CIECO PPC1000R Installation Manual V3.3

PPC1000R
RESOLVER BASED PUNCH PRESS

CONTROL
INSTALLATION AN INSTRUCTION MANUAL
V3.3
2401 Hookstown Grade Rd. Clinton, PA 15026 •PH: 412-262-5581 •FX: 412-264-9272
WWW.CIECOCONTROLS.COM
TABLE OF CONTENTS
ABOUT THE MANUAL.................................................... 3

PPC1000R DESCRIPTION
HOW THE SYSTEM WORKS ......................................... 4

BLOCK DIAGRAM
KEYPAD AND STANDARD INDICATORS................... 5
KEYPAD FUNCTION DESCRIPTION........................... 6
SYSTEM CHECKS ........................................................... 8

PREPARING THE PRESS
T-STOP and AUTO UP LIMIT SWITCH OUTPUTS
INSTALLATION PROCEDURE .................................... 9-15
ADDITIONAL OPTION INFO ...................................... 15A
OPERATING INSTRUCTIONS ...................................... 16

STROKE SELECT
MICRO INCH INPUT
INTERRUPTED STROKE
HAND/FOOT KEYSWITCH INPUT
LIGHT GUARD KEYSWITCH INPUT
RESET
INITIAL KEY .................................................................... 18

Motion Detect
Motion Delay
Zero Set
Brake Monitor
Speed Compensation
PROGRAMMABLE LIMIT SWITCH ............................ 21

OUTPUTS
CHANNEL KEY ................................................................ 22

Top Stop (channel 1)
AutoReturn (channel 2)
Aux. Limit Switch Outputs (channels 3-8)
TIMER KEY ...................................................................... 24

Timer Outputs
1 1
STATUS KEY ..................................................................... 26
Job Number Job change
Tool Number
Hour Meter
Input Status
Output Status
Limit Switch Outputs Status
Die Protection Inputs Status
COUNTER KEY .................................................................28

Strokes Counter
Parts Counter
Total Hits Counter
INPUT KEY ........................................................................ 31
Die Protection Inputs
HOW DIE PROTECTION INPUTS WORK .................. 33
QUICK PROGRAMMING REFERENCE ..................... 34
TROUBLE SHOOTING .................................................... 35
DISPLAY MESSAGES .......................................... ........... 36
PPC1000R SPECIFICATIONS ........................................ 40

PLS
PLS BACK PANEL
PRESS CONTROL
RESOLVER
STANDARD NEMA ENCLOSURE MTG....................... 42
RESOLVER MOUNTING................................................. 43
LIMIT SWITCH SEQUENCE GRAPH........................... 44
TOP STOP OVERRUN PROX SWITCH........................ 46
SHAFT EXTENSION MOUNTING................................. 47
PRESS CONTROL BOARD LAYOUT ........................... 48
PRESS CONTROL WIRING ........................................... 49-53

POWER
POWER FROM MOTOR CONTROLS
SOLENIOD VALVE RELAY OUTPUTS
GUARD MUTE
CHANNELS 3-5 OUTPUTS
KEYSWITCH AND PUSHBUTTON WIRING
PALM BUTTON AND FOOTSWITCH
PLS TO PRESS CONTROL CONNECTIONS
2 2
PLS BACK PANEL AND WIRING ................................. 54
4 RELAY BOARD FOR CHANNELS 6-8 ....................... 55
OPTIONAL EXTRA PLS OUTPUTS ............................. 56
OPTIONAL DIE PROTECTION INPUTS ..................... 57
OPTIONAL REMOTE SENSOR TERMINAL .............. 58
OPTIONAL DIE RECOGNITION .................................. 59
OPTIONAL MICRO INCH TIMER MODULE............. 60
WARRANTY
ABOUT THE MANUAL

This manual should be used for the programming and installation of the Model PPC1000R resolver based Punch
Press Control System. Read these instructions carefully before applying power to the system. If after studying
the manual, there are any questions, call the factory. You may void your warranty if the instructions in this
manual are not followed.
The PPC1000R System combines the PPC1000 punch press control with the K2000P automation control.
PPC1000R DESCRIPTION
The CIECO PPC1000R is a resolver based press control that eliminates the need for mechanical/cam operated
limit switches by using a programmable limit switch. The control receives position feed back from a resolver
mounted on the press crankshaft. The PLS (Programmable Limit Switch) continuously compares machine position to
preprogrammed limits. When the machine position falls between these preprogrammed limits, corresponding out-
puts are energized. This control allows an operator to monitor, fine tune, and reprogram PLS functions, as well as,
change jobs in a convenient and efficient manner. The PPC1000R includes other options that can be used to
automate your press. Optional features such as die protection, tonnage monitor and more can be added to reduce
the risk of crashed dies and ultimately increase productivity.
The CIECO PPC1000R is an easy to use, redundant control for part revolution mechanical power presses.
The PPC1000R meets or exceeds all ANSI B11.1-1988 and OSHA 1910.217 regulations including control
reliability.
3 3
HOW THE SYSTEM WORKS
Inc. Industrial Electronic Controls
The resolver provides absolute

CHANNEL INITIAL TIMER press position feedback to the
7 8 9 PLS. If the feedback is lost for
any reason, such as a cable
RECALL FROM/TO SAVE brake or shaft to resolver
4 5 6 decoupling, press initiation will
be inhibited until corrected.
COUNTER STATUS INPUT
ENABLE DISABLE
1 2 3
CLEAR TACH
Resolver
FUNCTION
0 POSITION
RPM/DEGREES
PLS-P LUS MODEL K-2000
The dual solenoid valve is

controlled by the press
The PLS sends the Top
The PLS continuously control with dual
stop limit switch and auto
sends a coded redundant relays. The
signal to the press
up limit switch signals to
control monitors the relay Dual
the press control.
control board so that
If they are out of the
contacts and the solenoid solenoid
the press control coils. Should one relay or valve
proper sequence, press
always knows that the valve fail to an unsafe
initiation will be inhibited
PLS is working and condition, the second
until corrected.
connected. If the PLS relay will stop the press.
The PLS restricts these
is disconnected from Initiation is inhibited until
limits to factory set values
the press control corrected.
to prevent incorrect
board, press initiation
programming
is inhibited until
corrected.
The external overrun proximity limit switch provides for
redundant check of the PLS limit switch outputs. If the limit
switch outputs from the PLS are out of sequence with the
prox switch or fail to turn on at the appropriate time, press
initiation will be inhibited until corrected. If the prox switch
becomes disconnected for any reason during any part of
Press Control the press stroke, the press will be stopped immediately
The press control is designed with and initiation inhibited until corrected.
redundant controllers, relays, power
Board
supplies, inputs, and system checks Prox switch
to ensure maximum safety.
C
(see the PPC series brochure for a
more details) m
pressure
switch
OFF ON
If air pressure falls below the

setpoint, press initiation will be The pushbuttons and keyswitches must be in the correct
inhibited until corrected . state for press initiation or resetting a fault. If they are
wired or set incorrectly, press initiation will be inhibited.
Note: The clear button must be pressed to clear a fault and to resume normal operation.
4 4
KEYPAD AND STANDARD INDICATORS
Dual function keypad. The blue half of the

keys are enabled when the FUNCTION key
LED is on. The white half are enabled when
the FUNCTION key LED is off. To change Two line LCD display shows all the programming
the state of the function LED, press the parameters and displays any fault message that may
FUNCTION key. occur.
Inc.
Industrial Electronic Controls
CHANNEL INITIAL TIMER
7 8 9
RECALL FROM/TO SAVE
4 5 6
COUNTER STATUS INPUT

ENABLE DISABLE
1 2 3
CLEAR TACH
FUNCTION
0 POSTION
RPM/DEGREES
PLS-P LUS MODEL K-2000
Red 3 digit LED display shows either RPM or Position in degrees. Programming enabled in the
Press the TACH/POSITION key to select which one to view. LED ENABLE position. Data can be
on in the upper right corner of the key will entered and viewed in the DISABLE
display RPM. LED off will display Degrees. position but not saved.
GROUNDED
White Indicator. 24VDC to ground
WHEN ON
Red Indicator. 24VDC to input# 20 on

press control board. Turns on when a INTERRUPTED
fault occurs that stops the press. The STROKE
control will be forced to inch mode until
reset.
5 5
KEYPAD FUNCTION DESCRIPTIONS
KEY SELECTOR SWITCH

Enable position allows all programming.
Disable position allows all parameters to be read, but disallows
any unauthorized change of those parameters.
CLEAR
Clears faults and the Function Display.
TACH/POS
Turns the tach LED on and off.
LED on; displays shaft speed in RPMs on the TACH/POS display.
LED off; displays position in Degrees on the TACH/POS display.
RECALL
Used to recall additional set points or settings under each function.
Successive keystrokes will recall other set points.
FROM/TO
Enables the entry of new limits directly below the currently displayed limits.
Successive keystrokes toggle back and forth between From and To set points displaying last data
entered.
SAVE
Saves new data entered.
FUNCTION
Turns the function LED on and off.
Function LED on; enables the functions (channel,timer,ect.) on the dual purpose keys. (cursor off)
Function LED off; enables numerical data entry (0,1,2.....9) from

the dual purpose keypad. (cursor on)
6 6
CHANNEL
PLS output programming
INITIAL
High/Low RPM limits
Motion Delay
Zero Set (resolver)
Brake Monitor
Speed Comp
TIMER
Program the timer outputs
COUNTER
Strokes
Parts
Total Hits
STATUS
Job changes
Tool#
Hour Meter
I/O status
7 7
SYSTEM CHECKS
In addition to the redundant checks performed by the CIECO safety press control board the CIECO program-
mable limit switch contains internal circuitry and software to detect faults in the system also.
• Computer Operating Properly; Watchdog Timer

• Clock Monitor
• Low Voltage Monitor
• Resolver Cable Break Monitor
• RPM Limits Monitor
• Resolver to Machine Shaft Coupling Break Monitor
• Clutch\Brake Solenoid Cable Break Monitor (The machine shaft must be operated above 4 RPM for proper operation)
• Brake Stop Time Monitor
• Die Protection Monitor (optional)
• Tonnage Monitor (optional)
If one of the above monitors detects a fault, press initiation will be inhibited until the fault is corrected.
PREPARING THE PRESS

The PPC1000R System will monitor the operation of the clutch/brake assembly. The press should be checked
before installing the control to verify proper operation. If after the brake is applied, there is excessive drift of
the ram, the clutch/brake assembly must be adjusted or repaired.
T-STOP and AUTO UP LIMIT SWITCH

