS29 PPS30 PPS31 PPS32 PPS33 PPS34 PPS35 PPS36 PPS37 PPS38 PPS39 PPS40 PPS41 PPS42 PPS43 PPS44 PPS45 PPS46 PPS47 PPS48 PPS49 PPS50 PPS51 PPS52 Status Word/Bit Descriptions Description Actual Segment 3 RPM [25] Average RPM during last Segment 3. Actual Segment 3 Pressure [01] Average ram (screw) pressure during last Segment 3. Actual Segment 3 Execution Time [21] Time required for last Segment 3.
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Status Word/Bit Descriptions 3–11 PTS Execution Times Word Description PPS57 Plastication Profile Execution Time [21] Total time required for last profile. PPS58 Post-decompression Movement Execution Time [21] Total time required for last movement. PPS59 - 60 RFU Post-decompression Movement Actuals Word PPS61 PPS62 Description Post-decompression Movement Actual Velocity [06] Average ram (screw) velocity during last movement, reported in in.(mm)/s.
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3–12 Word PTS09 PTS10 PTS11-14 PTS15 Status Word/Bit Descriptions Bit Description Reports the time (in hundredths of seconds) after injection starts until the first trace data point is recorded. Reports how many data points (0 to 400) have been collected for the trace indicated in PTS05 and PTS06. This value will not exceed the last data point for the block indicated in PTS06. RFU PTS16 Injection Segment 1 starting data point If one of PTS05-B01 to -B05 is set, PTS15 to PTS64 contain trace data.
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Status Word/Bit Descriptions RLS – Inject ERC Values Status Block Word RLS01 RLS02 RLS03 RLS04 RLS05-08 3–13 RLS Bit-mapped Status Words Description Block ID = 00001000 (Low byte).
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3–14 Word RLS37 RLS38 RLS39 RLS40 RLS41 - 64 Status Word/Bit Descriptions Description Plastication Segment 8 Plastication Segment 9 Plastication Segment 10 Plastication Segment 11 RFU SYS – System Status Block Word SYS01 Y 1 Bit B00-B07 B08-B15 B08 B09 Bit-mapped Status Words Description Block ID = 00000001 Power-up Status = 0 The module Wants Complete Download = 1 Valid MCC on Board Jog Execution Status = 0 Normal = 1 Executing Screw Rotate Jog The module sets this bit when responding to command bit
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Status Word/Bit Descriptions 3–15 SYS Word SYS03 Y 3 Bit B00 Description Miscellaneous Status SYS03:B00 for QI(A) SYSB03:B00 for QI(B) When set, indicates that injection has been suspended Injection suspension applies to these conditions: when A reaches screw position (IPC56), QI(A) suspends injection until B reaches screw position (IPCB08) to let QI(A) resume injection. upon a start command, QI(A) suspends injection until B reaches screw position (IPCB08) to let QI(A) start its injection profile.
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3–16 Status Word/Bit Descriptions Word Bit Description SYS05 B03 = 0 Normal = 1 High Screw RPM The module sets this bit when real-time screw RPM equals or exceeds MCC55. B04 = 0 Normal = 1 High Cavity Pressure The module sets this bit when real-time cavity pressure equals or exceeds MCC61.
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Status Word/Bit Descriptions 3–17 SYS Word Bit Description SYS07 B01 = 0 Normal = 1 Ram (Screw) Overtravel at Top The module sets this bit when real-time ram (screw) position equals or exceeds MCC14. The module resets this bit when real-time position is less than or equal to the position defined by MCC14 – MCC15. When SET, the module ignores any profile action execution command in DYC02. B02-15 RFU SYS08 Alarm Status for Loss of Input Sensor (Real Time). The module sets alarm bits in real time.
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3–18 Status Word/Bit Descriptions Word Bit Description SYS10 B05 Hold Profile High Cavity Pressure B06 Pre-decompress Movement High Ram (Screw) Pressure B07 Plastication Profile High Ram (Screw) Pressure B08 Post-decompress Movement High Ram (Screw) Pressure B09-15 RFU SYS11 Overtravel Alarm Status (Latched) Module latches alarm bits on each false-to-true transition of the corresponding real-time alarm bit in SYS07.
