Allen-Bradley 1771-QDC User manual

Plastic Molding Module

Inject Mode

(Cat. No. 1771-QDC)

PLC is a registered trademark of Allen-Bradley Company, Inc.

PanelView, and PanelBuider are trademarks of Allen-Bradley Company, Inc

Because of the variety of uses for the products described in this publication,

those responsible for the application and use of this control equipment must

satisfy themselves that all necessary steps have been taken to assure that

each application and use meets all performance and safety requirements,

including any applicable laws, regulations, codes and standards.

The illustrations, charts, sample programs and layout examples shown in

this guide are intended solely for purposes of example. Since there are

many variables and requirements associated with any particular installation,

Allen-Bradley does not assume responsibility or liability (to include

intellectual property liability) for actual use based upon the examples shown

in this publication.

Allen-Bradley publication SGI-1.1, Safety Guidelines for the Application,

Installation, and Maintenance of Solid State Control (available from your

local Allen-Bradley office), describes some important differences between

solid-state equipment and electromechanical devices that should be taken

into consideration when applying products such as those described in this

publication.

Reproduction of the contents of this copyrighted publication, in whole or in

part,

without written permission of Allen-Bradley Company

Inc. is prohibited.

Throughout this manual we use ATTENTION and Important to alert you

to the following:

ATTENTION: Tells readers where people may be hurt,

machinery may be damaged, or economic loss may occur, if

procedures are not followed properly.

ATTENTION helps you:

- identify a hazard

- avoid the hazard

- recognize the consequences

Important: Identifies information that is especially important for successful

application and understanding of the product.

Important: We recommend that you frequently back up your application

programs on an appropriate storage medium to avoid possible data loss.

Important User Information

Summary of Changes

We revised this publication to include changes due to upgrading the

1771-QDC/B module to a 1771-QDC/C.

For These Changes Refer to Page(s)

Lossofsensor detection

input range changed back to 0.00 to 10V dc

35, 310

A3, A4

Added the section, Record I/O Ranges.

Added the title Ground and Shield Your I/O Devices to

better describe the task.

21

29

Reversed the order of chapters 3 and 4 to present the

download procedure for the MCC block before the

download procedure for the other data blocks.

Revised the download procedure for the MCC block

(chapter 3) and for other command blocks (chapter 4).

Chapters 3 and 4

Added data codes to Profile Block worksheets. Chapter 8 and Appendix A

Placed 2page worksheets on facing pages Chapters 7 and 8

Minor corrections as found

To Help You Find Changes

To help you find these changes, we added change bars as shown to the left.

Summary of Changes

Summary of Changes 11. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Use This Preface P1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Manual

Objectives

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

Audience P2

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

Use

of T

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

Publications

P4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Overview of Inject Mode 11. . . . . . . . . . . . . . . . . . . . . . . . . .

Chapter

Objectives

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

Inject Mode Operation 11

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

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

Chapter

Objectives

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

Record

I/O Ranges

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

Set Module Jumper Plugs 22

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

Key Your I/O Chassis 25

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

Install

the QDC Module

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

Wire

the QDC Module

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

Ground and Shield Your I/O Devices 29

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

Plan for EStops and Machine Interlocks 211

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

Configure the QDC Module'

s I/O

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

Chapter

Objectives

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

Use Worksheets to Select Module Parameters and I/O Ranges 31

. . .

Determine Initial Sensorconfiguration Values 34

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

Download

MCC V

alues to the QDC Module

36. . . . . . . . . . . . . . . . .

Use SetOutput Operation to Move the Ram (Screw) 38

. . . . . . . . . . .

Complete Your Sensor Configuration 39

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

Select

Optional Configurations

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

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

Chapter

Objectives

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

Configuration Concepts 41

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

Special Command and Status Blocks 42

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

Overview of Remaining Configuration Procedures 43

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

Enter Data Table Values and Download Command Blocks 44

. . . . . . .

Table of Contents

Table of Contentsii

Jog

our Machine 51. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Chapter

Objectives

51. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

About Jogging 51

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

Use These Worksheets 51

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

Determine

Initial Jog V

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

Write Ladder Logic 55

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

Jog Your Ram (Screw) 57

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

Configure Jogs for the Clamp and Ejector 57

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

Write Ladder Logic to Assist with Clamp & Eject Jogs 59

. . . . . . . . . .