OUTPUTS
Programmable limit switch Channels 1 and 2 are dedicated to the Top Stop and AutoUp limit switch func-
tions of the press control. They are factory restricted so that they can be programmed only within the re-
stricted settings as follows:
• Channel 1: on between 120° - 359° and off between 0° - 90°. Channel one is also speed
compensated so that it can turn on sooner as the press speed increases.
• Channel 2: on between 160° - 358° and off between 161° - 359°
The above restrictions are used to prevent excessive adjustments for these critical press functions.
Channels one and two apply to all job numbers and do not change with a job change.
8 8
INSTALLATION PROCEDURE
This manual should be used for the installation of the PPC1000R punch press control. Read the instructions
carefully before applying power to the system. If after studying the manual, there are any questions, call
the factory. Damage and/or personal injury may result if the instructions in this manual are not followed!
1) Mount Punch Press Control enclosure. (refer to mounting diagram on page 42)
The control is designed to withstand normal vibrations and shock during press operations. The control
enclosure should be shock mounted or mounted off the press if unusually heavy vibration or shock are
created during press operation.
2) Mount and wire the Resolver. (refer to resolver mounting diagram on page 43)
3) Mount and wire the Top Stop Overrun Limit Switch. (Use the Proximity switch provided by CIECO)
DO NOT USE A SPARE OUTPUT IN THE PROGRAMMABLE LIMIT SWITCH FOR THE
TOP STOP OVERRUN LIMIT SWITCH. (see pages 46-47)
4) Install and wire guards. (follow the instructions included with the guard) Also see page 49
5) Mount, pipe and wire the Clutch Air Pressure Switch. (see page 52 terminal #40)
Air Pressure Switch must be mounted down stream from pressure regulators. Adjust it for slightly
lower than the recommended pressure required for proper operation of the air clutch.
6) Mount, pipe and wire the Dual Solenoid Valve in as close a proximity to the Air Clutch as possible.
(See page 49 terminals 14-15)
7) Mount Palm Button station/s.

Minimum distance between the Palm Button
station and the point of operation is determined by the following
formula: D = 63 x T
D = minimum safety distance in inches
T = stopping distance in seconds, of the press at approximately 90 degrees
8) Connect the Foot Switch, if applicable. (see page 51 terminal #29 and page 52 terminal #39)
9) Complete the wiring according to the diagrams in the back of this manual and local NEC codes.
16 guage wire is recommended. Cieco Press Controls require 115-120VAC 60Hz power.
10) After mounting and wiring are complete, check connections and apply power.
Allow 1-2 seconds for power up.
11) Zero resolver.

• Press the TACH/POSITION key so that the LED on the key is off. This will display the position.
• Key over to INCH mode
• Inch to top dead center of stroke (zero degrees) (ignore the PLS position reading at this time)
• Press the FUNCTION key so that the LED turns on in the corner of the key.
• Toggle the INITIAL key until ZERO SET is shown on the display.
• Press SAVE to zero the resolver. (make sure the keyswitch is in ENABLE position) (The position display will zero)
9 9
12) Set the limit switch timing.
(Use the timing diagram on page 44-45 to see where to set the limits)
TOP STOP PROGRAMMING

PRESS DESCRIPTION
FUNCTION Function LED on (function keys enabled)
CHANNEL CH 01 F323-T068 Current data at channel 01 T-STOP limit switch.

T-STOP
NOTE: channel 1 is restricted so that it can only be programmed within factory set limits. The From setting is restricted to 120°-359° and the
To setting is restricted to 000°-090°. Any attempt to program outside of these restrictions will be inhibited. The From setting is when the output will
turn on and the to setting is when the output will turn off. e.g. at the setting shown above the output will turn on From 323° To 068°.
FROM/TO CH 01 F323-T068 Enable entry of new From set point

T-STOP F323< directly below current set point.
FUNCTION Function LED off. (number keys enabled)
335 CH 01 F323-T068 enter the new From setting

T-STOP F335<
FUNCTION Function LED on. (function keys enabled)
FROM/TO CH 01 F323 -T068 Enable entry of new To set point

T-STOP F335>T068 directly below current set point.
045 CH 01 F323 -T068 Enable entry of new To set point

T-STOP F335>T045 directly below current set point.
FUNCTION Function LED on. (function keys enabled)
SAVE CH 01 F335 -T045 Saves the new settings.

T-STOP
AUTO UP PROGRAMMING
Use the same procedure as the T-STOP limit switch to program the AutoUp.
CHANNEL CH 02 F180-T345 Current data at channel 02 AutoUp limit switch.

AutoUp
NOTE: channel 2 is restricted so that it can only be programmed within factory set limits. The From setting is restricted to 160°-358° and the
To setting is restricted to 161°-359°. Any attempt to program outside of these restrictions will be inhibited.
13) Adjust the Top Stop Override Prox switch cams.

(Use diagrams on page 44-45)
10 10
14) The High and Low RPM limt settings (MOTION DETECT)
If low RPMs are not a concern then set the Low motion detector to zero. If the low motion detect is
programmed for any value the press will stop if the RPMs fall bellow the programmed setting during
normal operation.
Program the High RPM limit to the maximum RPM speed that is not to be exceeded.
If the press speed falls outside the above limits the press will stop and the control will display
MOTION FAULT.
The motion detector is disabled when the brake is on, eliminating motion faults caused by dropping
below RPM limits when stopping.
PRESS DISPLAY DESCRIPTION

FUNCTION Function LED on allows the use of the function keys.
INITIAL MOTION L050-H150 Current RPM limits displayed on first line.

DETECT
FROM/TO MOTION L050-H150 Enable entry of new data directly

DETECT L050< below current limit.
FUNCTION MOTION L050-H150 Function LED off. Allows the use of

DETECT L050< the number keys.
045 MOTION L050-H150 Enter new Low RPM limit.(000-998 RPM)

DETECT L045<
FUNCTION MOTION L050-H150 Function LED on (function keys enabled)

DETECT L045<
FROM/TO MOTION L050-H150 Enables entry of new High RPM limit.

DETECT L045>H150
FUNCTION MOTION L050-H150 Function LED off. (number keys enabled)

DETECT L045>H150
160 MOTION L050-H150 Enter new High RPM limit.(001-999 RPM)

DETECT L045>H160

DETECT L045>H160
Compare previous entry on top display line with new en
try on bottom display line. High RPM limit must be greater
than Low RPM limit or it will not allow the new data to
be saved. Turn program key selector switch to the enable
position.
SAVE MOTION L045-H160 New data is saved and transferred to

DETECT top line.
11 11
15) Program the motion Delay
The motion Delay is used to compensate for starting delays caused by clutch slippage. Slowly increase
the delay until motion faults are eliminated. Add delay time to allow for additional clutch slippage due to
normal clutch wear (see programming section below).
Cycle the machine normally checking that no faults occur.

When the clutch is energized the PPC1000R must sense motion after the motion delay has elapsed or
“MOTION FAULT” will appear on the Function Display and the press will stop, signifying a possible
resolver to machine shaft coupling break.

INITIAL MOTION D167 Recalls the second setting which is
DELAY the motion Delay.
FROM/TO MOTION D167 Enables entry of a new motion Delay.

DELAY D167 (026-999 milliseconds)
139 MOTION D167 Enter data directly below current delay.

DELAY D139
SAVE MOTION D139 Saves new motion delay.

DELAY Key selector switch to disable position.
16) Brake test (90 degree stop time test).

Turn ON the BRAKE TEST (90 degree stop test). When ON this function will stop the press at 90 degrees
each stroke while testing/setting-up the brake monitor. Turn this OFF after you set up the brake monitor in
step 17.

FUNCTION Toggle FUNCTION key so that the function LED is ON.
INITIAL BRAKE OFF Program to ON to enable the 90 deg brake stop test
TEST
FROM/TO BRAKE OFF Toggles ON/OFF in the bottom of screen. Toggle to ON.
TEST ON
SAVE BRAKE ON SAVE brake test to ON.

TEST
12 12
17) Program the Brake Monitor parameters. The Brake Monitor is used to measure the brake
stopping time of the machine. This stopping time is compared to the preprogrammed times.
• Press the FUNCTION key so that the function LED is on.

• Toggle the INITIAL key until BRAKE is shown on the display.
BRAKE S999-A998
T-.000 Current programmed
Actual brake stopping parameters. S=max stopping time.
time in milliseconds. A=brake alarm.
To determine the brake monitor parameters, cycle the machine using your heaviest die. On variable speed
machines use the fastest speed. This insures correct settings for worse case.
Run the press several times initiating a stop at 90 degrees. The actual brake stopping time will be dis-played in
the lower left corner of the screen as shown above. Record the longest stop time. Use the longest stop time
and add 20%. This represents significant brake wear.
The brake stop time Alarm should be set at 90% of your maximum programmed brake stop time. When the brake
stop time exceeds the programmed alarm time, a “BRAKE ALARM” message will appear on the Function
Display. This indicates brake wear and should be followed by brake maintenance. If the maximum brake stop
time is exceeded, a “BRAKE FAULT” message will appear on the Function Dis-play and the Fault Output will
de-energize inhibiting stroke initiation until reset is pressed. Program the maximum brake Stop time “S” and the
brake Alarm “A” according to the instructions below. Turn OFF brake test when finished.
PRESS DESCRIPTION
FROM/TO BRAKE S999-A998 Enable entry of new data directly
T-.378 S999< below the current limit.
FUNCTION Function LED off (number keys enabled).
450 BRAKE S999-A998 Enter new maximum brake Stop time

T-.378 S450< (.000 - .999 seconds).
FROM/TO BRAKE S999-A998 Enable entry of new brake Alarm stop

T-.378 S450>A998 time directly below current time.
380 BRAKE S999-A998 Enter new brake Alarm stop time.

T-.378 S450>A380 (.000-.998 seconds)
FUNCTION BRAKE S999-A998 Function LED on(Function keys enabled)

T-.378 S450>A380 Compare top and bottom entries.
Key selector switch to enable position.
SAVE BRAKE S450-A380 New data is saved and transferred to

T-.378 the top line.
13 Turn OFF brake test when finished setting up the brake monitor. 13
18) Program for Speed Compensation
Speed compensation is used to turn on limit switch outputs sooner as the press speed advances and only
applies to channel 1 standard. (channels 3 and 4 optional)
Speed compensation offset Angle is the number of degrees of advance per 100 RPM increase in
press speed over the programmed starting Speed.
EXAMPLE: TOP STOP (limit switch channel 1)

1. Program the speed compensation starting speed to the slowest operating speed of the press.
e.g. 50 spm.
2. Set the speed compensation offset angle to zero.
3. Run the press at its slowest operating speed and program the top stop channel so the press stops at
the top.
4. Set the press to its fastest operating speed. E.G. 125 spm
5. Run the press at its fastest operating speed (keeping the top stop window the same) and note the
number of degrees over top that the press stops. E.G. 23 degrees
6. Divide the degrees drifted over top stop by the difference in speed and multiply by 100. This is
your speed compensation offset angle per 100 spm. Round off if necessary.
E.G. 23 / (125-50) * 100 = 31 degrees per 100 spm
7. Program speed compensation offset angle per 100 spm
The From setting is advanced while the to setting remains unchanged to maintain the proper overlap
with the Overrun Limit Switch.
Speed Compensation will advance the TSLS to a position of 120 degrees maximum.

