Vestil EPT-30 User Manual

BW-REV-06-12-2007

EPT - 30- SERIES MASTER

SERVICE AND PARTS

MANUAL

VESTIL MFG. 2999 N. WAYNE ST. PO BOX 507 ANGOLA, INDIANA 46703 PH # 800-348-0868 FX # 800-526-3133 MADE IN P.R.C.

1

INDEX

Motor Controller......................................................... 3-71

Ept-****-30 change out instructions for

Battery ....................................................................72 - 77

Charger ..................................................................78 - 85

Charger Conversion to Soneil Brand...................86 - 97

Cylinder ................................................................98 - 113

Belly Switch Troubleshooting ...........................114 - 130

Program Values ..........................................................131

Troubleshooting Guide ......................................132 - 136

Warranty .....................................................................137

EPT-30-SERIES PARTS ...................................138 - 143

2

MANUAL

1207& 1207A

MultiMode™

MOTOR CONTROLLERS

DESIGN OF CURTIS PMC 1200 SERIES CONTROLLERS PROTECTED BY U.S. PATENT NO. 4626750.

CURTIS PMC

235 East Airway Boulevard Livermore, California 94568 USA Tel: 925-961-1088 Fax: 925-961-1099 www.curtisinst.com

1207 / 1207A Manual

p/n 16081, Rev. D: August 1999

3

1207 / 1207A Manual

p/n 16081, Rev. D: August 1999

This electronic version of the 1207/1207A manual is offered as a convenience to our customers. You may download any or all of it.

If you would like a hard copy of the published manual, please order it by part number from the Curtis office nearest you.

The electronic version of the manual is identical to the printed version published in August

A

1999 and revised March 2000. The revisions are in Figures 4, 4 and 28).

Bookmarks have been added to the electronic version to speed the process of going directly to a particular part of the document.

, and 9A (on pages 8, 24,

CURTIS INSTRUMENTS, INC.

200 KISCO AVENUE MOUNT KISCO, NEW YORK 10549 USA

914-666-2971

☎

■ CURTIS PMC

235 EAST AIRWAY BOULEVARD LIVERMORE, CALIFORNIA 94550 USA

925-961-1088

☎

ADDITIONAL OFFICES located in

■

FAX

914-666-2188

FAX

925-961-1099

Bulgaria, China, England, France, Germany, India, Italy, Japan, Netherlands, Puerto Rico, Russia, Sweden, and Switzerland

4

1

CONTENTS

234567890

CONTENTS

1. OVERVIEW .............................................................................. 1

2. INSTALLATION AND WIRING: 1207 controllers ................ 3

1207 Mounting ................................................................... 3

1207 Connections: Low Current ........................................ 4

1207 Connections: High Current ....................................... 5

Curtis PMC 1207/1207A Manual

A

2

1207 Adjustment Panel ....................................................... 5

1207 Wiring: Standard Conﬁguration (Series Motor) ......... 6

Power wiring for series motor ...................................... 7

Control wiring for series motor .................................... 7

1207 Wiring: Compound Motor Conﬁguration ................. 8

Power wiring for compound motor .............................. 9

Control wiring for compound motor ........................... 9

1207 Wiring: Throttle ...................................................... 10

5kΩ–0 throttle (“Type 1”) ......................................... 10

0–5V, 0–10V, 3-wire potentiometer, and

electronic throttles (“Type 2”)................................ 11

0–5kΩ throttle (“Type 3”) ......................................... 15

1207 Wiring: Emergency Reverse Check .......................... 15

1207 Switches and Other Hardware ................................. 16

Keyswitch ................................................................... 16

Main contactor .......................................................... 16

Forward/reverse contactors ......................................... 16

F/R and emergency reverse switches ........................... 16

Circuitry protection devices ....................................... 16

1207 Installation Checkout ............................................... 17

. INSTALLATION AND WIRING: 1207A controllers ............ 19

1207A Mounting .............................................................. 19

1207A Connections: Low Current .................................... 20

1207A Connections: High Current ................................... 21

1207A Wiring: Standard Conﬁguration (Series Motor) .... 22

Power wiring for series motor .................................... 23

Control wiring for series motor .................................. 23

234567890

iii

5

FIGURES

FIG

. 1: Curtis PMC 1207 and 1207A motor controllers

and handheld programmer ...........................................1

FIG

. 2: Mounting dimensions,

Curtis PMC 1207 controller ........................................3

FIG

. 3: Standard wiring diagram (series motors),

Curtis PMC 1207 controller ........................................6

FIG

. 4: Compound motor wiring diagram,

Curtis PMC 1207 controller ........................................8

FIG

. 5: Wiring for 5kΩ–0 throttle (1207 controller) ..............10

FIG

. 6: Wiring for 20kΩ potentiometer

used as a wigwag-style throttle (1207 controller) ........10

FIGURES

FIG

. 7: Wiring for 0–5V throttle (1207 controller) ................11

FIG

. 8: Wiring for 0–10V throttle (1207 controller) ..............12

FIG

. 9: Wiring for 3-wire pot throttle (1207 controller).........13

FIG

. 10: Wiring for Curtis ET-XXX electronic throttle

(1207 controller) ........................................................14

FIG

. 11: Wiring for 0–5kΩ throttle (1207 controller) ..............15

FIG

. 2A: Mounting dimensions,

Curtis PMC 1207A controller ....................................19

FIG

. 3A: Standard wiring diagram (series motors),

Curtis PMC 1207A controller ....................................21

FIG

. 4A: Compound motor wiring diagram,

Curtis PMC 1207A controller ....................................24

FIG

. 5A: Wiring for 5kΩ–0 throttle (1207A controller) ...........26

Curtis PMC 1207/1207A Manual

v

6

FIG

. 6A: Wiring for 20kΩ potentiometer

used as a wigwag-style throttle (1207A controller)......26

FIG

. 7A: Wiring for 0–5V throttle (1207A controller) ............. 27

FIG

. 8A: Wiring for 3-wire pot throttle (1207A controller) ......28

FIG

. 9A: Wiring for Curtis ET-XXX electronic throttle

(1207A controller) ......................................................28

FIG

. 10A: Wiring for 0–5kΩ throttle (1207A controller) ...........29

FIG

. 11A: Alternative wiring for emergency reverse check

(1207A controller) ......................................................29

TABLES

FIGURES/TABLES

TABLE

1: LED codes ..................................................................37

TABLE

2: Troubleshooting chart ................................................39

Curtis PMC 1207/1207A Manual

vi

7

OVERVIEW

1 — OVERVIEW

1

Fig. 1

Curtis PMC 1207 and 1207A electronic motor controllers and handheld programmer.

Curtis PMC 1207/1207A programmable motor speed controllers provide efﬁcient, cost-effective, and simple-to-install control for a variety of small electric vehicles. Typical applications include walkie fork/pallet trucks, mini personnel carriers, and sweepers. The microprocessor-based logic section combined with a proven MOSFET power section gives the 1207/1207A controllers high power and advanced features in a simple, compact package. The optional handheld programmer enables the user to set parameters, conduct tests, and obtain diagnostic information quickly and easily.

