Release Note Updates to Plastic Molding and Co-injection Modules (Catalog Numbers 1771- and 1771-QI) What s in This Release Note? this symbol applies to module only QI applies to QI module only QI means that this update applies to and QI modules This release note describes enhancements to the plastic molding module (catalog no. 1771-) and co-injection module (catalog no. 1771-QI). In this document, we refer to the plastic molding module as the module, and the co-injection module as the QI module. We discuss these enhancements to the modules: operating enhancements process trace this module catalog number 1771- (plastic molding module) 1771-QI (co-injection module) is upgraded to this series and revision Series C, Revision D Series D, Revision A Series A, Revision B Series B, Revision A Operating Notes O These notes describe previously undocumented operating features. Non-functional Bits The bits shown in the following table are non-functional (always reset to zero) on the module, series C, rev. A through C, when shipped from the factory. You may want to write ladder logic to support these functions in your application. The non-functional bits will work correctly with the module, series C, rev. D and later.
2 Updates to Plastic Molding and Co-injection Modules for this write ladder logic to support this function (non-functional) bit SYS08 B00 loss of signal from screw position sensor, stop actions in progress, and ignore commands from DYC02 B01 loss of signal from screw pressure sensor, stop actions in progress, and ignore commands from DYC02 B06 loss of signal from screw RPM sensor stop actions in progress, and ignore commands from DYC02 B07 loss of signal from cavity pressure sensor, stop actions in progress, and ignore commands from DYC02 SYS12 B00 loss of screw position sensor and latch alarm bits on false-to-true transition B01 loss of screw pressure sensor and latch alarm bits on false-to-true transition B06 loss of screw RPM sensor and latch alarm bits on false-to-true transition B07 loss of cavity pressure sensor and latch alarm bits on false-to-true transition Loss-of-Sensor Protection The module continuously monitors all inputs for sensor loss. When it detects that the process input is greater or less than the input s range, the module sets an alarm that is displayed on your operator interface panel. The module shuts down and sets all outputs to zero. To protect against out-of-control operation, you can use loss-of-sensor protection for all module inputs Avoiding Nuisance Alarms To avoid nuisance alarms caused by electrical noise, you can set MCC 64 so the module must monitor continuous out-of-range signals for a period of time before setting the loss-of-sensor alarm. You can set the delay in a range from 0 200 samples (a sample takes 2 ms to complete).! ATTENTION: Do not use a delay value greater than 200 ms. Unpredictable module operation may result. Setting the time delay to 0 gives no protection against nuisance alarms.
Updates to Plastic Molding and Co-injection Modules 3 Overriding Loss-of-Sensor Protection For some applications, you may want to override loss-of-sensor protection by setting the appropriate inhibit bit. To inhibit loss-of-sensor protection on selected inputs, set the bits in module block MCC02 as shown in the following table. to inhibit protection for this input screw position screw pressure clamp position clamp pressure ejector position ejector pressure screw RPM cavity pressure (system pressure in Inject Clamp-Eject mode) set this bit MCC02 B08 MCC02 B09 MCC02 B10 MCC02 B11 MCC02 B12 MCC02 B13 MCC02 B14 MCC02 B15 Absolute Final Screw Position at End of Post-decompress This enhancement assures that the screw position at the end of the post-decompression phase is stable. Prior to this enhancement, the screw stopped moving at a position which was the sum of the actual position at the end of plastication plus an incremental post-decompression length. How Does the Enhancement Improve Operation? With this enhancement, the module calculates the shot size plus cushion plus post-decompression length for more accurate positioning at the end of the post-decompression phase. We express this calculation with this formula: PSTDEPOS = PPC61 + PPC62 + PSC05 where: PSTDEPOS = position PPC61 = cushion size PPC62 = shot size PSC05 = incremental post-decompression length How Does the Enhancement Affect my System Operation? You may need to modify ladder logic you have already written.