INITIAL SPEED S200-A025 Recalls the speed compensation
COMP starting Speed and offset Angle per 100RPM.
FROM/TO SPEED S200-A025 Enable entry of new starting Speed

COMP S200< directly below current speed.
FUNCTION Function LED off (numbers enabled).
100 SPEED S200-A025 Enter new starting Speed (0-999RPM).

COMP S100<
FUNCTION Function LED on (functions enabled).
FROM/TO SPEED S200-A025 Enable entry of new offset Angle per

COMP S100>A025 100 RPM.
FUNCTION Function LED off (numbers enabled).
027 SPEED S200-A025 Enter new offset Angle (0-255 degrees)

COMP S100>A023 Compare settings.
FUNCTION Function LED on (functions enabled)
SAVE SPEED S100-A023 New data is saved and transferred to

COMP top line.
14 14
19) Test each mode of the control with the press in a safe condition
to make sure it has been wired correctly.
20) Program the auxillary programmable limit switch outputs as required. (see Channel Key for more info)
Program for:
Feed initiate
Roll release
Part transfer
Air blow off
Spray lubricant
Shear ..........................
21) Program timer output as required (see Timer Key for more info)
22) Program counters (see Counter Key for more info)
23) Set up sensors and program die protection inputs as required. (die protection option only)
24) Set up tonnage monitor. (tonnage monitor option only see tonnage monitor manual)
15 15
OPERATING INSTRUCTIONS
STROKE SELECTOR
To select a mode of operation, move the stroke selector key switch to the desired position.
•OFF
No mode is enabled, and movement of the press is disabled.
•INCH (input terminal #25)

-Set the stroke selector switch to INCH.
-Pressing the palm buttons or foot switch will engage the clutch as long as they are held on. -
Release the palm buttons or foot switch to stop the ram.
-When the Top Stop Limit Switch closes, the ram will stop and require the actuating means to
be released and reactivated to start movement again.
•SINGLE STROKE (input terminal #26)

-Set the stroke selector keyswitch to SINGLE (Must start at Top Stop to single stroke).
-The actuating device (palm buttons or foot switch) must be released.
-If using a foot switch the guard output must be checked or press initiation will be inhibited. Momen
tarily interrupt the guard to satisfy the check. (If using a fixed barrier guard the guard keyswitch can be
set to OFF to eliminate the guard check requirement.)
-To initiate a stroke, the actuating device (palm buttons or foot switch) must be held until the Auto
Up/Mute Limit Switch (bottom of stroke) closes. After this, the ram returns to the top automatically.
-When the Top Stop is reached (T-stop limit closed), the solenoid outputs will open and the press will
stop.
-Repeat the procedure for each stroke.
•CONTINUOUS (input terminal #27)

-Set the stroke selector switch to CONT (Must start at Top Stop to initiate continuous mode). -
With the palm buttons or foot switch released the guard output must be checked by momen-tarily
interrupting the light guard (Resetting the control also satisfies the guard check if using a fixed barrier
guard).
-Momentarily press the Continuous Preset button to start a timer that allows 3.5 seconds to initiate the
press.
-Activate the palm buttons or foot switch to initiate the press. If in HAND mode, the palm buttons must
be held to the bottom of the stroke, after which they can be released resulting in automatic stroking. If in
FOOT mode, the foot switch must be maintained at all times. Releasing the foot switch anytime after the
first 1/2 stroke will top stop.
-Pressing the Top Stop button will stop the press the next time the Top Stop Limit Switch closes.
MICRO INCH (input terminal #43)

-Set the Stroke Selector to INCH and Micro-Inch keyswitch to ON. (If the Stroke Selector is not in
the INCH mode, Micro Inch keyswitch is ignored)
-Engage the palm buttons to pulse the solenoid outputs for a predetermined time, regardless of how
long the palm buttons are held ON. (The ON time can be adjusted to get a very small and
consistent ram movement by adjusting the dip switches on the timer module (optional)).
-To pulse the solenoid outputs again, the palm buttons must be released and pressed again.
-The Micro-Inch keyswitch must be OFF to Inch in Foot mode. Micro-Inch input requires an
16 external timing relay (part# PT1). 16
INTERRUPTED STROKE INDICATION (terminal#20)
-If a fault occurs when the press is not at the top of the stroke,” Interrupted stroke” will be
displayed along with the cause of the fault.
(see fault messages )
-A remote indicator light may also be used to indicate an interrupted stroke.
-The press is forced into Inch mode.
-Inch the ram to Top Stop.
-Once the ram is returned to the top of the stroke, the fault can be reset by pressing the reset
button.
-After pressing the the reset button, the control will automatically return to the selected mode.
HAND/FOOT KEYSWITCH (input terminal #29)

-This keyswitch determines which actuating device will be used to initiate a cycle, two hand
palm buttons or foot switch.
-Switching the keyswitch position will not change the actuating device until both the foot switch
and palm buttons are released.
•PALM BUTTONS (input terminals # 33 and 34)

Pressing either palm button in any mode starts a .425 second timer. The other palm button must be
pressed within this time to initiate the press. If the timer runs out, both palm buttons must be
released to reset the timer. This prevents tieing down one palm button and using just one palm
button to initiate a stroke. Palm buttons can be used with or without the guarding system in Inch or
Single Stroke modes. In these modes, the operator must maintain contact with both hands on the palm
buttons during the downstroke of the press cycle. This provides for an acceptable guarding system in
Single Stroke and Inch modes.
•FOOT SWITCH (input terminal #39)

Pressing the foot switch will initiate a cycle. The guarding system cannot be disabled regardless
of the Light Guard keyswitch position.
LIGHT GUARD KEYSWITCH (input terminal #32)

-GUARD ON position, enables the guarding system during the down stroke of the press cycle
and only disables (muted) the guarding system during the upstroke of the press cycle in INCH
and SINGLE. No muting occurs in CONTINUOUS mode.
-GUARD OFF position, disables the guarding system during the entire press cycle only in Two-
Hand-Inch mode, Two-Hand-Single-Stroke and Two-Hand Interrupted Stroke mode. Mutes the
guard ing system on the upstroke in CONTINUOUS mode. Eliminates the requirement for testing
the guard in Foot-Switch-Single-Stroke mode for use with fixed barrier guarding.
-The guarding system is enabled during the down stroke regardless of the light guard keyswitch
position in Foot Switch and in CONT modes.
RESET (input terminal #28)

-To reset a fault, the press must be stopped and the actuating device must be
released. -Press the CLEAR key on the PLS-PLUS.
-Some faults may need corrected before the control can be reset (see Fault Messages if a fault will
not reset).
17 17
INITIAL KEY
THE FOLLOWING PAGES 18-20 ARE FOR REFERENCE ONLY. THE FUNCTIONS UNDER THIS
KEY SHOULD BE PROGRAMMED ACCORDING TO PAGES 9-15.
PRESS FUNCTION DISPLAY COMMENTS
FUNCTION Function LED on allows the use of the function keys.
INITIAL MOTION L050-H150 Current RPM limits displayed on first line.

DETECT
FROM/TO MOTION L050-H150 Enable entry of new data directly

DETECT L050< below current limit.
FUNCTION MOTION L050-H150 Function LED off. Allows the use of

DETECT L050< the number keys.
045 MOTION L050-H150 Enter new Low RPM limit.(000-998 RPM)

DETECT L045<

DETECT L045<
FROM/TO MOTION L050-H150 Enables entry of new High RPM limit.

DETECT L045>H150
FUNCTION MOTION L050-H150 Function LED off. (number keys enabled)

DETECT L045>H150
160 MOTION L050-H150 Enter new High RPM limit.(001-999 RPM)

DETECT L045>H160

DETECT L045>H160
Compare previous entry on top display line with new en
try on bottom display line. High RPM limit must be greater
than Low RPM limit or it will not allow the new data to
be saved. Turn program key selector switch to the enable
position.
SAVE MOTION L045-H160 New data is saved and transferred to

DETECT top line.
Return key selector switch to the disable position.
INITIAL MOTION D167 Recalls the second setting which is

DELAY the motion Delay.
18 18
FROM/TO MOTION D167 Enables entry of a new motion Delay.

DELAY D167 (026-999 milliseconds)
139 MOTION D167 Enter data directly below current delay.

DELAY D139
SAVE MOTION D139 Saves new motion delay.

DELAY Key selector switch to disable position.
INITIAL ZERO SET Enables the PLS position to be zeroed

(with key selector switch in the enable position, and the machine
at rest, press the save key to zero the position)
INITIAL BRAKE S475-A375 Recalls the brake monitor limits

T-.378 and actual brake stop Times.
FROM/TO BRAKE S475-A375 Enable entry of new data directly

T-.378 S475< below the current limit.
450 BRAKE S475-A375 Enter new maximum brake Stop time

T-.378 S450< (.000 - .999 seconds).
FROM/TO BRAKE S475-A375 Enable entry of new brake Alarm stop

T-.378 S450>A375 time directly below current time.
380 BRAKE S475-A375 Enter new brake Alarm stop time.

T-.378 S450>A380 (.000-.998 seconds)
FUNCTION BRAKE S475-A375 Function LED on(Function keys enabled)

T-.378 S450>A380 Compare top and bottom entries.
SAVE BRAKE S450-A380 New data is saved and transferred to

T-.378 the top line.
Key selector switch to disable position.
19 19
INITIAL KEY continued
INITIAL BRAKE OFF Recalls the 90 deg stop test.

TEST Program to ON for test.
INITIAL SPEED S200-A025 Recalls the speed compensation

COMP starting Speed and offset Angle per 100RPM.


FUNCTION SPEED S200-A025 Function LED off (numbers enabled).

COMP S200<
219 SPEED S200-A025 Enter new starting Speed (0-999RPM).

COMP S219<
FUNCTION SPEED S200-A025 Function LED on (functions enabled).

COMP S219<
FROM/TO SPEED S200-A025 Enable entry of new offset Angle per

COMP S219>A025 100 RPM.
FUNCTION SPEED S200-A025 Function LED off (numbers enabled).