Like all Curtis PMC motor controllers, the 1207 and 1207A models offer superior operator control of the vehicle’s motor drive speed. Features include:

✓ Power MOSFET design, providing

✓ Compact size

✓ Overvoltage and undervoltage protection

✓ Thermal protection and compensation circuitry provides undertemperature

Curtis PMC 1207/1207A Manual

• inﬁnitely variable drive and plug brake control

• silent high-frequency operation

• high efﬁciency (for reduced motor and battery losses)

cutback, constant current limit, and linear rollback in overtemperature— thus preventing sudden power loss regardless of thermal conditions

More Features

☞

1

8

1 — OVERVIEW

✓ Intelligent handheld programmer (optional) provides a full set of parameter

and function settings

✓ Diagnostic and test information for the controller—and other system com-

ponents—readily available both on-board and through the programmer

✓ On-board potentiometers allow direct manual adjustment of acceleration

rate, creep speed, maximum speed, plug current, and main current limit

(1207 single-mode models only)

✓ Circuitry and software detects faults in the throttle circuit, MOSFET drive

circuit, MOSFET transistors, contactor drivers, and contactors—ensuring that the controller meets EEC fault detect requirements

✓ Input sequencing options include neutral start and static return to off (SRO)

✓ Microprocessor-controlled contactor sequencing provides true arcless

contactor switching

✓ Smooth, controlled plug braking—with either variable (throttle-dependent)

or ﬁxed plug current limit

✓ Neutral braking option provides automatic plug braking in neutral

✓ MultiMode™ input selects between two different operating modes, thus

allowing optimization of vehicle characteristics for different driving conditions

✓ Emergency reverse (belly button switch) with a single input

✓ Ramp-start feature provides full power for starting on ramps

✓ Simple contactor and switch wiring, with coil drivers monitored for faults—

✓ Flexible throttle circuitry accommodates a variety of throttle types

✓ Programmable “ramp shape” (static throttle map) provides ﬂexibility in

✓ Connections made by solid copper power busses with a polarized Molex

✓ Solid, well-protected construction—with an aluminum mounting plate and

Familiarity with your Curtis PMC controller will help you install and operate it properly. We encourage you to read this manual carefully. If you have questions, please contact the Curtis ofﬁce nearest you.

Curtis PMC 1207/1207A Manual

thus ensuring fail-safe operation

selecting throttle response feel

connector for control signals

injection-molded cover.

2

9

2 — INSTALLATION & WIRING: 1207 Controller

INSTALLATION AND WIRING: 1207

2

Fig. 2

Mounting dimensions, Curtis PMC 1207 controller.

MOUNTING

The 1207 controller can be oriented in any position, but the location should be carefully chosen to keep the controller as clean and dry as possible. If a clean mounting location cannot be found, a cover must be used to shield the controller from water and contaminants.

To ensure full rated output power, the controller should be fastened to a clean, ﬂat metal surface with three screws. The case outline and mounting hole dimensions are shown in Figure 2. The controller should be mounted with sufﬁcient clearance to allow the sliding cover to be opened, providing access to

165 (6.50)

22 (0.85)

28 (1.10)

66 (2.60)

122

(4.80)

127 (5.00)

C

L

SLIDING

COVER

Curtis PMC 1207/1207A Manual

10

152 (6.00)

60

(2.35)

Dimensions in millimeters and (inches)

6.6 (0.26) dia., 3 plcs

6.5 (0.25)

21 × 16 × 1.5

×

0.63 × 0.06);

(0.83

8.4 (0.33) dia. hole thru

4.8 (0.19)

3

2 — INSTALLATION & WIRING: 1207 Controller

the user-adjustable potentiometers. Access is also needed to plug the programmer into the connector beneath the sliding cover, and to view the Status LED.

Although not usually necessary, a thermal joint compound can be used to

improve heat conduction from the case to the mounting surface.

CONNECTIONS:

Low Current

An integrated 16-pin low power connector molded into the front of the controller provides the low power logic control connections (see pin list below). The mating connector is Molex Mini-Fit Jr., part number (5557) 39-01-2165. Contact Molex regarding compatible pins for various wire sizes.

16 15 14 13 12 11 10 9

87654321

Pin 1 Pin 2 Pin 3 Pin 4 Pin 5 Pin 6 Pin 7 Pin 8

shunt ﬁeld driver output; n/c for series motors reverse contactor driver output forward contactor driver output main contactor driver output throttle: 3-wire pot high throttle: 3-wire pot wiper or 0–5V throttle: pot low throttle: 2-wire 5kΩ–0 or 0–5kΩ input

Curtis PMC 1207/1207A Manual

Pin 9 Pin 10 Pin 11 Pin 12 Pin 13 Pin 14 Pin 15 Pin 16

throttle: 0–10V emergency reverse (BB) check output [optional] reverse input forward input emergency reverse input mode selection input brake input keyswitch input (KSI)

4

11

M-

2 — INSTALLATION & WIRING: 1207 Controller

CONNECTIONS: High Current

Four tin-plated copper bus bars are provided for the high current connections to the battery and motor:

M-

output to motor armature

B-

negative connection to battery

B+

positive connection to battery/ﬁeld

A2

plug diode to motor armature

B+B-

Cables are fastened to the bus bars by M8 (

5

⁄16") bolts. When tightening the bolts, two opposing wrenches should be used to prevent bending the bus bars and putting undue strain on the internal connections.

ADJUSTMENT PANEL

The adjustment panel is located on top of the 1207 controller, under a sliding protective cover. The panel provides access to a set of adjustable potentiometers, and also contains the Status LED and a connector for the handheld programmer.

12

30

OFF

4

OFF

12

30 4

12

OFF

Manually Adjustable Potentiometers

12

30

OFF

4

12

30

OFF

4

30 4

LIMITSPEEDLIMITCURRENT

STATUSACCEL. L O WCREEPPLUGMAIN

Five screwdriver-adjustable potentiometers (“trimpots”) allow manual adjustment of the main and plug current limits, acceleration rate,

LOW

maximum creep speed, and maximum speed (labeled “

”), as described in Section 3. The trimpots can be enabled or disabled at the factory; if they are enabled, MultiMode™ operation is not available.

NOTE

: To adjust any of these parameters electronically with the pro-

OFF

grammer, its potentiometer must be set to “

.”

12

Curtis PMC 1207/1207A Manual

Programmer Connector

An RJ11 modular connector is provided for the handheld programmer. The mating cable is supplied with the programmer.

Status LED

The LED displays ﬂashing codes to indicate controller status; the codes are listed in Section 5.

5

Fig. 3

Standard wiring diagram (series motor), Curtis PMC 1207 controller.

2 — INSTALLATION & WIRING: 1207 Controller

WIRING: Standard Configuration (Series Motor)

The basic wiring for series motors with ﬁeld reversing is shown in Figure 3.

SWITCHES

MULTI

BRAKE FORWARD

KEYSWITCH

POLARITY

PROTECTION

DIODE

MODE

5kΩ–0 (TYPICAL)

EMERGENCY

REVERSE

THROTTLE

FORWARD

M- A2

REVERSE

CONTACTORS

B+B-

FUSE

CONTROL

POWER

FUSE

B+

MAIN

CONTACTOR

PRECHARGE RESISTOR

(250 Ω, 5 W)

FORWARD

CONTACTOR

S1S2

REVERSE

CONTACTOR

MAINREVERSE

B-

The conﬁguration shown in Figure 3 is a typical arrangement for a series motor. Curtis PMC controllers are designed for use in a wide range of applications, and accordingly can be installed in a variety of ways to best meet customer needs.

NOTE

factory option.

Curtis PMC 1207/1207A Manual

A

A1

A2

: The emergency reverse check feature (wiring shown by dashed line) is a

6

13

2 — INSTALLATION & WIRING: 1207 Controller

Power Wiring for Series Motor

In every wiring conﬁguration, it is imperative that the ﬁeld be wired between the controller’s

B+

and A2 terminals and that the armature be wired between the

M-

and A2 terminals. The internal plug diode used in the 1207 is connected between

M-

and A2. Therefore, the armature and ﬁeld positions cannot be interchanged.

Reversing contactors can be used to switch either the armature or the ﬁeld.