Jog Your Clamp and Ejector 510

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

Select Command and Status Bits to Sequence

Machine Operation 61. . . . . . . . . . . . . . . . . . . . . . . . . . .

Chapter

Objectives

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

Assess Your Logic Requirements 61

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

Use

Command and Status Bit T

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

Load

Initial Configuration V

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

Chapter

Objectives

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

Use These Worksheets 72

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

Procedure

to Determine and Enter Initial V

alues 712. . . . . . . . . . . . . .

Determine

Bit Selections: Assign Module Outputs

for Your Control Valves 712. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Select the T

ype of PID Algorithm

714. . . . . . . . . . . . . . . . . . . . . . . . .

Set Values for Expert Response CompensationE (ERC) 715

. . . . . . . .

Determine Unselected Valve Setoutput Values 715

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

Set Your Acceleration/Deceleration Ramp Rates 717

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

Determine Setoutput Values for End of Profiles 718

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

Set Pressure Control Limits 719

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

Set V

elocity Control Limits

722. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Set

RPM Control Limits

723. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Set

Profile T

uning Constants, PressureAlarm Setpoints,

and Watchdog Timer Preset 725

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

Enter and Download your Worksheet Values 726

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

Load

Initial Profile V

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

Chapter

Objectives

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

Use These Worksheets 81

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

Determine and Record Setpoints for the Injection Profile (IPC) 82

. . . .

Determine Bit Selections for Worksheet 8A 84

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

Determine Word Values for Worksheet 8A 85

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

Enter and Download your Worksheet Values 89

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

Determine and Record Setpoints for the Pack/Hold Profile (HPC) 89

. .

Determine Bit Selections for Worksheet 8B 812

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

Table of Contents iii

Determine Word Values for Worksheet 8B 814. . . . . . . . . . . . . . . . . .

Enter and Download your Worksheet Values 815

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

Determine and Record Setpoints for Plastication Profile (PPC) 816

. . . .

Determine Bit Selections for Worksheet 8C 818

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

Determine Word Values for Worksheet 8C 819

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

Enter and Download your Worksheet Values 822

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

Span

our V

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

Chapter

Objectives

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

Referenced Worksheets 91

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

Span Your Injection Pressure Valve 92

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

Span Your Injection V

elocity V

alve 97. . . . . . . . . . . . . . . . . . . . . . . .

Span Your Pack and Hold Pressure Valves 913

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

Span Your Plastication Pressure Valve 920

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

Span Y

our Plastication RPM V

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

Tune

our Machine for Producing Parts 101. . . . . . . . . . . . . . .

Chapter

Objectives

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

Closedloop Control 102

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

Tune Closedloop Pressure Control 102

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

Tune Closedloop V

elocity Control

105. . . . . . . . . . . . . . . . . . . . . . . .

Tuning Considerations for Production Parts 108

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

Profile Requirements 108

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

Cushion, Shot Size, and T

ransition Setpoints

1011. . . . . . . . . . . . . . . .

Unselected Valve Setoutput Values 1013

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

Logical Bridges and Endofprofile Setoutput Values 1015

. . . . . . . . . . .

Decompression Pullback 1016

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

Acceleration and Deceleration Ramp Rates 1016

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

Watchdog T

imer and Profile Of

fsets 1018. . . . . . . . . . . . . . . . . . . . . . .

Pressure

Alarm Setpoints

1018. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pressurelimited

Injection V

elocity vs. Position

1019. . . . . . . . . . . . . . .

Expert Response Compensation 1021

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

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

Chapter

Objectives

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

Use LEDs to Troubleshoot Your QDC Module 111

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

Module

Calibration

112. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Preface

P-1

Use This Preface

Use this preface to familiarize yourself with this manual so you can use it

effectively. This manual shows you how to apply the QDC module to your

molding machine in the minimum length of time.

Since this manual is task oriented, we recommend that you perform these

tasks in the following order:

Perform this task: As discussed in this

chapter:

Browse through the entire manual to become familiar with its

contents.

All chapters

Overview the inject process. This presents an overview on

how the QDC module controls the inject phase of your injection

molding system.

Chapter 1

Install the QDC module. This includes such tasks as wiring

and setting jumpers.

Chapter 2

Configure the QDC module mode to match your specific

application, and to communicate with inputs and outputs.

Chapter 3

Overview of remaining configuration procedures that you will

perform throughout the remainder of this manual.