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Status Word/Bit Descriptions 3–19 SYS Word SYS13 Bit Description B07 = 0 Normal = 1 Hold Profile Command Error The module latches this bit when both of the following are true: DYC02-B06 is SET SYS15-B11 is RESET The module unlatches this bit when it decodes a valid Dynamic Command Block with any SET action execution bit other than DYC02-B06.
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3–20 Status Word/Bit Descriptions Word Bit Description B10 = 0 Normal = 1 Post-decompression Movement Command Error The module latches this bit at completion of the Plastication Profile if both of the following are true: PPC03-B08 is RESET SYS15-B15 is RESET The module also latches this bit if all of the following are true: Ram (screw) position equals or exceeds the sum of PPC61 and PPC62 PPC03-B08 is RESET SYS15-B15 is RESET The module also latches this bit if both of the following are true: DYC02-B0
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Status Word/Bit Descriptions 3–21 SYS Word Bit SYS15 Description Status of On-board Command Blocks Module latches bits individually when it successfully decodes the referenced command block and places new data into operational memory. The module does not latch any bit associated with an unrecognizable command block.
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3–22 Status Word/Bit Descriptions Bit Word SYS18 Description Status of Last Successful Decode The module latches one of the bits in SYS17 and SYS18 (while unlatching all others) when it successfully decodes the referenced command block and places the new data into operational memory. The module does not latch any bit associated with an unrecognizable command block. Set no more than one bit at a time in SYS17 and SYS18.
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Status Word/Bit Descriptions 3–23 SYS Word SYS21 Y 21 Bit B00-03 B04 B05 B06 Description Status of Profile Execution RFU SYS21.B04 for QI(A) SYSB21.B04 for QI(B) = 0 Normal = 1 Injection Profile in Progress The module sets this bit when it starts the profile. Important: This bit remains set independent of injection suspensions.
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3–24 Status Word/Bit Descriptions Word Bit B06 B07 B08 B09 B10-15 Description = 0 Normal = 1 End of Hold Profile Set-Output in Progress The module sets this bit when holding its outputs to HDC33-36 after completion of the profile. The module resets this bit when it receives any new action execution command bit. = 0 Normal = 1 End of Pre-decompression Movement Set-Output in Progress The module sets this bit when holding its outputs to PRC33-36 after completion of the movement.
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Status Word/Bit Descriptions 3–25 SYS Cycle Maximum Pressures Word SYS49 Description Maximum Ram (Screw) Pressure During Last Cycle [01] If bit patterns in MCC02 and MCC03 indicate that the module is connected to a ram (screw) pressure transducer, the module reports the highest ram (screw) pressure it detected since the last F-to-T transition of DYC02-B04.
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3–26 Status Word/Bit Descriptions Process Times Word SYS57 SYS58 Description RFU Accumulated Cure Time [22] If bit patterns in MCC02 and MCC03 indicate that the module is connected to a ram (screw) position transducer, the module: At completion co letion of o the Hold Profile: Pro ile: starts an internal cure timer et master a ter status tatu bit SYS03-B03 Y 3- 3 sets reports re ort the accumulated accu ulated time ti e in this thi word ord When the value in this word equals the cure timer preset (HPC61)
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Chapter 4 Programming Error Codes Programming error codes indicate that you entered invalid data in a command block. This chapter lists programming error codes for all command blocks.
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4–2 Programming Error Codes Type 022 033 Publication 1771-6.5.126 – March 1998 Example 0222 222 0311 04 0427 055 0502 5 2 06 0600 077 712 0712 088 0816 816 09 0960 10 1015 Description Outside fixed limits MCC22 is out of range. Valid range is 00000 ≤ MCC22 ≤ 00099. Cannot be equal MCC11 is equal to MCC12. They must not be equal. Outside range established by another entry MCC27 is out of range. If MCC28 is non-zero, MCC27 must be within MCC23 ≤ MCC27 ≤ MCC28.
