6500-10.1, Installing Co-injection and Plastic Molding Modules
Contents
1. Attach the PLC processor to the operator interface Refer to the Pro Set 700 Operator Interface Installation Manual publication 6500 6 2 1 From the Setup menu select the Rack Configuration screen Move the cursor to the appropriate field on the screen Press k You see a pop up menu Place the cursor on the selection you want to make and press You can select e PLC type machine type mode of operation al Press to confirm your selections D lt Press to download your selections to the PLC processor PLC and Pro Set 700 are trademarks of Allen Bradley Company Inc 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 1 2 Rack Configuration 3 aoai 4 p EEE er 5 aaa EE NotUsed ize 3m Inject eee a Make your selection from the pop up list that appears when you cursor to the field and press 6 S 7 OA Rockuvell Automation Allen Bradley Worldwide representation 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 4 ah Ji N i Argentina e Australia e Austria e Bahrain e Belgium e Brazil e Bul2. circuit boards install the modules into the chassis ground and shield 1 0 devices Wo CO S BD U1 eI WIN make a proper ground connection familiarize yourself with the PLC processor power distribution circuit wire the modules power up the modules read module indicator lights enter I O ranges on the Module Configuration screen P ro Set 700 only Hakaa eaea a SMS S11 use the Rack Configuration screen to select operating mode Pro Set 700 only Publication 6500 10 1 March 1996 Related Publications Installing Co injection and Plastic Molding Modules This document provides an abbreviated procedure for installing the modules Refer to the appropriate manual for complete procedures To order additional manuals contact your local Allen Bradley sales representative You can order the Plastic Molding Module Documentation Set 6500 QDCDOC or the individual manuals as listed below To do this task Use this manual title publication no Install and configure co injection QI modules Pro Set 700 Co injection Software User Manual 6500 6 5 19 Install plastic molding QDC modules Plastic Molding Module Inject Mode Manual 1771 6 5 85 Plastic Molding Module Inject and Clamp Mode Manual 1771 6 5 86 Plastic Molding Module Clamp and Eject Mode Manual 1771 6 5 87 Plastic Molding Module Inject Clamp and Eject Mode 1771 6 5 93 Manual Determine plast
3. Quick Start for Experienced Users Installing Co injection and Plastic Molding Modules Catalog Nos 1771 QI and 1771 QDC What s in This Quick Start This document describes how to install and configure co injection step m modules cat no 1771 QD and plastic molding modules cat no 1771 QDC Plastic molding modules 1771 QDC can be used to control inject clamp and eject phases of an injection molding machine You can also use the QDC modules to control the clamp and eject phases when you use the QI modules to control the inject phase p In this document we refer to plastic molding modules 1771 QDC as QDC modules and co injection modules 1771 QI as QI modules P You can use QI and QDC modules with applications other than Pro Set 700 software In this document we note where procedures are specific to Pro Set 700 software Important If you are using co injection modules in a Pro Set 700 application you must install Pro Set 700 software Release 2 02 or above and Pro Set 700 Co injection software Release 2 02 or above Contact your Allen Bradley sales representative for information This Quick Start will help you to do these tasks task cs 2 Q O choose the correct power supply p determine the I O chassis addressing mode determine the modules positions in the chassis key chassis slots for the modules determine and record I O ranges make jumper connections on the modules