COMP S219>A025
027 SPEED S200-A025 Enter new offset Angle (0-255 degrees)

COMP S219>A027 Compare settings.
FUNCTION SPEED S200-A025 Function LED on (functions enabled)

COMP S219>A027
SAVE SPEED S219-A027 New data is saved and transferred to

COMP top line.
Key selector to the disable position.
20 20
PROGRAMMABLE LIMIT SWITCH OUTPUTS
(CHANNELS)
There are 8 programmable limit switch outputs that are standard with the PPC1000R. The outputs are called
channels and are programmed using the CHANNEL key.
CHANNELS 1 - 2 are special purpose outputs used for the T-Stop and AutoUp signals to the press
control. (see Installation Procedure page 9 step 12)
CHANNELS 3 - 8 are general purpose outputs and can be used for auxiliary equipment.
3-6 are prewired to the press control and use the 3 auxiliary relays on the press
control board.
7,8, are not prewired and required an optional 4 output relay board.
TIMER1
TO PROGRAM THE OUTPUTS SEE NEXT PAGE : CHANNEL KEY
21 21
CHANNEL KEY
The CHANNEL key is used to program the PLS outputs.
FUNCTION Function LED on. Allows you to use the function keys.
CHANNEL CH 01 F270-T050 Current data on channel 1, is displayed.(Top Stop, window

T-STOP restrictions F=120-359 T=000-090) Top Stop setting are
universal to all jobs.
CHANNEL CH 02 F180-T350 Successive key strokes will increment the channel number.
AutoUp (AutoUp, window restrictions F=160-358 T=161-359)
AutoUp settings are universal to all jobs.
CHANNEL CH 03 F000-T000 Channel number increments

SP01

SP01

SP01
CHANNEL CH 06 F123-T142 Current data at channel 06 set point

SP 01 01 is displayed.
RECALL CH 06 F250-T068 Pressing RECALL again will give

SP 02 current data at channel 06 set point 02.
FROM/TO CH 06 F250-T068 Enable entry of new From set point

SP 02 F250< directly below current set point.
FUNCTION CH 06 F250-T068 Function LED off. (number keys enabled)

SP 02 F250<
4 CH 06 F250-T068 Enter new From set point(000-359 deg.

SP 02 F250< 450 would be an Illegal limit therefore data entry is prohibited.
3 CH 06 F250-T068 Enables change of From set point to 350.

SP 02 F350<
22 22
6 CH 06 F250-T068 Illegal entry prohibited. 360 > 359

SP 02 F350<

SP 02 F348<

SP 02 F298<
3 CH 06 F250-T068 398 is an illegal number so the From set point is set to the highest
SP 02 F359< allowable number.
FUNCTION CH 06 F250-T068 Function LED on (function keys enabled)

SP 02 F359<
FROM/TO CH 06 F250-T068 Enable entry of new To set point

SP 02 F359>T068 directly below current set point.
FUNCTION CH 06 F250-T068 Function LED off. (number keys enabled)

SP 02 F359>T068
083 CH 06 F250-T068 Enter new To set point (000-359 deg.).

SP 02 F359>T083 Illegal entries > 359 are prohibited.
FUNCTION CH 06 F250-T068 Function LED on (function keys enabled)

SP 02 F359>T083 Compare old entry on line one with new entry on line two.
SAVE CH 06 F359-T083 New data saved and transferred to

SP 02 first line.
End of programming of this channel unless you wish to program
another set point. Follow the same procedure.
A set point pair, or lobe, will have no effect on the channel output if both set points are set equal to each other.
For example:FROM = TO = 000
An output can be held on through the entire cycle by programming set point 2 to the exact reciprocal of set
point 1.
For example: set point 1 = F100-T200 , set point 2 = F200-T100
Attempting to overlap a set point by other than its exact reciprocal is prohibited and can not be saved.
For example: set point 1 = F100-T200 , set point 2 = F190-T110
Do not use Programmable Limit Switch outputs for press control functions unless the Press Control checks
for proper PLS operation every stroke of the press using a seperate Top Stop overrun proximity switch. The
top stop overrun proximity switch is required with a PPC1000R.
23 23
TIMER KEY
The TIMER key is used to program the timer output. The Timer output is *energized at the Position pro-
grammed and *de-energized at the expiration of the Time programmed.
* (opposite if programmed to normally closed)
TIMER TMR 01 P294-T506 Current TIMER limits displayed on

SP 01 first line.
TIMER TMR 02 P010-T030 Current limits of the second TIMER.

SP 01 (optional)
FROM/TO TMR 02 P010-T030 Enable entry of new Position directly

SP 01 P010< below current limit.
FUNCTION TMR 02 P010-T030 Function LED off. (number keys enabled)

SP 01 P010<
020 TMR 02 P010-T030 Enter new Position (000-359 DEG)

SP 01 P020< directly below current limit.
FUNCTION TMR 02 P010-T030 Function LED on (function keys enabled)

SP 01 P020<
FROM/TO TMR 02 P010-T030 Enable entry of new Time limit

SP 01 P020>T030 directly below current limit.
FUNCTION TMR 02 P010-T030 Function LED off. (number keys enabled)

SP 01 P020>T030
035 TMR 02 P010-T030 Enter new Time limit (000-999, 1/100 of a second)
SP 01 P020>T035 directly below current limit.
FUNCTION TMR 02 P010-T030 Function LED on (function keys enabled)

SP 01 P020>T035 Compare current value on top display line with new
entry on bottom display.
Key selector switch to enable.
SAVE TMR 02 P020-T035 New data is saved and transferred to

SP 01 the top line.
24 24
RECALL TMR 02 NO Displays whether the timer output is

OUTPUT Normally Open or Normally Closed.
FROM/TO TMR 02 NO Enables normal state of output to be changed.

OUTPUT NC
SAVE TMR 02 NC New normal state is saved and transferred to top line.
Return program key selector switch to the disable position.
The Timer outputs can also be programmed to only energize when a Batch count is reached.
(to program the timer outputs as multi-stroke outputs see the section on counters)
25 25
STATUS KEY
Displays the current job number in use and tool number and enables a change of jobs. A complete set of
channels and their corresponding set points , die protection settings, timer settings, and total hits count are
stored under each job number. Also displays the time in hours and minutes that the clutch has been energized.
Enables the status of inputs and outputs to be recalled.
FUNCTION Function LED on. Allows you to use the function keys.
STATUS J#003 T#085901 Displays current Job number and the reference tool number.
FROM/TO J#003 T#085901 Enables job number change.

J#003<
FUNCTION J#003 T#085901 Function LED off (number keys enabled)

J#003< Enables entry of new job number 001-020. (001-480 optional)
024 J#003 T#085901 Enables change of job to 24

J#024<
FUNCTION J#003 T#085901 Function LED on (function keys enabled)

J#024<
SAVE J#024 T#000000 Saves and displays the new job number and tool number and
initializes all the inputs and outputs to their new settings.
(machine must be stopped or a job change will be disabled)
FROM/TO J#024 T#000000 Enables change of jobs.

J#024<
FROM/TO J#024 T#000000 Enables change of reference tool

>T#000000 number.
FUNCTION J#024 T#000000 Function LED off(Data keys enabled)

>T#000000
140053 J#024 T#000000 Enter new tool number.

>T#140053
FUNCTION J#024 T#000000 Function LED on (function keys enabled)

>T#140053
Key selector to enable position.
26 26
SAVE J#024 T#140053 Saves new tool number.
RECALL J#024 HOURS Displays the time in hours and minutes

001482:37 that the clutch has been engaged. Use it to schedule routine
maintainance.
RECALL J#024 INPUT Recalls the status of the Brake,

BRK+ RST- INCH+ reset and Inch disable inputs.
(+) brake on
remote reset on
inch disable on (optional)
(-) brake off
remote reset off
inch disable off
RECALL J#024 OUTPUT Recalls the status of the E-Stop,

ES+ TS+ T1- T2- T-Stop,Timer 1, and Timer 2(optional) outputs.
(+) = energized
(-) = de-energized
RECALL J#024 C01-08 Recalls the status of channels 1-8.

+-+-++-- Channels 9-40 (optional).
(+) = energized (-) = de-energized
RECALL J#024 I01-08 Recalls the status of die protection

---+--+- inputs 1-8. (optional)
(+) = sensor closed (-) = sensor opened
A complete set of independent channel,timer,die protection,and total hits settings are stored under each job
number. All other paramaters apply to all jobs. The PLS Plus powers up with the Job# & Tool# display.
27 27
COUNTER KEY
The counter key has three different counters.
Strokes counter with batch

Parts counter with batch
Total hits counter with batch
STROKES COUNTER
The strokes counter will count up one every stroke of the press. It can be cleared any time by the opera-
tor. The strokes counter has a batch count that can be programmed to top stop after the programmed batch is
reached or to turn on the timer output every time the batch is reached. When it is programmed to the timer
output it acts as a multi stroke output. The count will increment until it reaches the programmed batch. Once the
batch is reached the count will automatically be set back to zero and the timer output will turn on at the pro-
grammed position (see timer key) and stay on for the programmed duration.
PARTS COUNTER
The parts counter will count up one every stroke of the press. It can be cleared any time by the operator.
The parts counter has a batch count that can be programmed to top stop after the programmed batch is reached.
If optional die protection is included, the parts counter will not count if a die protection fault occurs that triggers
an E-Stop. The parts counter will also not count in inch mode.
If the optional second timer is included, the parts count can be programmed to turn on the timer 2 (optional)
output every time the batch is reached. When it is programmed to the timer 2 output it acts as a multi stroke
output. The count will increment until it reaches the programmed batch. Once the batch is reached the count will
automatically be set back to zero and the timer output will turn on at the programmed position (see timer key) and
stay on for the programmed duration.
TOTAL HITS COUNTER
The total hits counter counts up one every stroke of the press. The total hits count is saved under the
current job number so that a total count can be kept for each die or job number. The total hits counter can be
cleared.
28 28
COUNTER KEY PROGRAMMING
Displays the Strokes,Parts,or Total Hits Counters.Enables the programmable preset (Batch count) to be changed.
Enables the Batch count output to be changed. If the programmed Batch count is reached by the strokes or
parts counter the count will reset. If the counter output is programmed to Top Stop the Top Stop output will de-
energize and the Function Display will read “BATCH COUNT” and show the batch value.(see FAULTS
to clear a BATCH COUNT) If the counter output is programmed to the timer the timer output will energize
every stroke the Batch count is reached.
FUNCTION Function LED on enables function keys.
COUNTER STROKE B328599 Recalls strokes count and the strokes

S039482 programmable preset (Batch count).
FROM/TO STROKE B328599 Enables entry of new Batch count.

S039482 B328599
FUNCTION STROKE B328599 Function LED off (number keys enabled).

S039482 B328599
118936 STROKE B328599 Enter new Batch count.