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Programming Error Codes ID = 1 MCC – Module Configuration Command Block Error Code Description 0211 MCC11 is out of range. MCC11 must be within: 00000 ≤ MCC11 ≤ 01000 (0 to 10 V dc sensor) 00100 ≤ MCC11 ≤ 00500 (1 to 5 V dc sensor) 00400 ≤ MCC11 ≤ 02000 (4 to 20 mA dc sensor) MCC12 is out of range. MCC12 must be within: 00000 ≤ MCC12 ≤ 01000 (0 to 10 V dc sensor) 00100 ≤ MCC12 ≤ 00500 (1 to 5 V dc sensor) 00400 ≤ MCC12 ≤ 02000 (4 to 20 mA dc sensor) 0212 MCC ID = 1 0215 MCC15 is out of range.
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4–4 Programming Error Codes Error Code Description 0248 MCC48 is out of range. MCC48 must be within: 00000 ≤ MCC48 ≤ 01000 (0 to 10 V dc sensor) 00100 ≤ MCC48 ≤ 00500 (1 to 5 V dc sensor) 00400 ≤ MCC48 ≤ 02000 (4 to 20 mA dc sensor) 0250 MCC50 is out of range. Valid range is 00000 ≤ MCC50 ≤ 00099 MCC53 is out of range. MCC53 must be within: 00000 ≤ MCC53 ≤ 01000 (0 to 10 V dc sensor) 00100 ≤ MCC53 ≤ 00500 (1 to 5 V dc sensor) 00400 ≤ MCC53 ≤ 02000 (4 to 20 mA dc sensor) MCC54 is out of range.
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Programming Error Codes 4–5 Error Code Description 0428 Your non-zero entry for MCC28 is out of range. If MCC27 is non-zero, MCC28 must be within MCC27 < MCC28 ≤ MCC24 If MCC27 is zero, MCC28 must be within MCC23 < MCC28 ≤ MCC24 0431 MCC31 is out of range. Valid range is 00000 ≤ MCC31 < MCC32 0432 0435 MCC32 is out of range. Valid range is MCC31 < MCC32 ≤ 09999 MCC35 is out of range. If non-zero, MCC35 must be within MCC31 < MCC35 ≤ MCC32 0437 MCC37 is out of range.
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4–6 Programming Error Codes Error Code Description 0929 MCC29 is too large. if: MCC27 and MCC28 are both non-zero MCC27 is zero and MCC28 is non-zero MCC27 is non-zero and MCC28 is zero MCC43 is too large. if: MCC41 and MCC42 are both non-zero MCC41 is zero and MCC42 is non-zero MCC41 is non-zero and MCC42 is zero 0943 ID = 2 Publication 1771-6.5.
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Programming Error Codes Error Code Description 0238 JGC38 is out of range. Valid range is 00000 ≤ JGC38 ≤ 09999 0239 JGC39 is out of range. Valid range is 00000 ≤ JGC39 ≤ 09999 0240 JGC40 is out of range. Valid range is 00000 ≤ JGC40 ≤ 09999 0241 JGC41 is out of range. Valid range is 00000 ≤ JGC41 ≤ 09999 0242 JGC42 is out of range. Valid range is 00000 ≤ JGC42 ≤ 09999 0243 JGC43 is out of range. Valid range is 00000 ≤ JGC43 ≤ 09999 0244 JGC44 is out of range.
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4–8 Programming Error Codes Error Code Description 0215 INC15 is out of range. Valid range is 00000 ≤ INC15 ≤ 09999 0216 INC16 is out of range. Valid range is 00000 ≤ INC16 ≤ 09999 0217 INC17 is out of range. Valid range is 00000 ≤ INC17 ≤ 09999 0218 INC18 is out of range. Valid range is 00000 ≤ INC18 ≤ 09999 0219 INC19 is out of range. Valid range is 00000 ≤ INC19 ≤ 09999 0220 INC20 is out of range. Valid range is 00000 ≤ INC20 ≤ 09999 0221 INC21 is out of range.
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Programming Error Codes ID = 9 4–9 IPC – Injection Profile Block Error Code Description 0207 IPC07 is out of range. When IPC03-B01 = 0, IPC09 must be within 00000 ≤ IPC07 ≤ 09999 IPC09 is out of range. When IPC03-B01 = 0, IPC09 must be within 00000 ≤ IPC09 ≤ 09999 IPC09 is out of range. When IPC03-B01 = 0, IPC09 must be within 00000 ≤ IPC09 ≤ 09999 0209 0209 IPC ID = 9 0212 IPC12 is out of range. Valid range is 00000 ≤ IPC12 ≤ 09999 0213 IPC13 is out of range.