Control Wiring for Series Motor

Wiring for the input switches and contactors is shown in Figure 3 (see detail below). The main contactor, if one is used, is normally connected directly to the controller. Optionally, the main contactor can be switched directly by the keyswitch or brake, leaving Pin 4 unconnected.

16-pin detail (see Fig. 3):

EMERGENCY

REVERSE

CHECK

OUTPUT

KEYSWITCH

BRAKE

MULTI MODE

FORWARD

EMERGENCY

REVERSE

16 15 14 13 12 11 10 9

87654321

CONTACTOR

MAIN

FORWARD

CONTACTOR

REVERSE

2-WIRE POT

(5 kΩ)

POT

LOW

CONTACTOR

The throttle shown in Figure 3 is a 5kΩ–0 type. Various other throttles can also be accommodated, and are discussed in the throttle wiring section.

Curtis PMC 1207/1207A Manual

14

7

2 — INSTALLATION & WIRING: 1207 Controller

WIRING: Compound Motor Configuration

A specially conﬁgured controller is available for compound motor applications. The wiring for a compound wound motor with armature reversing is shown in Figure 4.

Fig. 4 Compound

motor wiring diagram, Curtis PMC 1207 controller.

FUSE

CONTROL

B+

B-

BRAKE

KEYSWITCH

POLARITY

PROTECTION

DIODE

POWER

FUSE

SWITCHES

MULTI

EMERGENCY

MODE

CONTACTOR

PRECHARGE RESISTOR

(250 Ω, 5 W)

MAIN

REVERSE

THROTTLE

5k

Ω

–0 (TYPICAL)

FORWARD

REVERSE

SHUNT

M- A2

B+B-

S2

S1

FORWARD

CONTACTOR

A1

CONTACTORS

FWD

A2

A

MAINREV

REVERSE

CONTACTOR

The conﬁguration shown in Figure 4 requires the use of a compound wound motor. Pure shunt motors cannot be used with 1207 controllers. Although the conﬁguration shown is typical, various other conﬁgurations are possible.

NOTE: The emergency reverse check feature (wiring shown by dashed line) is a

factory option.

Curtis PMC 1207/1207A Manual 8

3/28/00

15

2 — INSTALLATION & WIRING: 1207 Controller

Power Wiring for Compound Motor

The ﬁeld must be wired between B+ and A2 and the armature between M- and A2.

M-

The internal plug diode in the 1207 is connected between

and A2; therefore,

the armature and ﬁeld positions cannot be interchanged.

If the shunt is rated for under 2 amperes, it can be connected directly to the controller as shown in Figure 4. If the shunt is rated for higher than 2 amperes, a contactor must be used to control the shunt ﬁeld.

Control Wiring for Compound Motor

Control wiring for the compound motor application is like that for the standard (series motor) wiring. The main contactor, if one is used, is normally connected directly to the controller. Optionally, the main contactor can be switched directly by the keyswitch or brake, leaving pig Pin 4 unconnected.

16-pin detail (see Fig. 4):

REVERSE

EMERGENCY

REVERSE

CHECK

OUTPUT

KEYSWITCH

BRAKE

MULTI MODE

FORWARD

EMERGENCY

REVERSE

16 15 14 13 12 11 10 9

87654321

CONTACTOR

MAIN

FORWARD

CONTACTOR

SHUNT

REVERSE

2-WIRE POT

(5 kΩ)

POT

LOW

CONTACTOR

The throttle shown in Figure 4 is a 5kΩ–0 type. Various other throttles can also be accommodated, and are discussed in the throttle wiring section.

Polarity protection diodes and control fuses must be sized appropriately to handle the increased current from the shunt ﬁeld.

16

Curtis PMC 1207/1207A Manual

9

Fig. 5

Wiring for 5kΩ–0

throttle (“Type 1”).

2 — INSTALLATION & WIRING: 1207 Controller

WIRING: Throttle

Wiring for various throttles is described below. They are characterized as Type 1, Type 2, and Type 3 throttles in the programming menu of the handheld programmer.

NOTE

: In the text, throttles are identiﬁed by their nominal range and

not by their actual active range.

If the throttle you are planning to use is not covered, please contact the

Curtis ofﬁce nearest you.

5kΩ–0 Throttle (“Type 1”)

The 5kΩ–0 throttle (called a “Type 1” throttle in the programming menu of the handheld programmer) is a 2-wire resistive throttle that connects between the 5kΩ–0/0–5kΩ pin (Pin 8) and the Pot Low pin (Pin 7), as shown in Figure 5. It doesn’t matter which wire goes on which pin. Zero speed corresponds to 5kΩ measured between the two pins and full speed corresponds to 0Ω.

5kΩ POT

16 15 14 13 12 11 10 9

Fig. 6

Wiring for 20k potentiometer used as a wigwag-style throttle (“Type 1”).

FASTER

87654321

PIN KEY (1207)

Pin 8

5kΩ–0

Pin 7

Pot Low

In addition to accommodating the basic 5kΩ–0 throttle, the Type 1 throttle is the easiest with which to implement a wigwag-style throttle. Using a 20kΩ potentiometer wired as shown in Figure 6, the pot wiper can be set such that the controller has 5kΩ between Pins 7 and 8 when the throttle is in the neutral position (i.e., at the center of the pot). The throttle mechanism can then be designed such that rotating it either forward or back decreases the resistance between Pins 7 and 8, which increases the controller output. The throttle

Ω

20 kΩ POT

FASTERFASTER

16 15 14 13 12 11 10 9

87654321

PIN KEY (1207)

Pin 8

5kΩ–0

Pin 7

Pot Low

Curtis PMC 1207/1207A Manual

10

17

2 — INSTALLATION & WIRING: 1207 Controller

mechanism must provide signals to the controller’s forward and reverse inputs independent of the throttle pot resistance. The controller will not sense direction from the pot resistance.

Broken wire protection for Type 1 throttles is provided by the controller sensing the current flow from the 5kΩ–0 input through the pot and into the Pot Low pin. If the Pot Low input current falls below 0.1 mA, a throttle fault is

NOTE

generated and the controller is disabled.

: The Pot Low pin (Pin 7) must not

be tied to ground.

0–5V, 0–10V, 3-Wire Potentiometer, and Electronic Throttles (“Type 2”)

With these throttles (“Type 2” in the programming menu), the controller looks for a voltage signal at either the pot wiper/0–5V input of the controller (Pin 6) or the 0–10V input (Pin 9). Zero speed corresponds to 0V and full speed corresponds to either 5V or 10V, measured relative to B-. Pot Low is the current return path for all Type 2 throttles.

A voltage source, 3-wire pot, or electronic throttle can be used with this throttle type. The wiring for each is slightly different and each has varying levels of throttle fault detection associated with it.

Fig. 7

Wiring for 0–5V

throttle (“Type 2”).

0–5V Throttle

Two ways of wiring the 0–5V throttle are shown in Figure 7. Broken wire protection is provided by the controller looking for a minimum current into the

(a)

0–5V throttle sensor

16 15 14 13 12 11 10 9

+

87654321

0–5V

SENSOR

(b)

Ground-referenced 0–5V throttle

+

-

SENSOR OUTPUT

SENSOR GROUND

(Shunt impedance 150 kΩ to ground)

B-

PIN KEY (1207)

Pin 7

Pot Low

Pin 6

0–5V Input

16 15 14 13 12 11 10 9

87654321

PIN KEY (1207)

Pin 7

Pot Low

Pin 6

4.7 kΩ

Pin 5

0–5V Input Pot High

18

Curtis PMC 1207/1207A Manual

11

Fig. 8

Wiring for 0–10V

throttle (“Type 2”).

2 — INSTALLATION & WIRING: 1207 Controller

Pot Low pin. If the Pot Low input current falls below 0.1 mA, a throttle fault is generated and controller shuts down. If a throttle sensor is used, the sensor’s ground return current must be less than 10 mA. If the 0–5V throttle input

NOTE

(Pin 7) exceeds 8 volts, controller output will shut down.