S039482 B118936
FUNCTION STROKE B328599 Function LED on (function keys enabled)

S039482 B118936
Compare previous entry to new entry.
SAVE STROKE B118936 New data saved and transferred to

S039482 first line.
RECALL ZERO STROKES Enables the strokes count to be

S039482 zeroed.
SAVE ZERO STROKES Resets the strokes count to zero.

S000000 Key selector switch to disable position.
COUNTER PARTS B018402 Recalls the parts count and the parts
P000387 programmable preset (Batch count).
FROM/TO PARTS B018402 Enables the parts batch count to be

P000387 B018402 changed.
29 29
015000 PARTS B018402 Enter new Batch count.

P000387 B015000 Compare previous entry with new entry.
SAVE PARTS B015000 New data saved and transferred to

P000387 first line.
RECALL ZERO PARTS Enable parts count to be zeroed.

P000387
SAVE ZERO PARTS Resets parts count to zero.

P000000
RECALL PARTS TMR 02 Enables Batch output to be changed.

OUTPUT
FROM/TO PARTS TMR 02 Toggle from T-STOP and TMR 02

OUTPUT T-STOP on the bottom line. Select
Key selector switch to enable position
SAVE PARTS T-STOP Saves Parts Batch output to Top Stop.

OUTPUT
COUNTER TOTAL HITS Recalls the total hits for the current
T01838402 job. (each job keeps a seperate count)
RECALL ZERO TOTAL HITS Enables the total hits count to be

T01838402 zeroed.
SAVE ZERO TOTAL HITS Resets the total hits count to zero.
T00000000 Key selector switch to disable position.
The Batch of the STROKES and PARTS counters are ignored when programmed to 000000. The count of
each counter is retained upon power down or power failure. When powering up or changing jobs the count
starts with the first complete stroke that goes thru zero and past 180 degrees for each counter. The parts counter
will not increment in inch mode.
30 30
INPUT KEY
(Optional) Displays die protection limits and enables choice of input type, fault output, and input name to be
recalled and changed.A momentary input expects a signal sometime within the programmed window. A mo-
mentary/open input requires a momentary signal within the window and no signal outside the window. Two
windows may be programmed per input so that two signals would be required per cycle.Constant inputs
require a constant signal during the entire programmed window either normally open or normally closed.
Two windows may be programmed.
PROGRAMMING THE DIE PROTECTION INPUTS (optional)
FUNCTION Function LED on enables function keys.
INPUT DP 01 F271-T345 Current data at input 1 set point 1

MOM 01 is displayed (MOM indicates a momentary signal is required
within the programmed window).
INPUT DP 02 F180-T270 Current data at input 2 set point 1is displayed. Successive key
MOM 01 strokes will increment the input number.
RECALL DP 02 F295-T340 Current data at input 2 set point 2

MOM 02 is displayed.
FROM/TO DP 02 F295-T340 Enable entry of new From set point

MOM 02 F295< directly below current set point.
FUNCTION DP 02 F295-T340 Function LED off (number keys enabled).

MOM 02 F295<
300 DP 02 F295-T340 Enter new From set point(000-359 deg.)

MOM 02 F300<
FUNCTION DP 02 F295-T340 Function LED on (function keys enabled).

MOM 02 F300<
Compare previous entry to new entry.
Key selector switch to enable position
SAVE DP 02 F300-T340 New data saved and transferred to first line.

MOM 02 Key selector switch to disable position.
RECALL DP 02 MOM Recall the type of input programmed.

TYPE
FROM/TO DP 02 MOM Toggles between Momentary and

TYPE MOM Momentary/Open.
31 31
FROM/TO DP 02 MOM Enables new type to be saved.

TYPE M-O Key selector switch to enable position
SAVE DP 02 M-O Momentary/Open type input has been

TYPE saved. Press must be stopped.
RECALL DP 02 E-STOP Recalls which output the die protection input will de-energize
STOP when a signal is not sensed.
FROM/TO DP 02 E-STOP Toggles between Emergency stop and

STOP E-STOP Top stop.
FROM/TO DP 02 E-STOP Enables new entry to be saved.

STOP T-STOP Key selector switch to enable position
SAVE DP 02 T-STOP Saves new entry.

STOP Key selector to disable position.
RECALL DP 02 CYCLICAL Recalls current name of input.

NAME
FROM/TO DP 02 CYCLICAL Toggles through 16 stored names.

NAME CYCLICAL
FROM/TO DP 02 CYCLICAL Continues to toggle through stored names.

NAME PARTEJECT Key selector switch to enable position
SAVE DP 02 PARTEJECT Saves new entry.

NAME Key selector to disable position.
AVAILABLE DIE PROTECTION NAMES
CYCLICAL cyclical event MATL ADV material advance

NC STATIC normally closed static event OVERLOAD overload
NO STATIC normally open static event MIS FEED mis feed
PARTEJECT part eject PRT TRANS part transfer
BUCKLE stock buckle PILOTHOLE pilot holes
SHORTFEED short feed STCKWIDTH stock width
STOCKLUBE stock lube THICKNESS stock thickness
ENDOFSTCK end of stock SHUT HT die shut height
32 32
HOW DIE PROTECTION INPUTS WORK
Die protection inputs labled “MOM” (momentary) must receive at least a momentary signal for each window
programmed. If both From/To set points are set equal to each other e.g. F000-T000 or exactly overlapped e.g.
F000-T180 and F180-T000 the input is disabled. Die protection inputs labled “M-O” (momentary-open) are the
same as above but must remain open outside the programmed windows. If both From/To set points are set
equal to each other the input act like a normally open constant input. Exactly overlapping the set points dis-
ables the input. Die protection constant inputs are labled “NC” for normally closed or “NO” for normally
opened. These inputs must receive a signal for the entire duration of each programmed window. If both From/
To set points are set equal to each other e.g. F000-T000 the input is disabled. If both From/To set points are
exactly overlapped e.g. F000-T180 and F180-T000 the input is enabled through the entire cycle and becomes
a static input.
Two configurations are available:
M type board
6 momentary inputs
2 constant inputs
or
C type board
1 momentary input
7 constant inputs
Additional die protection inputs can be added in groups of 8 for a total of up to 32. An inch disable input is
included with the die protection option to disable the die protection inputs during setup. The parts counter
becomes a “good” parts counter with the die protection option. The count is incremented only when no die
protection faults that trigger E-STOP occur between 0-180 degrees.
33 33
QUICK REFERENCE
PARAMETER TO VIEW KEY SEQUENCE (with function LED lit)
PLS output window CHANNEL
RPM Limits INITIAL
Start Up Delay INITIAL - INITIAL
Brake Stop Time INITIAL - INITIAL - INITIAL - INITIAL
Speed Compensation INITIAL - INITIAL - INITIAL - INITIAL - INITIAL
Timer 1 TIMER
Timer 2 TIMER - TIMER
Strokes Counter & Preset COUNTER
Parts Counter & Preset COUNTER - COUNTER
Total Hits Counter COUNTER - COUNTER - COUNTER
Job Number & Tool Number STATUS
Hour Meter STATUS - RECALL
Brake, Reset, & Inch STATUS - RECALL - RECALL

Disable Input Status
E-Stop,T-Stop,and Timers STATUS - RECALL - RECALL - RECALL

Output Status
Channel Status 1-8 STATUS - RECALL - RECALL - RECALL - RECALL
Die Protection Input Status STATUS - RECALL - RECALL - RECALL - RECALL(1-8)- RECALL
Die Protection Limits INPUT
Die Protection Input Type INPUT - RECALL - RECALL
Die Pro. Input Stop Circuit INPUT - RECALL - RECALL - RECALL
Die Pro. Input Name INPUT - RECALL - RECALL - RECALL - RECALL
34 34
TROUBLE SHOOTING
•The first step in trouble shooting is to see if the Function Display and/or fault LEDs are indicating a fault. If
so refer to the fault descriptions. If there is no indication check the input power and the .315A input power
fuse.
•Each input has a green LED indicating its current status. When the LED is on the input is on. When the LED
is off the input is off. Check for the correct status of all inputs.
•A single red LED on the press control (terminal 20) indicates when the interrupted stroke mode is active.
“InteruptedStroke” will also appear on the display.
A remote indicator light may also be used.
•Each output relay has two indicator LEDs on the press control associated with it. A green LED indicates that
coil should be energized. If not energized check the .25 amp coil fuse. If the fuse is ok try replacing
the relay.
•The yellow LEDs indicate the following:
LED LED LED MUTE RELAY LIGHT GUARD SOLENOID A SOLENOID B

D9 D10 D11 CONTACTS CONTACTS CONTACTS CONTACTS
OFF OFF OFF OPEN CLOSED OPEN OPEN
OFF OFF ON OPEN CLOSED OPEN CLOSED
OFF ON OFF OPEN CLOSED CLOSED OPEN
OFF ON ON OPEN CLOSED CLOSED CLOSED
ON OFF OFF CLOSED EITHER OPEN OPEN
ON OFF ON CLOSED EITHER OPEN CLOSED
ON ON OFF CLOSED EITHER CLOSED OPEN
ON ON ON OPEN OPEN EITHER EITHER

or
CLOSED EITHER CLOSED CLOSED
•If the press will not run and there are no faults indicated, check the following:
-The light guard is permanently interrupted or misaligned.
-The palm buttons or foot switch was pressed while the guard was broken. (release to reset)
•If the relays are operating properly but the solenoid won’t energize check the 2.5 amp fuse.
•If all power is lost to the control check the .315 amp fuse.
NOTE: For fuse and LED locations see the drawing: Press Control Board Layout
35 35
DISPLAY MESSAGES
THE FOLLOWING ARE FAULTS DETECTED BY THE PLS
Once a Fault has been detected the press will be stopped and a Fault message will appear on the Func-
tion Display. Anything previously displayed will be cleared.
D2 D3 D4 D5
• A PLS-Plus E-stop fault will turn on the following press control fault LEDs. ON ON OFF ON
• A PLS-Plus T-stop fault will turn on the following press control fault LEDs. OFF OFF OFF ON
• Only one Fault may be serviced at any one time.Once a Fault occurs all other Fault messages are disabled
until the current fault has been reset.
• After a Fault message has appeared, all keys but the FUNCTION,CLEAR and RPM/POSITION keys are inhib-
ited until a successful reset has been initiated.
• To reset the Fault Output the machine must be stopped. Then press the CLEAR button. If the Fault message
remains and the Fault Output remains de-energized a fault condition still exists. If all is correct the
display will clear, the Brake Stop Time will reset to zero, and the Fault Output will energize.
MESSAGE POSSIBLE CAUSES
MOTION FAULT •Resolver shaft speed equals or exceeds the boundaries of the programmed RPM
limits while the brake solenoid inputs read 115VAC (brake off).
•A broken resolver to machine shaft coupling or chain.
•Excessive clutch slippage or the motion delay is set to short.
•An attempt is made to run the machine with the brake solenoid inputs disconnected.
ANGLE FAULT •The resolver cable becomes disconnected.