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4–10 Programming Error Codes Error Code Description 0411 IPC11 is out of range. if: 0413 0414 0415 0417 0418 0419 0421 0422 0423 0425 Publication 1771-6.5.126 – March 1998 IPC ID = 9 then: MCC13 and MCC14 are both non-zero IPC11 must be within 00000 ≤ IPC11 ≤ MCC14 – MCC13 MCC13 is non-zero and MCC14 is zero IPC11 must be within 00000 ≤ IPC11 ≤ MCC10 – MCC13. MCC13 is zero and MCC14 is non-zero IPC11 must be within 00000 ≤ IPC11 ≤ MCC14 – MCC09.
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Programming Error Codes Error Code Description 0426 IPC26 is out of range. If non-zero, IPC26 must be within INC41 ≤ IPC26 ≤ INC42 IPC27 is out of range. if: then: 0427 0429 0430 0431 0433 0434 0435 0437 0438 0439 4–11 IPC ID = 9 MCC13 and MCC14 are both non-zero IPC27 must be within 00000 ≤ IPC27 ≤ MCC14 – MCC13 MCC13 is non-zero and MCC14 is zero IPC27 must be within 00000 ≤ IPC27 ≤ MCC10 – MCC13. MCC13 is zero and MCC14 is non-zero IPC27 must be within 00000 ≤ IPC27 ≤ MCC14 – MCC09.
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4–12 Programming Error Codes Error Code Description 0441 IPC41 is out of range. When IPC03-B14 = 1, a non-zero IPC41 must be within INC45 ≤ IPC41 ≤ INC46 IPC42 is out of range. If non-zero, IPC42 must be within INC41 ≤ IPC42 ≤ INC42 IPC43 is out of range. if: then: 0442 0443 0445 0446 0447 0449 0450 0451 MCC13 and MCC14 are both non-zero IPC43 must be within 00000 ≤ IPC43 ≤ MCC14 – MCC13 MCC13 is non-zero and MCC14 is zero IPC43 must be within 00000 ≤ IPC43 ≤ MCC10 – MCC13.
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Programming Error Codes Error Code Description 0461 Your non-zero entry for IPC61 is out of range. if: then: 0462 0463 0464 0503 4–13 IPC ID = 9 MCC13 and MCC14 are both non-zero IPC61 must be within 00000 ≤ IPC61 ≤ MCC14 – MCC13 MCC13 is non-zero and MCC14 is zero IPC61 must be within 00000 ≤ IPC61 ≤ MCC10 – MCC13. MCC13 is zero and MCC14 is non-zero .
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4–14 Programming Error Codes Error Code Description 0728 0731 IPC28 cannot be 00000 when IPC30 > 00000. IPC31 cannot be 00000 because it conflicts with one of: IPC33 P 33 > 00000 when hen IPC03-B01 P 3- 1 = 0 IPC34 > 00000 when IPC03-B01 = 1 0732 0735 IPC32 cannot be 00000 when IPC34 > 00000. IPC35 cannot be 00000 because it conflicts with one of: P 37 > 00000 when hen IPC03-B01 P 3- 1 = 0 IPC37 IPC38 > 00000 when IPC03-B01 = 1 0736 0739 IPC36 cannot be 00000 when IPC38 > 00000.
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Programming Error Codes Error Code Description 1023 IPC23 is not in decreasing positional order. If non-zero, IPC23 must be less than IPC19. IPC27 is not in decreasing positional order. If non-zero, IPC27 must be less than IPC23. IPC31 is not in decreasing positional order. If non-zero, IPC31 must be less than IPC27. IPC35 is not in decreasing positional order. If non-zero, IPC35 must be less than IPC31. IPC39 is not in decreasing positional order. If non-zero, IPC39 must be less than IPC35.