4 Updates to Plastic Molding and Co-injection Modules Single Transfer for Ejector Status To improve the PLC processor s ability to detect ejector status, this status information is now returned in a single transfer. How Does the Enhancement Improve Operation? Returning status information with a single transfer allows for quicker detection and reporting of ejector operation. How Does the Enhancement Affect my System Operation? You may need to modify ladder logic you have already written. The following table lists the words and/or bits that have been added. bit B08 B09 B10 B11 B12 B13 B14 B15 description initial advance stroke completed Set during ejector profile execution when module monitors completion of the initial advance stroke. Reset when the module receives any execution command except DYC02 B10 through DYC02 B13. ejector is retracting or ready to retract Set during ejector profile execution when module monitors completion of any advance stroke. Reset during ejector profile execution when the module monitors completion of any retract stroke. dwell timer timing Set and reset as specified by bit SYS03 B10 (refer to bit description for SYS03 B10 in the Plastic Molding Module Reference Manual, pub. 1771-6.5.88). final advance stroke completed Set during ejector profile execution when module monitors completion of the final advance stroke. Reset when the module receives any execution command except DYC02 B10 through DYC02 B13. end-of-dwell ejector profile continuation pending Set during ejector profile execution when ejector forward dwell timer is timing and the module is prepared to continue the ejector profile when dwell time expires. Reset at all other tmes. not used ejectors running Set during ejector profile execution when SYS03 B08 and SYS03 B10 are both reset. Reset during ejector profile execution when either SYS03 B08 or SYS03 B10 are set. ejector profile complete Set and reset as specified by bit SYS02 B14 except that it is not reset by DYC03 B10 (refer to bit description for SYS02 B14 in the Plastic Molding Module Reference Manual, pub. 1771-6.5.88).
Updates to Plastic Molding and Co-injection Modules 5 Hysteresis for Ejector Retract and Mold Open Bits A tolerance of 0.005 in. ( 0.127 mm) was added to the instructions that control ejector retract and mold open status bits. How Does the Enhancement Improve Operation? The increased tolerance helps to eliminate the nuisance of bits resetting too soon after an ejector retract or mold open. Adjustable Stop Output Voltage QI Prior to this enhancement, the stop position output was 0V dc or 4 ma. This enhancement adds an offset of 10% ( 1000 to +1000). How Does the Enhancement Improve Operation? This parameter lets you adjust the stop point to an offset rather than 0V dc or 4 ma. How Does the Enhancement Affect my System Operation? You may need to modify ladder logic you have already written to accommodate this change. The following table lists the words and/or bits that have changed. output word 1 MCC05 2 MCC06 3 MCC07 4 MCC08 If you use a stop point value outside of the valid range ( 1000 to +1000), you will see these error codes: this error code 405 406 407 408 means your entry for MCC05 is out of range change to 1000 MCC05 1000 your entry for MCC06 is out of range change to 1000 MCC05 1000 your entry for MCC07 is out of range change to 1000 MCC05 1000 your entry for MCC08 is out of range change to 1000 MCC05 1000
6 Updates to Plastic Molding and Co-injection Modules System Status Returns Double Command Error QI If, because of an error in ladder logic programming, two or more command bits are downloaded at the same time, the module returns a double command error. This enhancement returns the two command bits downloaded at the same time. How Does the Enhancement Improve Operation? This enhancement returns words 1 and 2 of the dynamic command block. By reviewing SYS23 and SYS24, you can determine which bits were set or downloaded at the same time. How Does the Enhancement Affect my System Operation? You may need to modify ladder logic you have already written. These words and/or bits that have changed. word SYS23 SYS24 contains DYC01 DYC02 Error Checking Allows Maximum Limits as Setpoints QI This enhancement lets setup personnel enter the maximum travel limits of position axes as setpoints. Added Process Trace (1771-, Series D Rev. A Only) The Process Trace feature lets you chart process variables, such as: injection position injection pressure injection velocity cavity pressure screw RPM injection flow valve output injection pressure valve output You can collect data for up to four traces. Important: Because of memory limitations, PLC-5/20 processors can collect data for only one trace. We do not recommend PLC-5/20 processors for use with process trace or co-injection.