•The line voltage momentarily drops below minimum.
•Noise on the line voltage, the brake solenoid input, or the resolver inputs.
•The resolver speed exceeds 999 RPM.
•Position updates are inhibited until a successful clear is initiated.
BRAKE FAULT •Maximum programmed brake stop time is exceeded due to brake wear.
BRAKE ALARM •The brake stop time falls between the programmed brake alarm time and the pro-
grammed maximum brake stop time. (the fault output is not de-energized)
DP 01 PARTEJECT •A signal is not received between the programmed limits (optional) of this die protec-
tion input.
BATCH COUNT •Strokes count or Parts counter has reached its programmed batch setting.
Although not a fault, the batch count (programmable preset) outputs to T-stop.
The batch count will T-stop every time the actual count reaches or exceeds the pro
grammed batch count. (the batch count is disabled if the preset is programmed to zero)
36 36
DISPLAY MESSAGES
THE FOLLOWING ARE FAULTS DETECTED BY THE PRESS CONTROL BOARD
The faults are indicated by four yellow LEDs on the press control. Faults are also displayed in plain English on
the Function Display.
To reset a fault the press must be stopped , the palm buttons and foot switch released, and the CLEAR button pressed.
FAULT DISPLAY MESSAGE FAULT LEDs

D2 D3 D4 D5
(no message) OFF OFF OFF OFF

There are no faults. System is ready to go.
AutoUp Limit Sw ON OFF OFF OFF

An incorrect limit switch sequence was detected when the AutoUp/Mute Limit Switch(31) closed or opened.
•When the AutoUp Limit Switch closes:

a) The Top Stop Overrun Limit Switch(36) must opened.
Possible problems are the Top Stop Overrun Limit Switch is stuck closed or the timing
between the Top StopOverrun Limit Switch opening and the AutoUp Limit Switch
closing is to short.
•When the AutoUp Limit Switch opens:

a) The Top Stop Limit Switch(30) must be closed.
Possible problems are the Top Stop Limit Switch is stuck open or doesn’t overlap the
AutoUp Limit Switch enough or the timing between the AutoUp Limit Switch open-
ing and the Top Stop Overrun Limit Switch closing is to short.
•Additional causes of Limit Switch Sequence Faults are:

a) Excessive cam or contact bounce of mechanical Top Stop Overrun
limit switch.
b) Resolver to machine shaft chain break.
c) Limit Switch output or 24VDC wiring becomes disconnected.
AUX. TOP STOP OFF OFF OFF ON

If this input (42) loses its 24VDC signal, the press will be stopped when the Top Stop Limit Switch closes. *
(input 42 is wired to the Top Stop output of the PLS-Plus)
GUARD FAULT ON ON OFF OFF

Guard output opened during downstroke or the Mute relay contacts stuck closed during downstroke. *
PLS-Plus Disconnectd ON ON OFF ON

Input(44) must be connected to the PLS-Plus E-stop fault output or a fault will occur immediately. *
AuxImmediateStop OFF ON ON OFF

Input(41) must receive 24VDC or a fault will occur immediately. If input not used tie to 24VDC. *
* can not be reset until the fault condition is corrected.

37 37
FAULT DISPLAY MESSAGE FAULT LEDs
D2 D3 D4 D5
TopStop Limit Sw OFF ON OFF OFF

An incorrect limit switch sequence was detected when the Top Stop LimitSwitch(30) closed or opened.
•When the Top Stop Limit Switch closes:

a) The Top stop Overrun Limit Switch(36) must be open.
The timing between the AutoUp Limit Switch opening and the Top Stop Overrun
Limit Switch closing is to short.
•When the Top Stop Limit Switch opens:

a) The AutoUp Limit Switch(31) must be open.
The AutoUp Limit Switch is stuck closed or the timing between the AutoUp Limit
Switch opening and the Top Stop Limit Switch closing is to short.
b) The Top Stop Overrun Limit Switch(36) must be closed.

The Top Stop Overrun Limit Switchis stuck open or does not overlap the Top Stop
Limit Switch enough.
•Other causes of limit switch sequence faults

a) Excessive cam or contact bounce of mechanical Top Stop Overrun limit switch.
b) Resolver to machine shaft chain break.
c) Limit Switch output or 24VDC wiring becomes disconnected.
d) Speed compensated Top Stop limit switch turns on before AutoUp limit switch turns on.
Overrun Limit Sw OFF OFF ON OFF

An incorrect limit switch sequence was detected when the Top Stop Overrun Limit Switch(36) closed or
opened.
•When the Top Stop Overrun Limit Switch closes:

a) The Top Stop Limit Switch(30) must be closed.
The Top Stop Limit Switch may be stuck open or does not overlap the Top Stop Over
run Limit Switch enough.
•When the Top Stop Overrun Limit Switch opens:

a) The AutoUp Limit Switch(31) must be open.
Possible problems are the timing between the Top Stop Limit Switch opening and the
AutoUp Limit Switch closing is to short.
b) The Top Limit switch 36 must be open
Possible problems are the timing between the Top Stop Limit Switch opening and the
Brake Monitor Limit Switch opening is too short or the Top Stop Limit Switch is stuck ON.
•The Top Stop Overrun Limit Switch Normally open(36) and Normally closed(35) inputs must always be the
opposite of each other.
Contacts may be stuck.
•Additional causes of Limit Switch Sequence Faults are:

a) Excessive cam or contact bounce of mechanical Top Stop Overrun limit switch.
b) Resolver to machine shaft chain break.er based
38 c) Limit Switch output or 24VDC wiring becomes disconnected. 38
DISPLAY MESSAGES CONT. DETECTED BY THE PRESS CONTROL BOARD
FAULT DISPLAY MESSAGES FAULT LED CODE

D2 D3 D4 D5
HandOrFoot LetGo ON ON ON OFF

In Single Stroke mode a fault occurs if the palm buttons or foot switch are released before the AutoUp/Mute
Limit Switch closes. In Continuous mode a fault occurs if the palm buttons are released before 1 1/2 strokes are
achieved or if the foot switch is released at anytime.
Low Air Pressure * ON OFF ON OFF

This input(40) must receive 24VDC from the air pressure switch or a fault will occur.
RELAY FAULT * OFF OFF ON ON

If the relay contacts to the clutch/brake solenoid stick closed or open a fault will occur (replace the relay).
If the .25A or 2.5A fuse is blown. (replace the fuse)
If the redundant circuits do not agree, a fault will occur. (Contact the factory)
* can not reset until fault condition is corrected.
THE FOLLOWING ARE MESSAGES DISPLAYED TO HELP THE OPERATOR
MustStart at Top ON OFF ON ON

Production modes must be started at Top Stop. If the press is stopped at other than Top Stop in Single or
Continuous modes this message will be displayed and interrupted stroke mode will take effect, allowing
the operator to go to Top Stop to initiate a stroke. Automatically resets at top.
TEST GUARD OFF ON ON ON

This message appears if the Foot switch or Palm buttons are pressed and the Light Guard was not tested.
Interrupting the Light Guard will clear this message. Resetting the control will also clear this message.
PUSH PRESET ON ON ON ON
This message appears if the Foot switch or Palm buttons are pressed before pushing the continuous preset
button. This message will clear once the preset button is pressed. If the preset timer runs out before
the operator initiates the press this message will reappear.
39 39
PPC1000R SPECIFICATIONS
PROGRAMMABLE LIMIT SWITCH
Input Power: 100-130 VAC,50/60 Hz,36W

Accurracy: 1 degree to 500 SPM
Operating Temperature: 0 to 50 degrees Celsius
Number of Channel (limit switch) outpus: 8 standard (up to 32 optional)
Number of “from/to” set points(lobes) per channel: chan 1-5 = 1 chan 6-32 = 2
Number of Die Protection Inputs: up to 24 (optional)
Other Inputs: reset
inch disable (included with die protection option)
Standard number of jobs = 20
Optional number of jobs:
480 - 8 outputs
235 - 16 I/O
150 - 24 I/O
115 - 32 I/O
95 - 40 I/O
Motion Detector: 0-999 RPM, dual limits

Timer: 0-9.99 seconds
Rotation: cw or ccw
Program Data Storage: EEPROM
+15Vdc power supply 320mA available from the PLS
Each expansion port that is used requires 80mA and should be subtracted from available power shown above.
Type of Outputs: source transistor
Vref = 12VDC - 24VDC Imax = 25mA
PROGRAMMABLE LIMIT SWITCH BACK PANEL
POWER TERMINAL BLOCK

The Power Terminal Block is used for the 115VAC input power, and the Brake/Clutch solenoid input.
RESOLVER TERMINAL BLOCK

The RESOLVER terminal block connects to the resolver. Run the resolver cable in conduit. Never run 120VAC
and low voltage wires in the same conduit.
MAIN TERMINAL BLOCK

The MAIN TERMINAL is used to wire the first 8 channels, E-stop, T-stop, timer, reset and inch disable.
EXPANSION PORT TERMINAL BLOCKS

Expansion port terminals are terminals A, B, C, and D. One is used for press control fault inputs and the rest for
optional functions such as die protection inputs, additional PLS outputs, RS232, servo feed interface, tonnage
monitor, ect....
CONTRAST
Adjusts the viewing angle of the LCD display.
40 40
PPC1000R SPECIFICATIONS continued.
PRESS CONROL BOARD SPECIFICATIONS
Input Power: 100-130 VAC, 50/60 Hz,25W