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4–16 Programming Error Codes Error Code Description 0249 PKC49 is out of range. Valid range is 00000 ≤ PKC49 ≤ 09999 0250 PKC50 is out of range. Valid range is 00000 ≤ PKC50 ≤ 09999 0251 PKC51 is out of range. Valid range is 00000 ≤ PKC51 ≤ 09999 0252 PKC52 is out of range. Valid range is 00000 ≤ PKC52 ≤ 09999 0253 PKC53 is out of range. Valid range is 00000 ≤ PKC53 ≤ 09999 0254 PKC54 is out of range. Valid range is 00000 ≤ PKC54 ≤ 09999 0343 PKC43 is equal to PKC44. They must not be equal.
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Programming Error Codes Error Code Description 0230 HDC30 is out of range. Valid range is 00000 ≤ HDC30 ≤ 09999 0231 HDC31 is out of range. Valid range is 00000 ≤ HDC31 ≤ 09999 0232 HDC32 is out of range. Valid range is 00000 ≤ HDC32 ≤ 09999 0233 HDC33 is out of range. Valid range is 00000 ≤ HDC33 ≤ 09999 0234 HDC34 is out of range. Valid range is 00000 ≤ HDC34 ≤ 09999 0235 HDC35 is out of range. Valid range is 00000 ≤ HDC35 ≤ 09999 0236 HDC36 is out of range.
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4–18 Programming Error Codes Error Code Description 0231 HPC31 is out of range. Valid range is 00000 ≤ HPC31 ≤ 09999 0234 HPC34 is out of range. Valid range is 00000 ≤ HPC34 ≤ 09999 0237 HPC37 is out of range. Valid range is 00000 ≤ HPC37 ≤ 09999 0240 HPC40 is out of range. Valid range is 00000 ≤ HPC40 ≤ 09999 0261 HPC61 is out of range. Valid range is 00000 ≤ HPC61 ≤ 09999 0409 HPC09 is out of range. If non-zero, HPC09 must be within PKC45 ≤ HPC09 ≤ PKC46 HPC10 is out of range.
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Programming Error Codes 4–19 Error Code Description 0504 You have selected closed-loop RamPress/Time execution for the Pack Profile by HPC04-B00 = 0; however, your bit patterns in MCC02 and MCC03 indicate that the QI module does not have access to a connected ram (screw) pressure transducer. 0507 You have selected CavPress/Time execution for the Hold Profile by HPC03-B02 = 1; however, your bit pattern in MCC02 indicates that your QI module is not configured for connection of a cavity pressure sensor.
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4–20 Programming Error Codes ID = 13 Publication 1771-6.5.126 – March 1998 Error Code Description 0822 HPC22 must be 00000 when HPC23 = 00000. 0829 HPC29 must be 00000 when HPC31 = 00000. 0830 HPC30 must be 00000 when HPC31 = 00000. 0832 HPC32 must be 00000 when HPC34 = 00000. 0833 HPC33 must be 00000 when HPC34 = 00000. 0835 HPC35 must be 00000 when HPC37 = 00000. 0836 HPC36 must be 00000 when HPC37 = 00000. 0838 HPC38 must be 00000 when HPC40 = 00000.
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Programming Error Codes Error Code Description 0405 PRC05 is out of range. if: 0457 0905 ID = 14 4–21 PRC ID = 13 then: MCC13 and MCC14 are both non-zero PRC05 must be within 00000 ≤ PRC05 ≤ MCC14 – MCC13 MCC13 is non-zero and MCC14 is zero PRC05 must be within 00000 ≤ PRC05 ≤ MCC10 – MCC13 MCC13 is zero and MCC14 is non-zero PRC05 must be within 00000 ≤ PRC05 ≤ MCC14 – MCC09 MCC13 and MCC14 PRC05 must be within 00000 ≤ PRC05 ≤ MCC10 – MCC09 are both zero PRC57 is out of range.
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4–22 Programming Error Codes Error Code Description 0230 PLC30 is out of range. Valid range is 00000 ≤ PLC30 ≤ 09999 0231 PLC31 is out of range. Valid range is 00000 ≤ PLC31 ≤ 09999 0232 PLC32 is out of range. Valid range is 00000 ≤ PLC32 ≤ 09999 0233 PLC33 is out of range. Valid range is 00000 ≤ PLC33 ≤ 09999 0234 PLC34 is out of range. Valid range is 00000 ≤ PLC34 ≤ 09999 0235 PLC35 is out of range. Valid range is 00000 ≤ PLC35 ≤ 09999 0236 PLC36 is out of range.