: In Figure 7(b),

the throttle’s voltage input signal is in reference to Pot Low.

0–10V Throttle

Two ways of wiring the 0–10V throttle are shown in Figure 8. Broken wire protection is provided by the controller looking for a minimum current into the Pot Low pin. If the Pot Low input current falls below 0.1 mA, a throttle fault is generated and the controller shuts down. If a throttle sensor is used, the sensor’s ground return current must be less than 10 mA. If the 0–10V throttle input

NOTE

(Pin 9) exceeds 16 volts, the controller will shut down.

: In Figure 8(b), the

throttle’s voltage input signal is in reference to Pot Low.

(a)

0–10V throttle sensor

16 15 14 13 12 11 10 9

87654321

PIN KEY (1207)

Pin 9

0–10V Input

Pin 7

Pot Low

0–10V

SENSOR

+

SENSOR OUTPUT

SENSOR GROUND

Curtis PMC 1207/1207A Manual

(b)

Ground-referenced 0–10V throttle

(Shunt impedance 150 kΩ to ground)

+

-

B-

16 15 14 13 12 11 10 9

87654321

PIN KEY (1207)

Pin 9

4.7 kΩ

Pin 7 Pin 5

0–10V Input Pot Low Pot High

12

19

Fig. 9

Wiring for 3-wire potentiometer throttle (“Type 2”).

2 — INSTALLATION & WIRING: 1207 Controller

3-Wire Potentiometer (500Ω–10kΩ) Throttle

A 3-wire potentiometer with a total resistance value anywhere between 500Ω and 10kΩ can be used, wired as shown in Figure 9. The pot is used in its voltage divider mode—with the voltage source and return being provided by the 1207 controller. Pot High provides a current-limited 5V source to the potentiometer, and Pot Low provides the return path.

3-WIRE POT

OFFON

16 15 14 13 12 11 10 9

87654321

PIN KEY (1207)

Pin 7

Pot Low

Pin 6

0–5V Input

Pin 5

Pot High

As with the 2-wire throttles, broken wire protection is provided by the controller looking for a minimum current into the Pot Low pin. If the Pot Low input current falls below 0.1 mA, a throttle fault is generated and the controller

NOTE

shuts down.

: The Pot Low pin (Pin 7) must not be tied to ground.

Curtis PMC 1207/1207A Manual

20

13

2 — INSTALLATION & WIRING: 1207 Controller

Curtis ET-XXX Electronic Throttle

The Curtis ET-XXX provides throttle and forward/reverse inputs to the 1207. Wiring for the Curtis ET-XXX is shown in Figure 10.

Fig. 10

Wiring for Curtis ET-XXX electronic throttle (“Type 2”).

B+

KEYSWITCH

WHT/ GRN

ET-XXX

BLACK

BLACK/WHITE

WHITE

WHT/BRN

GREEN

ORANGE

B-

16 15 14 13 12 11 10 9

87654321

PIN KEY (1207)

Pin 16 Pin 12 Pin 11

Pin 7 Pin 6

KSI Input Forward Reverse

Pot Low 0–5V Input

There is no fault detection built into the ET-XXX, and the controller will detect only open wiper faults. It is the responsibility of the vehicle manufacturer to provide any additional throttle fault detection necessary for the application.

The ET-XXX can be integrated into a control head to provide wigwag-style throttle control. Alternatively, a complete control head assembly is available from Curtis. This control head assembly—the CH series—combines the ET-XXX throttle with a variety of standard control head switch functions for use in walkie and lift truck applications.

Curtis PMC 1207/1207A Manual

14

21

2 — INSTALLATION & WIRING: 1207 Controller

0–5kΩ Throttle (“Type 3”)

The 0–5kΩ throttle (“Type 3” in the programming menu) is a 2-wire resistive throttle that connects between the 5kΩ–0/0–5kΩ pin (Pin 8) and the Pot Low pin (Pin 7), as shown in Figure 11. It doesn’t matter which wire goes on which pin. For Type 3 throttles, zero speed corresponds to 0Ω and full speed corresponds to 5kΩ.

Fig. 11

Wiring for 0–5

throttle (“Type 3”).

Ω

5kΩ POT

16 15 14 13 12 11 10 9

FASTER

87654321

PIN KEY (1207)

Pin 8 Pin 7

Broken wire protection is provided by the controller sensing the current flow from the 0–5kΩ input through the pot and into the Pot Low pin. If the Pot Low input current falls below 0.1 mA, a throttle fault is generated and the controller shuts down.

NOTE

: The Pot Low pin (Pin 7) must not be tied to ground.

WIRING: Emergency Reverse Check

An optional wire connected directly to the emergency reverse (belly button) switch provides for broken wire detection when that option is enabled at the factory. The emergency reverse check output wire periodically pulses the emergency reverse circuit to check for continuity. If there is no continuity in the circuit, the controller shuts down and a fault code is indicated.

This feature must be enabled at Curtis PMC. If the option is selected and the check wire is not connected, the vehicle will not operate. If the option is not selected and the check wire is connected, no harm will occur—but continuity will not be checked.

The emergency reverse check output wire is connected to Pin 10, as shown by the dashed lines in the two basic wiring diagrams (Figures 3 and 4).

5kΩ–0 Pot Low

Curtis PMC 1207/1207A Manual

22

15

2 — INSTALLATION & WIRING: 1207 Controller

SWITCHES AND OTHER HARDWARE

Keyswitch

The vehicle should have a master on/off switch to turn the system off when not in use. The keyswitch provides logic power for the 1207 controller, coil current for the contactors, and shunt current (in compound motor applications). The keyswitch must be capable of carrying these currents.

Main Contactor

A main contactor allows the 1207 controller to be disconnected from the battery. In 24V applications a main contactor is optional, but in 36V applications a main contactor is required. A heavy-duty single-pole, single-throw (SPST) contactor with silver-alloy contacts is recommended, such as an Albright SW80 or SW180 (available from Curtis).

After initial closing of the contacts, inrush currents flow as the controller’s internal ﬁlter capacitors are charged. A 250Ω, 5W resistor (such as Curtis PMC p/n MP-2) can be used across the contactor to precharge the capacitors and reduce the inrush current through the contacts.

Forward/Reverse Contactors

For forward/reverse, a paired single-pole, double-throw (2×SPDT) contactor is recommended, such as an Albright DC88 or DC182 (available from Curtis). With 4-terminal split ﬁeld motors, two single-pole, single-throw (SPST) contactors are typically used. The coil voltage should match the vehicle voltage. The maximum allowed coil current is 1 ampere.

Forward/Reverse, Emergency Reverse, and Mode Switches

The direction input switches can be any type of single-pole, single-throw (SPST) switch capable of switching the battery voltage at 10 mA.

Circuitry Protection Devices

For reverse polarity protection, a diode should be added to the control circuit. It must be sized appropriately for the maximum contactor coil currents (and shunt current, in compound motor applications). To protect the control wiring from accidental shorts, a low current fuse (appropriate for the maximum current draw) should be connected in series with the battery feed. These devices are both shown in the wiring diagrams.

Curtis PMC 1207/1207A Manual

16

23

2 — INSTALLATION & WIRING: 1207 Controller

1207 INSTALLATION CHECKOUT

Before operating the vehicle, carefully complete the following checkout procedure. If you ﬁnd a problem during the checkout, refer to the diagnostics and troubleshooting section (Section 5) for further information.

The installation checkout can be conducted with or without the handheld programmer. The checkout procedure is easier with a programmer. Otherwise, observe the Status LED for codes.