4. dule housing Publication 6500 10 1 March 1996 Installing Co injection and Plastic Molding Modules Top g 3 Orient the circuit board as shown in the figure Bo o amp lt 4 E El 4 Locate the jumper plugs as shown in the figure B as 5 Use a pair of small needle nose pliers to pick up and place the m A T a jumper plugs Refer to the table below for the correct settings e _ Rig Ta 6 Re assemble the module a EM E EBE 5 E158 p E17 o E168 o Bottom jumper function setting comments El run calibrate calibrate right run left default E5 I O density standard top default do not use bottom position E6 input 1 voltage right default E7 input 2 current left E8 input 3 E9 input 4 E10 output 1 Valve 1 current top If you select current output with E10 E14 output 2 Valve 2 voltage bottom E14 E13 and or E17 you must select E13 output 3 Valve 3 default the 4 to 20 mA position with E11 E12 E17 output 4 Valve 4 E15 and or E16 Ell output 1 Valve 1 10 to 10V dc top If you select current output with E10 E12 output 2 Valve 2 Oto 10V dc or 4 to 20 E14 E13 and or E17 you must select E15 output 3 Valve 3 mA bottom default the 4 to 20 mA position with E11 E12 E16 output 4 Valve 4 E15 and or E16 Publication 6500 10 1 March 1996 For bi directional valve operation if an output
5. ections 4 Refer to the specifications that accompanied your sensors to determine the operating range 5 Determine the outputs you want the modules to control Record your output selections on the worksheet 6 Determine the sensors and valves that the injection molding machine will use to monitor and control system operation Installing Co injection and Plastic Molding Modules 5 7 Circle the I O ranges on the worksheet for each sensor and valve used Bo Here is a blank worksheet you can photocopy and use to record your own I O ranges Module Operating Modes for co injection applications select module A or B Module A __ 1 7 Module B_ Signal Ranges 0 to 10V dc 1 to 5V dc 4 to 20m 0 to 10V dc 1 to 5V dc 4 to 20m 0 to 10V dc 1 to 5V dc 4 to 20m 0 to 10V dc 1 to 5V de 4 to 20 m Signal Ranges 10 to 10V dc 10 to 10V dc 4 to 20 m 10 to 10V dc 0 to 10V dc 4 to 20 m 10 to 10V dc 0 to 10V dc 4 to 20 m 10 to 10V dc 0 to 10V dc 4 to 20 m Step 6 Make Jumper Connections on the Modules Circuit Boards After determining I O operating ranges you make jumper connections on the modules circuit boards to select the ranges Important Handle the circuit board by the edges to avoid touching conductive surfaces or components 1 Remove the module cover plate on the label side by removing the four screws holding it in place 2 Remove the circuit board from the mo
6. garia e Canada e Chile e China PRC e Colombia e Costa Rica e Croatia e Cyprus e Czech Republic e Denmark e Ecuador e Egypt El Salvador e Finland e France e Germany e Greece e Guatemala e Honduras e Hong Kong e Hungary e Iceland e India e Indonesia e Ireland e Israel e Italy e Jamaica e J apan e J ordan e Korea e Kuwait e Lebanon e Malaysia e Mexico e Netherlands e New Zealand e Norway e Pakistan e Peru e Philippines e Poland e Portugal e Puerto Rico e Qatar e Romania e Russia CIS e Saudi Arabia e Singapore e Slovakia e Slovenia e South Africa Republic e Spain e Sweden e Switzerland e Taiwan e Thailand e Turkey e United Arab Emirates e United Kingdom e United States e Uruguay e Venezuela Yugoslavia Allen Bradley Headquarters 1201 South Second Street Milwaukee WI 53204 USA Tel 1 414 382 2000 Fax 1 414 382 4444 Publication 6500 10 1 March 1996 PN 955125 43 Copyright 1996 Allen Bradley Company Inc Printed in USA
7. ic molding QDC module operating Plastic Molding Module Application Guide 1771 4 10 modes Use the QDC module with your machine s hydraulic system Configure QDC modules Pro Set 700 Software User Manual 6500 6 5 18 Find reference information such as command and Pro Set 700 Co injection Software User Manual 6500 6 5 19 status bits for the QI module Find reference information such as command and Plastic Molding Module Reference Manual 1771 6 5 88 status bits for the QDC module Pro Set 700 Software Reference Manual 6500 6 4 3 1Contained in the Plastic Molding Module Documentation Set 6500 QDC DOC r Publication 6500 10 1 March 1996 What if Want Other Pro Set 700 Publications You can order the Pro Set 700 Documentation Set cat no 6500 PS7DOC for more information Or if you prefer you can order the publications in the documentation set individually Contact your Allen Bradley sales representative or distributor to order To order the Pro Set 700 publications individually use these publication numbers title publication no Installing Pro Set 700 Software 6500 5 3 Pro Set 700 Software User Manual 6500 6 5 18 Pro Set 700 Software Reference Manual 6500 6 4 3 Pro Set 700 Operator Interface Installation Manual 6500 6 2 1 J obsetting Guide for Pro Set 700 Systems 6500 6 9 3 ControlView Runtime Reference Manual 6195 6 5 4 ControlView Statistical Process Control User Man