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Programming Error Codes Error Code Description 0229 PPC29 is out of range. Valid range is 00000 ≤ PPC29 ≤ 09999 0232 PPC32 is out of range. Valid range is 00000 ≤ PPC32 ≤ 09999 0233 PPC33 is out of range. Valid range is 00000 ≤ PPC33 ≤ 09999 0236 PPC36 is out of range. Valid range is 00000 ≤ PPC36 ≤ 09999 0237 PPC37 is out of range. Valid range is 00000 ≤ PPC37 ≤ 09999 0240 PPC40 is out of range. Valid range is PPC40 ≤ PPC40 ≤ 09999 0241 PPC41 is out of range.
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4–24 Programming Error Codes Error Code Description 0423 PPC23 is out of range. if: 0426 0427 0430 0431 0434 0435 0438 Publication 1771-6.5.126 – March 1998 PPC ID = 15 then: MCC13 and MCC14 are both non-zero PPC23 must be within 00000 ≤ PPC23 ≤ MCC14 – MCC13 MCC13 is non-zero and MCC14 is zero PPC23 must be within 00000 ≤ PPC23 ≤ MCC10 – MCC13. MCC13 is zero and MCC14 is non-zero .
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Programming Error Codes Error Code Description 0439 PPC39 is out of range. if: 0442 0443 0446 0447 0450 4–25 PPC ID = 15 then: MCC13 and MCC14 are both non-zero PPC39 must be within 00000 ≤ PPC39 ≤ MCC14 – MCC13 MCC13 is non-zero and MCC14 is zero PPC39 must be within 00000 ≤ PPC39 ≤ MCC10 – MCC13 MCC13 is zero and MCC14 is non-zero . PPC39 must be within 00000 ≤ PPC39 ≤ MCC14 – MCC09 MCC13 and MCC14 PPC39 must be within 00000 ≤ PPC39 ≤ MCC10 – MCC09 are both zero PPC42 is out of range.
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4–26 Programming Error Codes Error Code Description 0462 PPC62 is out of range. if: 0503 Publication 1771-6.5.126 – March 1998 PPC ID = 15 then: MCC13 and MCC14 are both non-zero PPC62 must be within 00000 ≤ PPC62 ≤ MCC14 – MCC13 MCC13 is non-zero and MCC14 is zero PPC62 must be within 00000 ≤ PPC62 ≤ MCC10 – MCC13.
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Programming Error Codes Error Code Description 0820 PPC20 must be 00000 when PPC16 = 00000. 0823 PPC23 must be 00000 when PPC19 = 00000. 0824 PPC24 must be 00000 when PPC20 = 00000. 0827 PPC27 must be 00000 when PPC23 = 00000. 0828 PPC28 must be 00000 when PPC24 = 00000. 0831 PPC31 must be 00000 when PPC27 = 00000. 0832 PPC32 must be 00000 when PPC28 = 00000. 0835 PPC35 must be 00000 when PPC31 = 00000. 0836 PPC36 must be 00000 when PPC32 = 00000.
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4–28 Programming Error Codes ID = 16 PSC – Post-Decompression Configuration Block Error Code Description 0208 PSC08 is out of range. Valid range is 00000 ≤ PSC08 ≤ 09999 0209 PSC09 is out of range. Valid range is 00000 ≤ PSC09 ≤ 09999 0210 PSC10 is out of range. Valid range is 00000 ≤ PSC10 ≤ 09999 0211 PSC11 is out of range. Valid range is 00000 ≤ PSC11 ≤ 09999 0212 PSC12 is out of range. Valid range is 00000 ≤ PSC12 ≤ 09999 0213 PSC13 is out of range.
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Programming Error Codes ID = 25 ID = 26 4–29 Error Code Description 0905 PSC05 is too large.