Max speed: 1000 SPM
Operating Temperature: 0 to 50 degrees Celsius
+24VDC power supply: 400mA available
Inputs: Require 24VDC @ 5mA sourcing
Relay outputs: 10A,277VAC 1/2HP,250VAC
15A,120VAC 1/3HP,120VAC
15A,30VDC RES.
Small panel mounted indicator lights: 24VDC @ 15mA
RESOLVER SPECIFICATIONS
The ultra rugged brushless resolver provides absolute position information even if the shaft is moved after a power
failure. This compact unit features an aluminum housing, 100 pound capacity bearings, and a sealed shaft. The model
HD13 resolver conforms to NEMA 13 requirements for harsh industrial environments, such as mechanical shock,
vibrations, extreme humidity and temperature changes, exposure to oil mists, coolants and solvents. The resolver is
insensitive to frequency and voltage fluctuations.
Model# HD13
Starting Torque:8 in-oz max. @ 25 degrees celsius
Shaft Loading:100 lbs. axial and 100 lbs. radial
Maximum RPM:3000
Shock: 200 G’s for 11msec. duration
Vibration: 20 G’s to 2000 Hz
Maximum allowable distance between PLS and Resolver is 1000 Ft.
41 41
STANDARD NEMA ENCLOSURE MOUNTING
12.00
15.50 14.75
10.00
USE 1/4-20 SCREWS.
IF MOUNTING DIRECTLY
TO THE PRESS USE
SHOCK MOUNTS
8.00
42 42
RESOLVER MOUNTING
The resover shaft and stator should NEVER be rigidly coupled to the machine shaft and stator. Either the shafts
or the stators should have a flexible member which will allow freedom of movement in all planes except rota-
tion. (No two shafts ever have equal runout regardless of their precision. Even if individual shaft
assemblies have the same "amount" of runout, these assemblies will have different patterns which result
in different magnitudes at various rotational positions. This applies regardless of bearing types.)
If a pulley or sprocket is to be mounted to the resolver shaft, DO NOT hammer or force fit it onto or off the
shaft. If the resolver is belt or chain driven, DO NOT overtighten the drive belt or chain. To much side loading
can destroy the resover bearings.
If these mounting rules are ignored, (warranty will be void) the machine shaft assembly will "fight" the resolver
shaft assembly and the final result will be failure of the weakest bearing.
2 3/
4"
3 1/
1/ 16" 3/16
2" 0.50
1 "
"
2 3/ 2 1/
4" 16" 3/32
5/ 1 3/
8" 4"
(4) 1/4-20 Mtg holes
1/ 3 1/ 2 1/
2" 8" 16"
Model HD13 resolver

SPECIFICATIONS
·Max voltage input: 10V p-p
·Max@
·25mA voltage
5kHz,input:
4V p-p 10Vref.p-p
·25mA @ 5kHz,
·Frequency: 2-7 kHz 4V p-p ref.
·Frequency:
·Error +/- 7 Arc2-7 kHz
minutes
·Error +/- 7 Arcratio:
·Transformation minutes
.9 +/- 10%
1.0 ·Transformation ratio: .9 +/- 10%
·Resolver Meets MIL SPEC
·Resolver Meetsand
S20708 MILS81963
SPEC
Inches from housing
·Max RPM =S20708

10,000and S81963
.75 ·Max RPM
·Requires = 10,000
6 conductors:
·Requires
R1,6R2,
conductors:
S1, S2, S3, S4
·NEMA 4X R1, R2, S1, S2, S3, S4
.50 ·NEMA double
4X
·Bearing: row heavy duty
·Bearing:
·Axial double
load: 400 lbs.row heavy duty
·Axial load: 400 lbs.
.25
110 120 130 140 150

Max radial load - LBS
43 43
PRESS CONTROL LIMIT SWITCH
SEQUENCE GRAPH
A
Terminals shown on graph are B
reference to the press control board.
See page 4 F
TDC 90 180 270 360
1/2 E
TOP STOP LIMIT SWITCH

Terminal #30
T-Stop overrun PROX switch

Complimentary outputs
Terminal #36
Terminal #35
AutoUp/Mute limit switch

Terminal #31
E
SHOWS CLOSED CONTACTS C D
*Each letter below corresponds to a letter on the graph above

T-Stop limit switch setting
A. Program the T-Stop output (limit switch #1) to close so that the press will stop at TDC (top dead center).
B. Program the T-Stop (limit switch #1) to open far enough past TDC so that when the press is stopped at
top stop, it will not drift past this setting. (even with some brake wear).
Auto Up/Mute limit switch setting

C. Program the AutoUp/Mute (limit switch #2) to close at 180 degrees, or when all pinch points are reduced to
less than 1/4”. Example of auto up setting:
D. Set the AutoUp/Mute (limit switch #2) to open at 359 degrees. F180>T359
Overrun Prox cam setting

E. The MINIMUM overrun cam length in inches = SPM x R / 2867
SPM = maximum press speed in strokes per minute
R=crankshaft radius in inches
For most applications a 1/4-20 hex head bolt can be used for the overrun cam. It is ok for the overrun cam to
be larger than the above formula calculates. To check if the cam is to large and will interfere with the correct
Limit Switch sequences use the following formula to calculate the cam length in degrees:
Cam length in degrees = CL x 57.3 / R
CL=cam length in inches Use the graph above to confirm the
cam lengths are correct.
R=crankshaft radius in inches
F. The overrun prox. switch should be centered over the overrun prox. cam when the Top Stop limit switch
opens as described in step B above.
44 SEE NEXT PAGE FOR EXAMPLE 44

TOP STOP OVERRUN
.30" min.
Crank-
shaft
.20" max.
2 4 VD
C Brow
n
k
Blac 0.71" (18mm)
N.O. t ite
outpu Wh
Dia.
e
.
B lu
N.C tput
o u
nd
ou
Gr
Prox.
switch
TDC
Install the overrun cam so that when the center

On
of the cam is lined up with the center of the proximity Rotation
switch, the press angle equals the Top Stop Off
(limit switch #1) open position. Reprogram the Top Stop

limit switch position if any misadjustment occurs during
overrun cam installation.
If shaft diameter is too large to make a practical cam use

the cam plates shown on the page 47.
45 45
PRESS CONTROL LIMIT SWITCH
SEQUENCE EXAMPLE

Terminal #30
0
F. =1/2 E
D. overlap
B.
A. T-STOP OVERRUN
PROX SWITCH
TERMINAL #36
E.
270 90
AUTO-UP / MUTE
LIMIT SWITCH
Terminal #31
Represents a closed contact.
C.
46 46
SHAFT EXTENSION INSTALLATION
Shaft extension mounting holes
1
Drill a 1/4" hole in the exact center of the press shaft.
Shaft extension place the centering nib into the 1/4" hole and mount the
centering nib. shaft extension with the mounting holes or by welding.
Keyway set
screw
2 Install sprocket if needed.
Lobe ring
mounting 3 Overrun timing using cam plates if needed.
Slide the lobe ring onto the shaft extension.
LOBE RING holes Screw down the keyway set screw into the keyway to
prevent the lobe ring from slipping.
4 Once the lobes have been adjusted properly

fasten them together through the lobe slots to
the lobe ring mounting holes.
Shaft hole Lobe 1

Lobe 2
Rotate lobe 2 until the

desired window
duration is set.
Minimum cam opening
must be greater than
Lobe slots the prox. diameter.
(.71")
47 47
PRESS CONTROL BOARD
7.35"
5.75"
Mounting holes
use #10 screw
2 places
POWER OUTPUTS
LNLN
8 9 10 11 12 13 14 15 16 17
SOL CONTACTS
2.5 AMP FUSE
Mute
Sol B Sol A
.315 AMP FUSE relay
INPUT POWER
5.25"
.25 AMP FUSE
RELAY COILS
mounting
dimension coil coil coil 6.00"
INTERRUPTED
STROKE LED
Red D1 D9 D10 D11
FAULT LEDs
Yellow D2-D5 INPUT
LEDs
24VDC Green
18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
FAULTS INPUTS INPUTS
Mounting hole MAXIMUM BOARD

use #6 screw HEIGHT = 3.4"
1 place
3.525"
48 48
PRESS CONTROL POWER AND OUTPUTS
L1 L2
GROUND
N
NEUTRAL L
N To pin 4 of the power terminal on the PLS
CONTROL BOARD
100-130VAC L To pin 5 of the power terminal on the PLS
L1 L2
10
Light guard
9 Muted indicator
8
GUARD
17
MUTE RELAY GUARD
MOV
16
CLUTCH/BRAKE
SOLENOID
SOL B OUTPUT 15
SOL A OUTPUT 14
To K2000, 5 pin
13 terminal: T#1
Page 54
MOV
SOL A OUTPUT 12 Sol A aux. contacts * Place MOVs or "quench-arcs"

AUX. CONTACTS
energize with the sol A across any solenoid or coils
output. It can be wired to which could be a source of
11 indicators to show when
the press is engaged or
electrical noise.
to start auxiliary
equipment only when the
press is running.
49 49
TYPICAL POWER CONNECTION FROM
MOTOR CONTROLS
fuse
120VAC
Motor Motor
Stop Start
E-Stop
Overload
M
relay
To Press control To press control

power terminal L power terminal N
50 50
PRESS CONTROL TERMINALS 25-36
OFF SINGLE
INCH CONT
24VDC PRESS
25 INCH
CONTROL TERMINAL
(15) INCH DISABLE INPUT
26 SINGLE STROKE
27 CONTINUOUS
PLS main terminal
(14) RESET OUTPUT 28 RESET
(1) REF HAND FOOT
29 ENGAGEMENT
MODE
(6) TOP STOP LIMIT SWITCH 30 TOP STOP LIMIT

SWITCH
(7) AUTO-UP/MUTE LIMIT 31 AUTO-UP/MUTE
SWITCH LIMIT SWITCH
OFF ON
32 GUARD OFF/ON
"GROUNDED WHEN ON"

INDICATOR FOR 24VDC
POWER
33 STA 1 PALM BTN A
34 STA 1 PALM BTN B
TOP STOP
35 OVERRUN LIMIT
SWITCH
Use the inductive
proximity switch
complimentary terminals 35 and 36 inputs
outputs provided must always be opposite
by CIECO. Follow each other
the instructions
on page 46.
TOP STOP
36 OVERRUN LIMIT
SWITCH
51 51
*WIRE TO 24VDC IF NOT USED
24VDC 37 CONTINUOS PRESET
38 TOP STOP BUTTON
39 FOOT SWITCH
*40 *AIR PRESSURE

SWITCH
AUXILIARY EQUIPMENT
*41 *AUXILIARY
IMMEDIATE STOP
42 T-STOP fault from

PLS
Micro-inch input requires a CIECO
timer module part number.
Timer module not included with the 43 MICRO INCH
standard control package.
(see Micro-inch on page59)
T-STOP FAULT OUTPUT (3) 44 IMMEDIATE STOP

Programmable Limit Switch
fault from PLS
(2) E-STOP FAULT OUTPUT

main terminal
45 NO CONNECT
46 NO CONNECT
47 NO CONNECT
48 NO CONNECT
52 52
and PANEL INDICATORS.
PLS
EXPANSION PORT
1 2 3 4 5 6 7 8 9 10 11 12
REMOTE
RESET
18 19 20 21 22 23 24
PRESS CONTROL
BOARD
Remote Red interrupted
stroke indicator
24VDC
Standard Miniature Indicator

for ground and interrupted stroke indication.
Warning: Reversing
the polarity will
damage the indica-
tor.
Connect to ground for

the WHITE light. To the
Connect to terminal 20 24VDC
of the press control terminal on
board for the RED the press
light. control.
BOTTOM VIEW
53 53
54
L1 L2
LINE NEUTRAL 1/2A CIECO INC
FUSE
MODEL_______________
S/N__________________
1-BRAKE
1 2 3 4 5 2-NEUTRAL
3-GROUND
4-NEUTRAL
5-115VAC
EXPANSION PORTS
B OPTIONS___________________________ OPTIONS___________________________ D
Page 49
A OPTIONS___________________________ OPTIONS___________________________ C
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 1 2 3 4 5 6 7
To T# 14 of press control
REF ES TS T1 T2 C1 C2 C3 C4 C5 C6 C7 C8 ZR IN 15V R1 R2 S3 S1 S4 S2 SHD
REF BLUE/WHITE STRIPE

24VDC TERMINAL
E-STOP SEE PG.55 WHITE/BLUE STRIPE
44
T-STOP WHITE/GREEN STRIPE
42
TOP STOP LIMIT SWITCH GREEN/WHITE STRIPE
30
AUTO-UP LIMIT SWITCH WHITE/ORANGE STRIPE
31
ORANGE/WHITE STRIPE
28 RESET
PRESS CONTROL
SHIELD
INCH Crossing S1 and S3 will reverse

25 the position direction. Keep the
resolver cable at least 2 inches
from any 115VAC wiring and 12
K2000 TO PRESS CONTROL WIRING
inches from any motor wiring.