Updates to Plastic Molding and Co-injection Modules 7 How Does Process Trace Work with Pro-Set 700 Software? You configure traces on the Process Trace Setup screen. Then you download the screen to the PLC processor. The modules collect trace data and the PLC processor transfers the information into data table files. The operator interface reads these data table files and plots the information on the Process Trace screen. What Words/bits Were Added to Existing Module Blocks? We added these words and bits to the SYS and DYC blocks: word bit function SYS14 command block rejection errors The module latches this bit when it receives a PTC block for decode, and SYS53 B00 is set. The module unlatches this bit when it receives a PTC block for decode and SYS53 B00 is reset. B10 process trace command block rejected SYS16 on-board command block status B11 valid PTC block SYS18 last successful decode status B11 PTC block last successful decode SYS20 programming error alarms B11 PTC block programming error SYS53 process trace status B00 process trace data collection in progress B01 process trace data collection complete SYS54 process trace data collection in progress B00 module is collecting trace data points 1 to 50 B01 module is collecting trace data points 51 to 100 B02 module is collecting trace data points 100 to 150 B03 module is collecting trace data points 151 to 200 B04 module is collecting trace data points 201 to 250 B05 module is collecting trace data points 251 to 300 B06 module is collecting trace data points 301 to 350 B07 module is collecting trace data points 351 to 400 B08 to B15 open SYS55 process trace data collection done The module latches these bits when data trace points collected. The module unlatches these bits on false-to-true transition of SYS53 B00. B00 module has collected trace data points 1 to 50 B01 module has collected trace data points 51 to 100 B02 module has collected trace data points 101 to 150 B03 module has collected trace data points 151 to 200 B04 module has collected trace data points 201 to 250 B05 module has collected trace data points 251 to 300 B06 module has collected trace data points 301 to 350 B07 module has collected trace data points 351 to 400 B08 to B15 open
8 Updates to Plastic Molding and Co-injection Modules word DYC04 DYC07 DYC08 bit function profile status block clear commands B15 clear PTS process trace command bits B00 process trace data collection inhibited (examined at the beginning of the 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 to B14 open B15 return phase/segment start information in next PTS block process trace data block request B00 return trace data points 1 to 50 in next PTS block B01 return trace data points 51 to 100 in next PTS block. B02 return trace data points 101 to 150 in next PTS block B03 return trace data points 151 to 200 in next PTS block B04 return trace data points 201 to 250 in next PTS block B05 return trace data points 251 to 300 in next PTS block B06 return trace data points 301 to 350 in next PTS block B07 return trace data points 351 to 400 in next PTS block B08 to B15 open What New Module Blocks Were Added? We added the Process Trace Configuration Command (PTC) blocks and Process Trace Status (PTS) blocks listed in the following tables. Important: Important: To accept the PTC block, configure the modules to include an analog input for a screw position sensor (MCC02). The PTC block writes configuration information (such as trace start triggers and sample traces) to the modules. The PTS block reports requested process data from the modules.
Updates to Plastic Molding and Co-injection Modules 9 PTC Blocks word bit function PTC01 PTC02 block ID B00 to B07 process trace command block ID (00011100) B08 to B15 reserved do not use control bits B00 0 = process trace disabled 1 = process trace enabled B01 0 = trigger on time delay 1 = trigger on position PTC03 open PTC04 open PTC05 trigger delay (in hundredths of seconds) for data collection after injection begins (when PTC02 B01 is equal to 0) PTC06 trigger position (in hundredths of inches or tenths of millimeters) on which to collect data when PTC02 B01 is equal to 1 PTC07 sample rate at which the module collects trace data in milliseconds (must be an even number between 2 and 230) PTC08 trace #1 selection B01 injection position B02 injection pressure B03 injection velocity 1 PTC09 B04 cavity pressure B05 screw RPM B06 injection flow valve output B07 injection pressure valve output trace #2 selection B01 injection position B02 injection pressure B03 injection velocity 1 B04 cavity pressure B05 screw RPM B06 injection flow valve output B07 injection pressure valve output 1 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.
10 Updates to Plastic Molding and Co-injection Modules word PTC10 PTC11 PTC12 to PTC64 bit trace #3 selection B01 injection position B02 injection pressure B03 injection velocity 1 B04 cavity pressure B05 screw RPM B06 injection flow valve output B07 injection pressure valve output trace #4 selection B01 injection position B02 injection pressure B03 injection velocity 1 B04 cavity pressure B05 screw RPM B06 injection flow valve output B07 injection pressure valve output open function 1 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. PTS Blocks word bit function PTS01 B00 to B07 process trace status block ID (00001010) B08 to B15 power up and jog execution status (refer to bit description for SYS01 in the Plastic Molding Module Reference Manual, pub. 1771-6.5.88) PTS02 profile execution status (refer to bit description for SYS02 in the Plastic Molding Module Reference Manual, publication 1771-6.5.88) PTS03 miscellaneous status (refer to bit description for SYS03 in the Plastic Molding Module Reference Manual, publication 1771-6.5.88) PTS04 watchdog timeout status (refer to bit description for SYS04 in the Plastic Molding Module Reference Manual, publication 1771-6.5.88) PTS05 trace selection 1 B00 open B01 block contains injection position trace data B02 block contains trace #1 data B03 block contains trace #2 data B04 block contains trace #3 data B05 block contains trace #4 data B06 to B14 open B15 block contains phase/segment start information 1 If one of PTS05 B01 to B05 is set, PTS15 to PTS64 contain trace data. If PTS05 B15 is set, PTS15 to PTS48 contain phase/segment start information. Each word contains the starting data point (1 400) for the listed phase or segment. If the phase or segment was not executed, this value will be zero.