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4–30 Programming Error Codes ID = 28 Publication 1771-6.5.126 – March 1998 Error Code Description 0212 RLC12 is out of range. Valid range is 00000 ≤ RLC12 ≤ 09999 0213 RLC13 is out of range. Valid range is 00000 ≤ RLC13 ≤ 09999 0214 RLC14 is out of range. Valid range is 00000 ≤ RLC14 ≤ 09999 0215 RLC15 is out of range. Valid range is 00000 ≤ RLC15 ≤ 09999 0216 RLC16 is out of range. Valid range is 00000 ≤ RLC16 ≤ 09999 0217 RLC17 is out of range.
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Chapter 5 Sequencing CoĆinjection Chapter Objective This chapter describes how you program the operation of screws A and B for the following co-injection sequences: • A only, or B only • A and B • A then B (standard programming) – inject all of A – inject all of B • A then B (co-injection programming) – suspend the start of B – inject A to completion – from some point in A, inject B to completion • ABA – inject A to some point – from some point in A, inject B to completion – resume A to completion You c
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5–2 Sequencing Co-injection A then B You can use either standard or co-injection programming for this sequence. ÉÉÉÉÉÉÉÉ ÇÇÇÇÇÇ ÇÇÇÇÇÇ A B Time Standard Programming Set up QI(A) to wait at the end of its injection profile, and QI(B) to bridge into pack/hold. You command QI(A) to inject to completion and wait. Once your ladder code sees injection complete bit (SYS02:B04) transition from F to T, your code commands QI(B) to start injection.
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Sequencing Co-injection ABA 5–3 We present two examples: • QI(A)’s suspended outputs are turned off • QI(A)’s suspended outputs are programmed ÉÉÉÉÉÉ ÉÉÉÉ ÇÇÇÇÇÇÇ ÉÉÉÉÉÉ ÉÉÉÉ ÇÇÇÇÇÇÇ suspended outputs B A suspended start A Time Suspended Outputs are Turned Off You command QI(A) and QI(B) to start at the same time. QI(B) suspends start of injection, then starts on screw position of A when QI(A) suspends injection. Then QI(A) resumes injection on screw position of B.
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5–4 Sequencing Co-injection Suspended Outputs are Programmed Co-injection lets you program suspended outputs with these choices: • suspended outputs are turned off (previous example) • suspended outputs are your set-outputs in INC61-64 (example 1) • the injection output is closed-loop controlled (example 2) For these examples, refer to the diagram on the next page. Example 1, You suspend QI(A)’s outputs with set-outputs: Description: QI(A) setup: QI(B) setup: Co-inj.
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Sequencing Co-injection 5–5 During B, A Maintains Low Pressure or Flow (plateau). In this sequence, QI(A) maintains low pressure or flow with its profile which is NOT interrupted. QI(B) starts and completes its profile while QI(A)’s profile is at a low plateau.
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5–6 Sequencing Co-injection Flow Chart for Co-injection Programming Your ladder logic must monitor conditions and set command bits for QI modules to step through the various algorithms of co-injection. For the example of ABA, we present a list of parameters, a diagram, and a flow chart that indicates the logic that QI modules expect to see. (Remember that screw position values decrease going toward the mold.
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Sequencing Co-injection 5–7 Flow Chart for A in Sequence ABA Start Injection (DYC02-B04 = 1) SYS21-B04 = 1 Set to suspend start until other screw reaches position IPC08. TRUE DYC03-B04 = 1 FALSE Set to enable suspension when own screw reaches position IPC56. TRUE IPC02-B10 = 1 FALSE Wait for other screw to reach position IPC08. Use set-outputs INC61-64 during suspension.
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5–8 Sequencing Co-injection Flow Chart for Sequence ABA Start Injection (DYC02-B04 = 1)) Screw A (Suspend Profile on Position) SYS21-B04 = 1 Set to suspend start until screw B reaches position IPC08. Wait for screw B to reach TRUE position IPC08. Use set-outputs INC61-64 DYC03-B04 = 1 during suspension. SYS03-B00 = 1 FALSE Set to enable suspension when screw A reaches TRUE position IPC56.