8. is unconnected set the jumper E11 E12 E15 and or E16 for that output to 0 to 10V dc bottom position Important Setting the jumpers for 10 to 10V dc and later configuring the output as unconnected causes the modules to output 10V dc when stopped or when the system resets All outputs are forced to 0 since 0 10V de Installing Co injection and Plastic Molding Modules 7 Step 7 Install the Modules into the Chassis Follow these steps to install the modules ATTENTION Remove power from the chassis backplane and disconnect the cable from the module before installing or removing a module Failure to remove power may cause injury damage or loss of performance 1 Turn off power to the I O chassis 2 Place the module in the plastic tracks on the top and bottom of the slot that guide the module into position 3 Slide the module into the chassis Apply firm even pressure on the module to seat it against the backplane connector ATTENTION Do not force the module into the backplane connector Doing so may damage the module or the connector 4 Snap the chassis latch over the top of the module to secure it in the chassis 5 Attach the wiring arm 1771 WF to the rack Step 8 Ground and Shield I O Devices Analog inputs and outputs are sensitive to electrical noise Be sure to properly shield all devices Refer to the appropriate manual for more information Publication 6500 10 1 March 1996 Insta
9. lling Co injection and Plastic Molding Modules Attach this end to a good earth ground Publication 6500 10 1 March 1996 Step 9 Make a Proper Ground Connection ATTENTION Electrostatic discharge can damage semiconductor devices inside the module if you do not handle the module properly Follow the guidelines below p Wear a wrist strap grounding device N Attach the free end to a good earth ground Important Do not touch the module backplane connector or pins Store the module in an anti static bag when you are not using it or during shipment 3 Touch a grounded object such as a metal enclosure to rid yourself of electrostatic discharge before you handle the module Step 10 Familiarize Yourself with the PLC Processor Power Distribution Circuit Refer to the appropriate manual for a typical grounded power distribution circuit for PLC processors For ungrounded systems or for more information on wiring and grounding refer to Allen Bradley Programmable Controller Wiring and Grounding Guidelines publication 1770 4 1 Step 11 Wire the Modules Use the wiring arms provided with the modules to wire the modules The wiring arm lets you install or remove the modules from the chassis without rewiring Wiring arm terminals are numbered in descending order from the top down starting with terminal 18 Refer to the appropriate manual for a wiring diagram Important Use shielded cable between the modules S
10. mine the Modules Positions in the Chassis Refer to the appropriate manual for the modules positions in the chassis Publication 6500 10 1 March 1996 Installing Co injection and Plastic Molding Modules Publication 6500 10 1 March 1996 1 0 chassis Step 4 Key the I O Chassis for the Co injection Modules Use the plastic keying clips shipped with each I O chassis to key the appropriate I O slots to accept only the QI or QDC modules The modules are slotted in two places on the rear edge of the circuit board The keying clips you install must correspond to these slots to allow the module to be inserted only in the designated slot m U Ly y Install keying clips between e 20 and 22 e 26 and 28 Upper backplane connector 11022 1 Step 5 Determine and Record I O Ranges You must determine module I O ranges before you can make jumper selections To determine I O ranges follow these steps We provide a blank worksheet on the next page that you can complete for each module 1 For co injection applications determine whether the module will control injection unit A or B 2 Determine the inputs you want the modules to monitor Record your input selections on the worksheet 3 For co injection applications select screw A or B for inputs 1 through 4 Your screw selections must match your module sel
