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
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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Related
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 Y 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 Y 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 Y 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.
Related Publications