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Chapter 6 Module Specifications This chapter gives 1771-QI module specifications including: • • • • I/O Specifications I/O specifications environmental conditions hardware requirements process control options The following table lists the I/O specifications.
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6–2 Module Specifications Process Control Options The following table lists process control options. Phase: Type of Profile: Mode: Injection phase: 10-step profile with selectable transition velocity vs. position or velocity vs. position pressure limited or injection pressure vs. position or injection pressure vs.
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Chapter 7 Calibration Instructions Use this section to calibrate your 1771-QI module. You should calibrate it once a year.
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7–2 Calibration Instructions Map Your BTW and BTR Data Blocks word 1 Create BTR and BTW calibration data blocks in your PLC-5 data table.
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Calibration Instructions 7–3 BTW BLOCK TRNSFR WRITE Rack Group Module Control Block Data file Length Continuous EN 00 3 0 N10:0 N11:0 0 Y DN ER N10:0 N10:0 U 15 12 BTR BLOCK TRNSFR READ Rack Group Module Control Block Data file Length Continuous N10:10 DN ER N10:10 U 15 12 Set Internal Jumpers EN 00 3 0 N10:10 N11:70 0 Y Set jumpers on the circuit board inside the QI module as follows: Important: To avoid electrostatic damage to internal electronic circuits, rid yourself of electric charge by t
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7–4 Calibration Instructions Figure 7.1 Jumper Settings and Locations on the Circuit Board Record Operational Jumper Settings Here: TOP Jumper Operational Setting Calibration Left Left Right E1 E1 Right X E6 Current Voltage Top Bottom E7 E8 E9 Jumper Top Bottom E10 Current Voltage E6 RIGHT LEFT E7 E14 E8 E13 E9 E17 E11 –10 to 0 to 10V E12 +10 V or E15 E16 E10 E11 4-20mA E14 E12 E13 E15 E17 E16 BOTTOM 10908-I 5. Install the circuit board on an extender card. 6.
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Calibration Instructions Wire the Wiring Arms 7–5 If you have extra wiring arms, wire them in advance to save time. Otherwise, remove system wiring and rewire for this procedure. Input Wiring 1. Connect all four (+) input terminals (18, 16, 13, 11) to the (+) terminal of the precision voltage source. 2. Connect all four (–) input terminals (17, 15, 12, 10) to the (–) terminal of the precision voltage source. Output Wiring 1.
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7–6 Calibration Instructions Calibration Setup Using Optional Equipment Set up your calibration equipment at a remote location as follows: 1. Install the PLC-5 processor in the I/O chassis. 2. Verify that you set all the QI module’s jumpers to initial calibration settings (see Set Internal Jumpers, above). 3. Install the QI module circuit board with extender card in the I/O chassis slot location corresponding to the module address of your BTR and BTW instructions.
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Calibration Instructions Calibration Procedure for Inputs 7–7 Important: Calibrate inputs before outputs. Follow this procedure for: • calibrating the QI module’s inputs • verifying the calibration For each calibration below, you will: • apply precise voltages using the input wiring arm • enter command codes in BTW word 2 with your programming terminal For each verification below, you will: • apply precise voltages using the input wiring arm • read verification codes in BTR words 10-13 1.
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7–8 Calibration Instructions Calibration Procedure for Outputs After calibrating inputs, calibrate outputs as follows: • • • • change jumpers as required (with power ON) enter command codes in BTW word 2 enter voltage codes in BTW words 3, 4, 5, and 6 read verification codes in BTR words 10, 11, 12, and 13 Important: Do not remove module from the I/O chassis or turn off power. Loss of power voids the procedure and requires that you repeat the entire calibration procedure starting with inputs. 1.
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Calibration Instructions 7–9 6. To calibrate the 4-20mA output range, first change the following jumpers with power ON, then calibrate: • E6-E9 to the current position (left) E6 E7 E8 E9 • E10, E14, E13, E17 to the current position (top) E10 E14 E13 E17 Step Enter Command Code (BTW 2): 1 2 0080H 8080H and Read in BTR: word 4 = 0FFF word 5 = 0FFF 7. To verify 4-20mA range, enter command codes 0400H and 8400H.
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7–10 Calibration Instructions Notes: Publication 1771-6.5.
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