11. tep 12 Power up the Modules 1 Make all power connections from the I O chassis to the in plant power source 2 Apply power to the chassis power supply ee ACTIVE O e FAULT D comm HoHo HoHhoHhoHeHe Q1 8 arzi aDC Plastic Molding Module s Input Range Selections Output Range Selections i crew Position to 10 VDC Output L i to 16 VDC Si crew Pressure to 18 VDC Output 2 B to 18 VDC Screw A RPM to 18 UDC Output 3 18 to 18 VDC Cavity Pressure to 16 UDC Output 4 to 18 UDC Sere Sere 0 to 10V dc 10 to OV dc Ejec Output 1 i to 10 UDC Output 2 i to 16 UDC Output 3 1 to 16 UDC Output 4 i to 16 VIC Output HL 18 to 10 VDC Output 2 Output 3 B to 18 VDC 1B to 18 VDC Ejector Pressure to 1 UDC Output 4 to 14 UDC Screw RPM A Cavity Pressure Switch Over N a0 Sorew RPM B Cavity Pressure Switch Over De aa Make your selection from the pop up list that appears when you cursor to the field and press Installing Co injection and Plastic Molding Modules 9 Step 13 Read Module Indicator Lights The module front panel contains three indicators that you use to troubleshoot the mod
12. ual 6195 6 5 20 Installing the Modules Installing Co injection and Plastic Molding Modules 3 Follow the procedures in this section to install the QI and QDC modules ATTENTION Remove power from the I O chassis backplane and wiring arm before removing or installing modules Failure to remove power could cause injury or equipment damage due to unexpected operation Step 1 Choose the Correct Power Supply The modules are powered through the chassis backplane with a power supply To select the correct power supply for the system ensure that the total current load for all modules does not exceed the power supply s maximum load specification To calculate the total current load 1 Add the modules current loads to the loads of all other modules in the chassis Important The QI and QDC modules are rated at 1 2A Check specifications for all other modules in the I O chassis 2 Compare your total with the power supply s maximum load rating 3 If the total voltage exceeds the power supply s maximum load rating select a larger power supply See your Allen Bradley representative for more information Important We recommend a standalone power supply such as catalog number 1771 P1 This power supply is mounted beside the I O chassis and provides an output of up to 16A Step 2 Determine I O Chassis Addressing Mode Each module has 4 inputs and 4 outputs and is compatible with single slot addressing Step 3 Deter
13. ule during integration or operation Check the lights to ensure that no fault conditions are present LED color ACTIVE green FAULT red COMM yellow Refer to the appropriate manual for the operating conditions reported by the module and how to correct them Step 14 Enter I O Ranges on the Module Configuration Screen Pro Set 700 Applications Only Enter the information you recorded on the worksheet on page 5 pn the Plastic Molding Module s Configuration screen 1 If you have not already done so attach the PLC processor to the operator interface Refer to the Pro Set 700 Operator Interface Installation Manual publication 6500 6 2 1 2 From the Hardware Setup menu select the Configure Plastic Molding Module s screen 3 Move the cursor to the appropriate field on the screen 4 Press k You see a pop up menu 5 Place the cursor on the selection you want to make and press You can select input and output voltages for the QI and QDC modules 6 Press to confirm your selections o 7 Press o to download your selections to the PLC processor Publication 6500 10 1 March 1996 10 Installing Co injection and Plastic Molding Modules Step 15 Use the Rack Configuration Screen to Select Operating Mode Pro Set 700 Applications Only Use the Pro Set 700 and Co injection Rack Configuration screens to select operating modes for each module
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