Updates to Plastic Molding and Co-injection Modules 11 word PTS06 PTS07 PTS08 PTS09 PTS10 PTS11 to PTS14 bit trace data block number B00 block contains trace data points 1 to 50 B01 block contains trace data points 51 to 100 B02 block contains trace data points 101 to 150 B03 block contains trace data points 151 to 200 B04 block contains trace data points 201 to 250 B05 block contains trace data points 251 to 300 B06 block contains trace data points 301 to 350 B07 block contains trace data points 351 to 400 open open function 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. open PTS15 injection segment #1 starting data point 1 PTS16 injection segment #2 starting data point PTS17 injection segment #3 starting data point PTS18 injection segment #4 starting data point PTS19 injection segment #5 starting data point PTS20 injection segment #6 starting data point PTS21 injection segment #7 starting data point PTS22 injection segment #8 starting data point PTS23 injection segment #9 starting data point PTS24 injection segment #10 starting data point PTS25 injection segment #11 starting data point PTS26 pack segment #1 starting data point PTS27 pack segment #2 starting data point PTS28 pack segment #3 starting data point PTS29 pack segment #4 starting data point PTS30 pack segment #5 starting data point PTS31 hold segment #1 starting data point PTS32 hold segment #2 starting data point PTS33 hold segment #3 starting data point PTS34 hold segment #4 starting data point PTS35 hold segment #5 starting data point PTS36 pre-decompress starting data point PTS37 plastication segment #1 starting data point PTS38 plastication segment #2 starting data point PTS39 plastication segment #3 starting data point PTS40 plastication segment #4 starting data point PTS41 plastication segment #5 starting data point PTS42 plastication segment #6 starting data point PTS43 plastication segment #7 starting data point 1 If one of PTS05 B01 to B05 is set, PTS15 to PTS64 contain trace data. If PTS05 B15 is set, PTS15 to PTS48 contain phase/segment start information. Each word contains the starting data point (1 400) for the listed phase or segment. If the phase or segment was not executed, this value will be zero.
12 Updates to Plastic Molding and Co-injection Modules word PTS44 PTS45 PTS46 PTS47 PTS48 bit plastication segment #8 starting data point plastication segment #9 starting data point plastication segment #10 starting data point plastication segment #11 starting data point post-decompress starting data point function What Module Programming Block Error Codes Were Added? We added these PTC programming error codes. error code 0205 0206 0207 description PTC05 (trigger delay) is out of range Valid range is 00000 PTC05 09999. PTC06 (trigger position) is out of range Valid range is IPC61 PTC06 PPC61 + PPC62 + PSC05. PTC07 (sample rate) is out of range Valid range is 00002 PTC07 00230. 0407 PTC07 (sample rate) is not an even number 0208 PTC08 (trace #1 selection) is invalid 0209 PTC09 (trace #2 selection) is invalid 0210 PTC10 (trace #3 selection) is invalid 0211 PTC11 (trace #4 selection) is invalid Allen-Bradley, a Rockwell Automation Business, has been helping its customers improve productivity and quality for more than 90 years. We design, manufacture and support a broad range of automation products worldwide. They include logic processors, power and motion control devices, operator interfaces, sensors and a variety of software. Rockwell is one of the world s leading technology companies. Worldwide representation. Argentina Australia Austria Bahrain Belgium Brazil Bulgaria Canada Chile China, PRC Colombia Costa Rica Croatia Cyprus Czech Republic Denmark Ecuador Egypt El Salvador Finland France Germany Greece Guatemala Honduras Hong Kong Hungary Iceland India Indonesia Ireland Israel Italy Jamaica Japan Jordan Korea Kuwait Lebanon Malaysia Mexico Netherlands New Zealand Norway Pakistan Peru Philippines Poland Portugal Puerto Rico Qatar Romania Russia CIS Saudi Arabia Singapore Slovakia Slovenia South Africa, Republic Spain Sweden Switzerland Taiwan Thailand Turkey United Arab Emirates United Kingdom United States Uruguay Venezuela Yugoslavia Allen-Bradley Headquarters, 1201 South Second Street, Milwaukee, WI 53204 USA, Tel: (1) 414 382-2000 Fax: (1) 414 382-4444 PN 955127-19 Copyright 1997 Allen-Bradley Company, Inc. Printed in USA