CAUTION

☞

Put the vehicle up on blocks to get the drive wheel(s) off the ground before beginning these tests.

Turn the keyswitch off and make sure that the brake is applied (brake switch open), the throttle is in neutral, and the forward/reverse switches are open.

Do not stand, or allow anyone else to stand, directly in front of or behind the vehicle during the tests.

1. Slide open the cover on the top of the controller. The cover is not removable; be careful not to force it. If a programmer is available, connect it to the programmer connector.

2. Turn the keyswitch on. The programmer should “power up” with an initial display, and the controller’s Status LED should begin steadily blinking a single ﬂash. If neither happens, check for continuity in the keyswitch circuit and controller ground.

3. If you are using a programmer, put it into the diagnostic mode by pressing the Found.”

Release the brake (close the brake switch). To do this on a walkie, pull the tiller down to the operating position. The LED should continue blinking a single flash and the programmer should continue to indicate no faults. If there is a problem, the LED will ﬂash a diagnostic code and the programmer will display a diagnostic message. If you are conducting the checkout without a programmer, look up the LED diagnostic code in Section 5: Diagnostics and Troubleshooting.

When the problem has been corrected, it may be necessary to cycle the brake in order to clear the fault code.

DIAGNOSTICS

key. The display should indicate “No Faults

24

Curtis PMC 1207/1207A Manual

17

2 — INSTALLATION & WIRING: 1207 Controller

4. With the brake released, select a direction and operate the throttle. The motor should begin to turn in the selected direction. If it does not, verify the wiring to the forward/reverse switches, forward/reverse contactors, and motor. The motor should run proportionally faster with increasing throttle. If not, refer to Section 5.

5. If you are using a programmer, put it into the test mode by pressing

TEST

the

key. Scroll down to observe the status of the forward, reverse, brake, emergency reverse, and mode switches. Cycle each switch in turn, observing the programmer. Each input should show the correct state on the programmer.

6. Speciﬁc material handling directives, such as prEN1175, require testing of the controller’s fault detection circuitry. This can be done as follows:

a) Disconnect the battery and make sure the keyswitch is off. b) Using an inline fuse holder ﬁtted with a 10-amp fuse and

alligator clips, connect the controller’s M- and B- terminals.

c) Turn the keyswitch on, release the brake, and apply the throttle.

The motor should not operate, and the direction contactors should not pull in.

d) Leave the keyswitch on and remove the inline fuse wire. The

vehicle status should continue to remain off.

e) Cycle the keyswitch off and on, release the brake, and apply the

throttle. The vehicle should now operate normally.

Curtis PMC 1207/1207A Manual

7. Take the vehicle off the blocks and drive it in a clear area. It should have smooth acceleration and good top speed.

8. Test the plug braking of the vehicle. Verify that the plug braking option is as desired (variable or ﬁxed).

9. Verify that all options, such as high pedal disable (HPD), static return to off (SRO), and anti-tiedown, are as desired.

10. Check to see whether the emergency reverse (belly button) feature is working correctly. If you have the optional emergency reverse check wiring, verify that the circuit is operational by momentarily disconnecting one of the emergency reverse wires. The vehicle should be disabled and a fault indicated.

11. When you have completed the checkout procedure, be sure to close the protective sliding cover.

18

25

2A — INSTALLATION & WIRING: 1207A Controller

INSTALLATION AND WIRING: 1207A

2

Fig. 2

dimensions, Curtis PMC 1207A controller.

A

Mounting

MOUNTING

The 1207A controller can be oriented in any position, but the location should be carefully chosen to keep the controller as clean and dry as possible. If a clean mounting location cannot be found, a cover must be used to shield the controller from water and contaminants.

To ensure full rated output power, the controller should be fastened to a

clean, ﬂat metal surface with three screws. The case outline and mounting hole

A

dimensions are shown in Figure 2

122

(4.80)

C

L

.

165 (6.50)

127 (5.00)

Status LED

22 (0.85)

28 (1.1)

66 (2.6)

(2.60)

Curtis PMC 1207/1207A Manual

152 (6.00)

66

Dimensions in millimeters and (inches)

6.7 (0.265) dia., 3 plcs

6.3 (0.25)

21 × 16 × 1.5

(0.83 × 0.63 × 0.06);

8.4 (0.33) dia. hole thru

4.8 (0.19)

19

26

2A — INSTALLATION & WIRING: 1207A Controller

Although not usually necessary, a thermal joint compound can be used to

improve heat conduction from the case to the mounting surface.

CONNECTIONS:

Low Current

An integrated 16-pin low power connector molded into the front of the controller provides the low power logic control connections (see pin list below). The mating connector is Molex Mini-Fit Jr., part number (5557) 39-01-2165. Contact Molex regarding compatible pins for various wire sizes.

16 15 14 13 12 11 10 9

87654321

Pin 1 Pin 2 Pin 3 Pin 4 Pin 5 Pin 6 Pin 7 Pin 8

shunt ﬁeld driver output; n/c for series motors reverse contactor driver output forward contactor driver output main contactor driver output throttle: 3-wire pot high throttle: 3-wire pot wiper or 0–5V throttle: pot low throttle: 2-wire 5kΩ–0 or 0–5kΩ input

Curtis PMC 1207/1207A Manual

Pin 9 Pin 10 Pin 11 Pin 12 Pin 13 Pin 14 Pin 15 Pin 16

n/c emergency reverse (BB) check output [optional] reverse input forward input emergency reverse input mode selection input brake input keyswitch input (KSI)

20

27

2A — INSTALLATION & WIRING: 1207A Controller

Programmer Connector

A 4-pin Molex connector is provided for the handheld programmer. The mating cable is supplied with the programmer.

Status LED

The Status LED, located on top of the controller, displays ﬂashing codes to indicate controller status; the codes are listed in Section 5.

CONNECTIONS: High Current

Four tin-plated copper bus bars are provided for the high current connections to the battery and motor:

M-

output to motor armature

B-

negative connection to battery

B+

A2

B+B-

Cables are fastened to the bus bars by M8 (

positive connection to battery/ﬁeld

A2

plug diode to motor armature

5

⁄16") bolts. When tightening the bolts, two opposing wrenches should be used to prevent bending the bus bars and putting undue strain on the internal connections.

Curtis PMC 1207/1207A Manual

28

21

Fig. 3

A

Standard wiring diagram (series motor), Curtis PMC 1207A controller.

2A — INSTALLATION & WIRING: 1207A Controller

WIRING: Standard Configuration (Series Motor)

The basic wiring for series motors with ﬁeld reversing is shown in Figure 3

SWITCHES

MULTI

BRAKE FORWARD

KEYSWITCH

POLARITY

PROTECTION

DIODE

EMERGENCY

MODE

REVERSE

THROTTLE

5kΩ–0 (TYPICAL)

FORWARD

M- A2

REVERSE

CONTACTORS

B+B-

FUSE

CONTROL

POWER

FUSE

B+

MAIN

CONTACTOR

PRECHARGE RESISTOR

(250 Ω, 5 W)

FORWARD

CONTACTOR

S1S2

REVERSE

CONTACTOR

A

.

MAINREVERSE

B-

The conﬁguration shown in Figure 3A is a typical arrangement for a series motor. Curtis PMC controllers are designed for use in a wide range of applications, and accordingly can be installed in a variety of ways to best meet customer needs.

NOTE

factory option.

Curtis PMC 1207/1207A Manual

A

A1

A2

: The emergency reverse check feature (wiring shown by dashed line) is a

22

29

2A — INSTALLATION & WIRING: 1207A Controller

Power Wiring for Series Motor

In every wiring conﬁguration, it is imperative that the ﬁeld be wired between the controller’s

B+

and A2 terminals and that the armature be wired between the

M-

and A2 terminals. The internal plug diode used in the 1207A is connected between

M-

and A2. Therefore, the armature and ﬁeld positions cannot be interchanged. Reversing contactors can be used to switch either the armature or the ﬁeld.