Chapter 4

Jog the ram (screw). This task requires jog setpoints to be

configured along with jog pressure alarm setpoints.

Chapter 5

Set up communications between your PLC5 processor and

the QDC module. Select command and status bits that you will

use when writing your ladder logic.

Chapter 6

Load your initial configuration values to the QDC module. This

task requires you to determine and enter values into

configuration blocks in preparation for chapter 9.

Chapter 7

Load your initial machine profile setpoints to the QDC module.

This is performed in preparation for chapter 9.

Chapter 8

Span your machine's valves for inject mode. This is done

using setoutput and openloop control.

Chapter 9

Tune your machine for producing parts. Chapter 10

Troubleshoot problems that may occur with the QDC module. Chapter 11

Refer to this appendix for a blank copy of each worksheet

contained in this manual.

Appendix A

Manual

Objectives

Preface

P-2

In order to apply the QDC module to a molding machine, we assume that

you are an:

injection molding professional

experienced programmer with Allen-Bradley PLC-5 processors

hydraulics designer or technician

We use these abbreviations:

Abbreviated Name: Item

QDC module 1771QDC Plastic Molding Module

PLCprocessor PLC5 Processor

T45 or T47

T50 or T53 terminal

1784T45 or T47

1784T50 or T53 Industrial Terminal

ProSet600 Software 6500PS600

ProSet 600 Injection Molding Operator Interface Software

PanelViewTerminal 2711KC1 PanelView Operator Interface Terminal

The next table presents other terms we commonly use in this manual:

Term: Definition:

Selected Valve In multivalve systems, depending on the configured profile, the QDC

module controls one valve and presets the setting of the remaining

valves to produce moldingmachine profiles. We call the valve being

controlled by the QDC module's algorithms the selected valve.

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

module controls one valve and presets the remaining valves to

produce moldingmachine profiles. We call the valves that are preset

with an open loop percentage setpoint the unselected valves.

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

to the QDC module.

Command Blocks

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

module to make configuration changes or to initiate machine actions.

Status Blocks Data blocks used by the QDC module to relay information to the

PLC5 processor about the QDC module's current operating status.

Profile Block Command block containing mold/part setpoints.

Configuration Block Command block containing machine setpoints.

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

with increasing signal input.

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

with decreasing signal input.

Audience

Use

of T

erms

Preface

P-3

Command Blocks

Command blocks provide the parameters that control machine operation.

They are transferred from the PLC processor to the QDC module by means

of block transfer write (BTW) instructions in software ladder logic. Their

abbreviations are:

Acronym: Description:

MCC Module Configuration Block

JGC Jog Configuration Block

INC Injection Configuration Block

IPC Injection Profile Block

PKC Pack Configuration Block

HDC Hold Configuration Block

HPC Pack/Hold Profile Block

PRC Predecompression Configuration Block

PLC Plastication Configuration Block

PPC Plastication Profile Block

PSC Postdecompression Configuration Block

DYC Dynamic Command Block

RLC Inject ERCValues Command Block

Status Blocks

Status blocks report current status of molding-machine operation. They

are returned from the QDC module to the PLC processor by means of

block transfer read (BTR) instructions in software ladder logic. Their

abbreviations are:

Acronym: Description:

SYS System Status Block

IPS Injection Profile Status Block

HPS Pack/Hold Profile Status Block

PPS Plastication Profile Status Block

RLS Inject ERCValues Status Block

Preface

P-4

Word and bit Numbering

The QDC module stores data in command and status blocks. Each word

location in a command or status block is identified by an alphanumeric

code containing the block acronym and word number. For example, word

09 of the Module Configuration Command Block (MCC) is identified as

MCC09.

Identify bits in a word location by adding bit numbering to the abbreviated

word location. For example:

Specific: MCC09-B15 General: MCCxx-Byy

where:

MCC = Module Configuration Command Block

xx=word number (01-64)

B = bit identifier

yy = bit number (00-15)

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 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4.10 Application guide Select QDC module's mode of operation and

match it to your machine's hydraulics

17716.5.86

17716.5.87

17716.5.93

Plastic Molding Module,

1771QDC, User Manuals

Configure, program, install, and operate your

QDC module in other QDC modes of

operation

17716.5.88 Plastic Molding Module

1771QDC, Reference

Manual

Program block transfers between PLC

processor and QDC. Also, information on

PLC5 data transfer logic.

Publications

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