The resolver cable should not
RESOLVER share conduit with any other
54
cable that may cause noise as
stated previously.
AUXILIARY LIMIT SWITCH OUTPUTS
3.25
2.75
0.25
OUTPUT
REFES TS T1 T2 C1 C2 C3 C4 C5 C6 C7 C8 ZR IN 15V
SIDE
1
2 CHANNEL 3 2
2
2-3
3 3
3
4 CHANNEL 4 4
4-5
5 5
4
main terminal
6 CHANNEL 5 6
5
7 6-7
7
6
8 8
CHANNEL 6 8-9
9 9
7
PLS
control G4PB4R field

9
OUTPUT
10 11 12 13 14 15 16
SIDE
2 CHANNEL 7 2 2-3
3 3
4 4
5
CHANNEL 8 5 4-5
6 6
7 TIMER 1 7
6-7
8 8
TIMER 2 8-9
9 9
control G4PB4R field
OPTIONAL
The solid state relay board can use either AC or DC relays.
RED = DC
BLACK = AC
CONNECTING RED DC RELAYS

*
DC RELAYS MUST BE
USED WITH THE COR-
RECT POLARITY AS
SHOWN. LOAD +
17 DC
RED DC RELAY OR POWER
18 SUPPLY
LOAD -
*
* USE 1N4005 WHEN CONNECTING TO INDUCTIVE LOADS
55 55
OPTIONAL EXTRA PLS OUTPUTS
Output terminals
SHIELD
Channel 9 = 1-2
Channel 10 = 3-4
RED .........
1
16 CHANNEL SOLID STATE

VIOLET
RELAY BOARD
2
YELLOW
3
EXPANSION PORT _________
PLS
+
BROWN -
4
1 CHANNEL 9 1
BLUE
5
2 2
ORANGE 3 CHANNEL 10 3
6
4 4
GREEN
5
7
CHANNEL 11 5
WHITE 6 6
8
7 CHANNEL 12 7
GRAY
8 8
9
BLACK 9 CHANNEL 13 9
10 11 12
10 10
11 CHANNEL 14 11
12 12
13 CHANNEL 15 13
14 14
15 CHANNEL 16 15
1
9.00 9.50
16 16
VIOLET 17 CHANNEL 17 17
2
18 18
YELLOW
3
19 CHANNEL 18 19
BROWN 20 20
EXPANSION PORT _________
PLS
21 CHANNEL 19 21
BLUE
5
22 22
ORANGE 23 CHANNEL 20 23
6
24 24
GREEN
7
25 CHANNEL 21 25
WHITE 26 26
8
27 CHANNEL 22 27
GRAY
9
28 28
BLACK 29 CHANNEL 23 29
10 11 12
30 30
31 CHANNEL 24 31
32 CONTROL FIELD 32
SHIELD
0.25
3.25
56 56
OPTIONAL DIE PROTECTION INPUTS
There is 80mA available at the +15VDC terminal (#1) for every expansion port NOT used for limit switch
outputs or die protection inputs. If all the ports (A, B, C, D) are used, then you must use an external power
supply for sensor power.
e.g. if only port A is used for 8 die protection inputs, 240mA is available at the +15VDC terminal.
MOM = Input that requires a momentary signal.

CON = Input that requires a constant signal
GROUND
GROUND
GROUND
15VDC
INPUT
INPUT
INPUT
INPUT
INPUT
INPUT
INPUT
INPUT
Mom Mom Mom Mom Mom Mom Con Con "M" type board
1 2 3 4 5 6 7 8 9 10 11 12
Mom Con Con Con Con Con Con Con "C" type board
Mechanical switch
Relay
NPN output from sensor
EXPANSION PORT BOARD TYPE M C

NPN transistors or electromechanical switches tied to ground can be used t trigger the die protection inputs.
Input modules used with the solid state relay boards can be used to interface high voltage AC or DC signals to
the PLS die protection inputs. (if special modules are needed contact CIECO for more information)
57 57
REMOTE SENSOR TERMINAL
PLS
EXPANSION PORT
10 11 12
6.75
SHIELD
*BLACK Remote Sensor Terminal

GRAY 8 1 2 3 4 5 6 7 8
9
WHITE 7
8
GREEN 6
7
GND GND GND GND

2.00
ORANGE 5
6
BLUE 4
5
+15V +15V +15V +15V

BROWN 3
4
YELLOW 2 POWER
3
VIOLET 1
2
*RED 15VDC
1
Power on LED
+15VDC power at 80mA
* Not used with internal power per unused expansion
supply option. port or 1 amp with internal
power supply option.
Ground Die protection inputs
OPTIONAL INTERNAL POWER SUPPLY

1/2” conduit
LINE 120VAC
NEUTRAL
58 58
DIE RECOGNITION INTERFACE
PLS
EXPANSION PORT
1 2 3 4 5 6 7 8 9 10 11 12
WHITE w/BLUE STRIPE
BLUE w/WHITE STRIPE

SHIEL
D
USING DRI MODULES
One DRI module is mounted to each die. Each module

is programmed with a unique job number.
Each time a new die is run, simply touch the DRI module
with the head of the wand and that job number will be
loaded into the PLS Plus. The PLS will then recall all the
parameters stored under that job#.
The job number that is

programmed into the DRI module
is engraved on the face of the
module
1.375 28
DRI bracket for mounting the
module to a Die.
0.187 dia hole

2 places
59 59
MICRO-INCH MODULE AND WIRING
GREEN DIN RAIL MOUNTED

TIMER MODULE
on DIP switches
off
located in the lower
right corner off the
module.
(factory setting=111)
1 2 3 4 5 6 7 8 9 10 11 12
Micro-Inch
24VDC OFF ON
To input terminal
number 43 of the
press control
board.
PBR
Tie these inputs to ground to increase the PBL

time intervals in 160 millisecond
increments. See chart below.
NC contacts on the Palm Buttons. (these
contacts are in addition to the required NO
contacts that are wired to the press control
board.
DIP Switch Timer Setting Terminal 7,8 and 10 Timer Setting

the time setting bellow will be added to the
Dip switch time of the dip switch setting.
123 TIME in milliseconds 7,8,10 TIME in milliseconds
000 20 000 000
100 40 100 160
010 60 010 320
110 80 110 480
001 100 001 640
101 120 101 800
011 140 011 960
111 160 111 1.12 seconds
0=off 0=not connected

1=on 1=connected to ground
60 60

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PPC1000R

RESOLVER BASED PUNCH PRESS

ABOUT THE MANUAL.................................................... 3

HOW THE SYSTEM WORKS ......................................... 4

KEYPAD AND STANDARD INDICATORS................... 5

KEYPAD FUNCTION DESCRIPTION........................... 6

SYSTEM CHECKS ........................................................... 8

INSTALLATION PROCEDURE .................................... 9-15

ADDITIONAL OPTION INFO ...................................... 15A

OPERATING INSTRUCTIONS ...................................... 16

INITIAL KEY .................................................................... 18

PROGRAMMABLE LIMIT SWITCH ............................ 21

CHANNEL KEY ................................................................ 22

TIMER KEY ...................................................................... 24

COUNTER KEY .................................................................28

HOW DIE PROTECTION INPUTS WORK .................. 33

QUICK PROGRAMMING REFERENCE ..................... 34

TROUBLE SHOOTING .................................................... 35

DISPLAY MESSAGES .......................................... ........... 36

PPC1000R SPECIFICATIONS ........................................ 40

STANDARD NEMA ENCLOSURE MTG....................... 42

LIMIT SWITCH SEQUENCE GRAPH........................... 44

TOP STOP OVERRUN PROX SWITCH........................ 46

SHAFT EXTENSION MOUNTING................................. 47

PRESS CONTROL BOARD LAYOUT ........................... 48

PRESS CONTROL WIRING ........................................... 49-53

4 RELAY BOARD FOR CHANNELS 6-8 ....................... 55

OPTIONAL EXTRA PLS OUTPUTS ............................. 56

OPTIONAL DIE PROTECTION INPUTS ..................... 57

OPTIONAL REMOTE SENSOR TERMINAL .............. 58

OPTIONAL DIE RECOGNITION .................................. 59

OPTIONAL MICRO INCH TIMER MODULE............. 60

ABOUT THE MANUAL

Inc. Industrial Electronic Controls

The resolver provides absolute

PLS-P LUS MODEL K-2000

The dual solenoid valve is

If air pressure falls below the

Dual function keypad. The blue half of the

CHANNEL INITIAL TIMER

RECALL FROM/TO SAVE

COUNTER STATUS INPUT

PLS-P LUS MODEL K-2000

Red Indicator. 24VDC to input# 20 on

KEY SELECTOR SWITCH

Function LED off; enables numerical data entry (0,1,2.....9) from

• Computer Operating Properly; Watchdog Timer

PREPARING THE PRESS

T-STOP and AUTO UP LIMIT SWITCH

• Channel 2: on between 160° - 358° and off between 161° - 359°

7) Mount Palm Button station/s.

11) Zero resolver.

TOP STOP PROGRAMMING

FUNCTION Function LED on (function keys enabled)

CHANNEL CH 01 F323-T068 Current data at channel 01 T-STOP limit switch.

FROM/TO CH 01 F323-T068 Enable entry of new From set point

FUNCTION Function LED off. (number keys enabled)

335 CH 01 F323-T068 enter the new From setting

FUNCTION Function LED on. (function keys enabled)

FROM/TO CH 01 F323 -T068 Enable entry of new To set point

FUNCTION Function LED off. (number keys enabled)

045 CH 01 F323 -T068 Enable entry of new To set point

FUNCTION Function LED on. (function keys enabled)

SAVE CH 01 F335 -T045 Saves the new settings.