Control Wiring for Series Motor

Wiring for the input switches and contactors is shown in Figure 3A (see detail below). The main contactor, if one is used, is normally connected directly to the controller. Optionally, the main contactor can be switched directly by the keyswitch or brake, leaving Pin 4 unconnected.

16-pin detail (see Fig. 3A):

REVERSE

EMERGENCY

REVERSE

CHECK

OUTPUT

KEYSWITCH

BRAKE

MULTI

MODE

FORWARD

EMERGENCY

REVERSE

16 15 14 13 12 11 10 9

87654321

POT LOW

2-WIRE POT

(5 kΩ)

The throttle shown in Figure 3

CONTACTOR

A

is a 5kΩ–0 type. Various other throttles can also

CONTACTOR

MAIN

FORWARD

CONTACTOR

REVERSE

be accommodated, and are discussed in the throttle wiring section.

Curtis PMC 1207/1207A Manual

30

23

Fig. 4

A

Compound motor wiring diagram, Curtis PMC 1207A controller.

2A — INSTALLATION & WIRING: 1207A Controller

WIRING: Compound Motor Configuration

A specially conﬁgured controller is available for compound motor applications. In this controller, the MOSFET output driver is used to drive the shunt ﬁeld. The wiring for a compound wound motor with armature reversing is shown in

A

BRAKE

.

MULTI MODE

SWITCHES

EMERGENCY

REVERSE

FORWARD

REVERSE

SHUNT

CONTACTORS

FWD

MAINREV

Figure 4

B-

KEYSWITCH

POLARITY

PROTECTION

DIODE

THROTTLE

5kΩ–0 (TYPICAL)

M- A2

B+B-

FUSE

CONTROL

POWER

B+

B-

FUSE

CONTACTOR

PRECHARGE RESISTOR

MAIN

(250 Ω, 5 W)

FORWARD

CONTACTOR

S2

S1

A1

A2

A

REVERSE

CONTACTOR

The conﬁguration shown in Figure 4A requires the use of a compound wound motor. Pure shunt motors cannot be used with 1207A controllers. Although the conﬁguration shown is typical, various other conﬁgurations are possible.

3/28/00

NOTE

factory option.

Curtis PMC 1207/1207A Manual

: The emergency reverse check feature (wiring shown by dashed line) is a

24

31

2A — INSTALLATION & WIRING: 1207A Controller

Power Wiring for Compound Motor

The ﬁeld must be wired between B+ and A2 and the armature between M- and A2.

M-

The internal plug diode in the 1207A is connected between

and A2; therefore,

the armature and ﬁeld positions cannot be interchanged.

If the shunt is rated for under 2 amperes, it can be connected directly to the

A

controller as shown in Figure 4

. If the shunt is rated for higher than 2 amperes,

a contactor must be used to control the shunt ﬁeld.

Control Wiring for Compound Motor

Control wiring for the compound motor application is like that for the standard (series motor) wiring. The main contactor, if one is used, is normally connected directly to B-.

16-pin detail (see Fig. 4A):

EMERGENCY

REVERSE

CHECK

OUTPUT

KEYSWITCH

BRAKE

MULTI

MODE

FORWARD

EMERGENCY

REVERSE

16 15 14 13 12 11 10 9

87654321

POT

LOW

2-WIRE POT

(5 kΩ)

The throttle shown in Figure 4

A

is a 5kΩ–0 type. Various other throttles can also

FORWARD

CONTACTOR

SHUNT

REVERSE

be accommodated, and are discussed in the throttle wiring section.

Polarity protection diodes and control fuses must be sized appropriately to

handle the increased current from the shunt ﬁeld.

Curtis PMC 1207/1207A Manual

32

25

Fig. 5

A

Wiring for 5k

Ω

–0 throttle

(“Type 1”).

2A — INSTALLATION & WIRING: 1207A Controller

WIRING: Throttle

Wiring for various throttles is described below. They are characterized as Type 1, Type 2, and Type 3 throttles in the programming menu of the handheld

NOTE

programmer.

: In the text, throttles are identiﬁed by their nominal range and

not by their actual active range.

If the throttle you are planning to use is not covered, please contact the

Curtis ofﬁce nearest you.

5kΩ–0 Throttle (“Type 1”)

The 5kΩ–0 throttle (called a “Type 1” throttle in the programming menu of the handheld programmer) is a 2-wire resistive throttle that connects between the

5kΩ POT

16 15 14 13 12 11 10 9

FASTER

87654321

PIN KEY (1207A)

Pin 8

5kΩ–0

Pin 7

Pot Low

5kΩ–0/0–5kΩ pin (Pin 8) and the Pot Low pin (Pin 7), as shown in Figure 5A. It doesn’t matter which wire goes on which pin. Zero speed corresponds to 5kΩ and full speed corresponds to 0Ω.

is the easiest with which to implement a wigwag-style throttle. Using a 20kΩ potentiometer wired as shown in Figure 6 controller has 5kΩ between Pins 7 and 8 when the throttle is in the neutral position (i.e., at the center of the pot). The throttle mechanism can then be designed such that rotating it either forward or back decreases the resistance

Fig. 6

A

Wiring for 20k potentiometer used as a wigwag-style throttle (“Type 1”).

Curtis PMC 1207/1207A Manual

Ω

In addition to accommodating the basic 5kΩ–0 throttle, the Type 1 throttle

A

, the pot wiper can be set such that the

20 kΩ POT

16 15 14 13 12 11 10 9

FASTERFASTER

87654321

PIN KEY (1207A)

Pin 8

5kΩ–0

Pin 7

Pot Low

26

33

Fig. 7

A

Wiring for 0–5V

throttle (“Type 2”).

2A — INSTALLATION & WIRING: 1207A Controller

between Pins 7 and 8, which increases the controller output. The throttle mechanism must provide signals to the controller’s forward and reverse inputs independent of the throttle pot resistance. The controller will not sense direction from the pot resistance.

0–5V, 3-Wire Potentiometer, and Electronic Throttles (“Type 2”)

With these throttles (“Type 2” in the programming menu), the controller looks for a voltage signal at the pot wiper/0–5V input of the controller (Pin 6). Zero speed corresponds to 0V and full speed corresponds to 5V. Pot Low is the current return path for all Type 2 throttles.

0–5V Throttle

Two ways of wiring the 0–5V throttle are shown in Figure 7A. If a throttle sensor is used, the sensor’s ground return current must be less than 10 mA. If the 0–5V throttle input (Pin 6) exceeds 8 volts, the controller will shut down.

(a)

0–5V throttle sensor

16 15 14 13 12 11 10 9

+

87654321

0–5V

SENSOR

(b)

Ground-referenced 0–5V throttle

SENSOR OUTPUT

SENSOR GROUND

(Shunt impedance 150 kΩ to ground)

+

-

B-

PIN KEY (1207A)

Pin 7

Pot Low

Pin 6

0–5V Input

16 15 14 13 12 11 10 9

87654321

PIN KEY (1207A)

Pin 7

Pot Low

Pin 6

4.7 kΩ

Pin 5

0–5V Input Pot High

Curtis PMC 1207/1207A Manual

34

27

Fig. 8

A

Wiring for 3-wire potentiometer throttle (“Type 2”).

2A — INSTALLATION & WIRING: 1207A Controller

3-Wire Potentiometer (500Ω–10kΩ) Throttle

The 3-wire potentiometer is used in its voltage divider mode—with the voltage source and return being provided by the 1207A controller. Pot High provides a current-limited 5V source to the potentiometer, and Pot Low provides the return

A

path. Wiring is shown in Figure 8

3-WIRE POT

OFFON

.

16 15 14 13 12 11 10 9

87654321

PIN KEY (1207A)

Pin 7 Pin 6 Pin 5

Pot Low 0–5V Input Pot High

Curtis ET-XXX Electronic Throttle

The Curtis ET-XXX (manufactured by Hardellet) provides throttle and forward/ reverse inputs to the 1207A controller. Wiring for the Curtis ET-XXX is shown

A

in Figure 9

.

Fig. 9

A

Wiring for Curtis ET-XXX electronic throttle (“Type 2”).

WHT/ GRN

ET-XXX

ORANGE

BLACK

BLACK/WHITE

WHITE

B+

WHT/BRN

GREEN

KEYSWITCH

B-

16 15 14 13 12 11 10 9

87654321

PIN KEY (1207A)

Pin 16 Pin 12 Pin 11

Pin 6

KSI Input Forward Reverse

0–5V Input

3/28/00

Curtis PMC 1207/1207A Manual

28

35

Fig. 10

A

Wiring for

Ω

throttle (“Type 3”).

0–5

2A — INSTALLATION & WIRING: 1207A Controller

0–5kΩ Throttle (“Type 3”)

The 0–5kΩ throttle (“Type 3” in the programming menu) is a 2-wire resistive throttle that connects between the 5kΩ–0/0–5kΩ pin (Pin 8) and the Pot Low

A

pin (Pin 7), as shown in Figure 10

. It doesn’t matter which wire goes on which

pin. Zero speed corresponds to 0Ω and full speed corresponds to 5kΩ.

5kΩ POT

16 15 14 13 12 11 10 9

Fig. 11

A

Alternative wiring for 1207A emergency reverse check.

FASTER

87654321

PIN KEY (1207A)

Pin 8

5kΩ–0

Pin 7

Pot Low

WIRING: Emergency Reverse Check

An optional wire connected directly to the emergency reverse (belly button) switch provides for broken wire detection when that option is enabled at the factory. The emergency reverse check output wire provides a dc bias to the emergency reverse circuit to check for continuity. If there is no continuity in the circuit, the controller shuts down and a fault code is indicated.

SWITCHES

MULTI

BRAKE FORWARD

MODE

EMERGENCY

REVERSE

9.1 kΩ

FORWARD

REVERSE

CONTACTORS

MAINREVERSE

Curtis PMC 1207/1207A Manual

36

For rest of wiring diagram, see Fig. 3A (series motors) or Fig. 4A (compound motors).

This feature must be enabled at Curtis PMC. If the option is selected and the check wire is not connected, the vehicle will not operate. If the option is not selected and the check wire is connected, no harm will occur—but continuity will not be checked.

The emergency reverse check output wire is connected to Pin 10, as shown

A

by the dashed lines in the two basic wiring diagrams (Figures 3

and 4A).

Alternatively, a 9.1kΩ resistor can be wired directly across the emergency reverse switch to provide the dc bias, as shown by the dashed line in Figure 10

29

A

.

2A — INSTALLATION & WIRING: 1207A Controller

SWITCHES AND OTHER HARDWARE

Keyswitch

The vehicle should have a master on/off switch to turn the system off when not

in use. The keyswitch provides logic power for the 1207A controller, coil current

for the contactors, and shunt current (in compound motor applications). The

keyswitch must be capable of carrying these currents.

Main Contactor

A main contactor allows the 1207A controller to be disconnected from the

battery. A heavy-duty single-pole, single-throw (SPST) contactor with silver-

alloy contacts is recommended, such as an Albright SW80 or SW180 (available

from Curtis).

After initial closing of the contacts, inrush currents flow as the controller’s internal ﬁlter capacitors are charged. A 250Ω, 5W resistor (such as Curtis PMC p/n MP-2) can be used across the contactor to precharge the capacitors and reduce the inrush current through the contacts.

In compound motor applications, the main contactor driver is used to drive the shunt ﬁeld. The main contactor—if one is used—is normally connected directly to B- in this conﬁguration.

Forward/Reverse Contactors

For forward/reverse, a paired single-pole, double-throw (2×SPDT) contactor is recommended, such as an Albright DC88 or DC182 (available from Curtis). With 4-terminal split ﬁeld motors, two single-pole, single-throw (SPST) contactors are typically used. The coil voltage should match the vehicle voltage. The maximum allowed coil current is 1 ampere.

Forward/Reverse, Emergency Reverse, and Mode Switches

The direction input switches can be any type of single-pole, single-throw (SPST) switch capable of switching the battery voltage at 10 mA.

Circuitry Protection Devices

For reverse polarity protection, a diode should be added to the control circuit. It must be sized appropriately for the maximum contactor coil currents (and shunt current, in compound motor applications). To protect the control wiring from accidental shorts, a low current fuse (appropriate for the maximum current draw) should be connected in series with the battery feed. These devices are both shown in the wiring diagrams.

Curtis PMC 1207/1207A Manual

30

37

2A — INSTALLATION & WIRING: 1207A Controller

1207A INSTALLATION CHECKOUT

Before operating the vehicle, carefully complete the following checkout procedure. If you ﬁnd a problem during the checkout, refer to the diagnostics and troubleshooting section (Section 5) for further information.

The installation checkout can be conducted with or without the handheld programmer. The checkout procedure is easier with a programmer. Otherwise, observe the Status LED for codes.

CAUTION

☞

Put the vehicle up on blocks to get the drive wheel(s) off the ground before beginning these tests.

Turn the keyswitch off and make sure that the brake is applied (brake switch open), the throttle is in neutral, and the forward/reverse switches are open.

Do not stand, or allow anyone else to stand, directly in front of or behind the vehicle during the tests.

1. If a programmer is available, connect it to the programmer connector.

2. Turn the keyswitch on. The programmer should “power up” with an initial display, and the controller’s Status LED should begin steadily blinking a single ﬂash. If neither happens, check for continuity in the keyswitch circuit and controller ground.

3. If you are using a programmer, put it into the diagnostic mode by pressing the Found.”

Release the brake (close the brake switch). To do this on a walkie, pull the tiller down to the operating position. The LED should continue blinking a single flash and the programmer should continue to indicate no faults. If there is a problem, the LED will ﬂash a diagnostic code and the programmer will display a diagnostic message. If you are conducting the checkout without a programmer, look up the LED diagnostic code in Section 5: Diagnostics and Troubleshooting.

When the problem has been corrected, it may be necessary to cycle the brake in order to clear the fault code.

DIAGNOSTICS

key. The display should indicate “No Faults

Curtis PMC 1207/1207A Manual

38

4. With the brake released, select a direction and operate the throttle. The motor should begin to turn in the selected direction. If it does not,

31

2A — INSTALLATION & WIRING: 1207A Controller

verify the wiring to the forward/reverse switches, forward/reverse contactors, and motor. The motor should run proportionally faster with increasing throttle. If not, refer to Section 5.

5. If you are using a programmer, put it into the test mode by pressing

the TEST key. Scroll down to observe the status of the forward, reverse, brake, emergency reverse, and mode switches. Cycle each switch in turn, observing the programmer. Each input should show the correct state on the programmer.

6. Speciﬁc material handling directives, such as prEN1175, require testing of the controller’s fault detection circuitry. This can be done as follows:

a) Disconnect the battery and make sure the keyswitch is off. b) Using an inline fuse holder ﬁtted with a 10-amp fuse and

alligator clips, connect the controller’s M- and B- terminals.

c) Turn the keyswitch on, release the brake, and apply the throttle.

The motor should not operate, and the direction contactors should not pull in.

d) Leave the keyswitch on and remove the inline fuse wire. The

vehicle status should continue to remain off.

e) Cycle the keyswitch off and on, release the brake, and apply the

throttle. The vehicle should now operate normally.

7. Take the vehicle off the blocks and drive it in a clear area. It should have smooth acceleration and good top speed.

8. Test the plug braking of the vehicle. Verify that the plug braking option is as desired (variable or ﬁxed).

9. Verify that all options, such as high pedal disable (HPD), static return to off (SRO), and anti-tiedown, are as desired.

10. Check to see whether the emergency reverse (belly button) feature is working correctly. If you have the optional emergency reverse check wiring, verify that the circuit is operational by momentarily disconnecting one of the emergency reverse wires. The vehicle should be disabled and a fault indicated.

Curtis PMC 1207/1207A Manual 32

39

3 — ADJUSTMENT OF PARAMETERS

ADJUSTMENT OF PARAMETERS

3

A number of controller parameters can be adjusted electronically via the optional handheld programmer; for a complete list of the adjustments that can be made, see Section 6: Programmer Operation. On some 1207 models, it is also possible to adjust the main current limit, plug current limit, acceleration rate, maximum creep speed, and maximum speed mechanically, by means of the built-in screwdriver-adjustable potentiometers.

ADJUSTMENT VIA THE PROGRAMMER

To change a parameter using the programmer, press the scroll down the Program Menu until the desired parameter is the top line of the display. Press the appropriate until the desired number is reached. The parameter is now set at the desired value. All programming occurs in real time. That is, the parameters can be changed while the vehicle is in operation.

The upper and lower limits of parameters are set at the factory. Some parameters have dependencies on other parameters. When the programmer is being used to adjust a parameter and a limit is reached, the display will stop changing. To see why the display has stopped changing, press the

MORE INFO

will be displayed; changing the value of the related parameter may allow the original parameter to be adjusted further. Otherwise, the display simply says “Max Limit” or “Min Limit.”

key. If the limit is related to another parameter, that information

Use of the programmer is described more fully in Section 6.

CHANGE VALUE

PROGRAM

key (“up” or “down”)

key, and

Curtis PMC 1207/1207A Manual

40

1207 single-mode controllers only

If a programmer is connected when a parameter is adjusted mechanically (see next page), the effect of the change can be seen in the programmer display. To adjust one of these ﬁve parameters with the

OFF

programmer, its potentiometer must be set to the “ the adjustment panel. If you attempt to use the programmer to adjust a parameter whose potentiometer is position, its value will not change. You will also note that the LEDs in the corners of both the another indication the parameter cannot be adjusted electronically. If you press the following message: “Protected by controller, can’t program.”

MORE INFO

CHANGE VALUE

key, the programmer will display the

not set to the “

keys do not light up—

” position on

OFF

”

33

3 — ADJUSTMENT OF PARAMETERS

MECHANICAL ADJUSTMENT

[1207 single-mode controllers only]

Five screwdriver-adjustable potentiometers (“trimpots”) allow mechanical adjustment of the main current limit, plug current limit, acceleration rate, maximum creep speed, and maximum speed (labeled “

LOW

”). The ﬁve trimpots are accessed through holes on the adjustment panel, located under the sliding protective cover on top of the controller. Adjustments are made with a small insulated screwdriver.

OFF

12

30 4

OFF

12

30 4

12

OFF

12

30

OFF

4

12

30

OFF

4

30 4

LIMITSPEEDLIMITCURRENT

STATUSACCEL. L O WCREEPPLUGMAIN

The trimpot’s relative position indicates the approximate value over the allowable range. For example: if the main current limit range is 20–250 amps, position “0” corresponds to 20 amps, and position “4” to 250 amps. Setting the pot halfway (at position “2”) corresponds to approximately 135 amps.

If you wish to adjust any of these parameters electronically, using the programmer, its trimpot must be set to “

NOTE

: On 1207 controllers with the MultiMode™ feature, the trimpots are

OFF

.”

disabled at the factory.

Curtis PMC 1207/1207A Manual

34

41

MAINTENANCE

4 — MAINTENANCE

4

CAUTION

☞

There are no user-serviceable parts inside Curtis PMC 1207 and 1207A controllers. No attempt should be made to open the controller. Opening the controller may damage it and will void the warranty.

However, it is recommended that the controller exterior be cleaned periodically, and—if a handheld programmer is available—this periodic cleaning provides a good opportunity to check the controller’s diagnostic history ﬁle. It is also recommended that the controller’s fault detection circuitry be checked whenever the vehicle is serviced.

The 1207/1207A controller is inherently a high power device.

When working around any battery powered vehicle, proper safety precautions should be taken. These include, but are

not limited to: proper training, wearing eye protection, avoiding loose clothing and jewelry, and using insulated wrenches.

CLEANING

Although the 1207/1207A controller requires virtually no maintenance if properly installed, the following minor maintenance is recommended in certain applications.

DIAGNOSTIC HISTORY

The handheld programmer can be used to access the controller’s diagnostic history ﬁle. Connect the programmer, press the

Curtis PMC 1207/1207A Manual

1. Remove power by disconnecting the battery.

2. Discharge the capacitors in the controller by connecting a load (such as a contactor coil or a horn) across the controller’s B+ and B- terminals.

3. Remove and dirt or corrosion from the bus bar area. The controller should be wiped clean with a moist rag. Allow it to dry before reconnecting the battery.

4. Make sure the connections to the bus bars are tight. Use two well insulated wrenches for this task in order to avoid stressing the bus bars.

MORE INFO

key, and then—while

35

42

4 — MAINTENANCE

continuing to hold the

MORE INFO

key—press the

DIAGNOSTICS

key. The programmer will read out all the faults that the controller has experienced since the last time the diagnostic history ﬁle was cleared. The faults may be intermittent faults, faults caused by loose wires, or faults caused by operator errors. Faults such as contactor faults may be the result of loose wires; contactor wiring should be carefully checked out. Faults such as HPD or overtemperature may be caused by operator habits or by overloading.

After a problem has been diagnosed and corrected, clearing the diagnostic history ﬁle is advisable. This allows the controller to accumulate a new ﬁle of faults. By checking the new diagnostic history ﬁle at a later date, you can readily determine whether the problem was indeed completely ﬁxed.

To clear the diagnostic history ﬁle, go to the Special Program Menu (by

pressing and holding the

MORE INFO

key, and then pressing the

PROGRAM

key), scroll through the menu until “Clear Diagnostic History” is the top line in the display, and then press

MORE INFO

again. The programmer will prompt you to acknowledge or cancel. See Section 6 of this manual for more detail on programmer operation.

TESTING THE FAULT DETECTION CIRCUITRY

Speciﬁc material handling directives, such as prEN1175, require periodic testing of the controller’s fault detection circuitry. It is recommended that each time the vehicle is serviced, the M- fault detection circuitry be checked as follows:

Curtis PMC 1207/1207A Manual

1. Put the vehicle up on blocks to get the drive wheel(s) off the ground, disconnect the battery, and make sure the keyswitch is off.

2. Using an inline fuse holder ﬁtted with a 10-amp fuse and alligator clips, connect the controller’s M- and B- terminals.

3. Turn the keyswitch on, release the brake, and apply the throttle. The motor should not operate, and the direction contactors should not pull in.

4. Leave the keyswitch on and remove the inline fuse wire. The vehicle status should continue to remain off.

5. Cycle the keyswitch off and on, release the brake, and apply the throttle. The vehicle should now operate normally.

36

43

5 — DIAGNOSTICS & TROUBLESHOOTING

DIAGNOSTICS AND TROUBLESHOOTING

5

The 1207/1207A controllers provide diagnostics information to assist technicians in troubleshooting drive system problems. The diagnostics information can be obtained in two ways: reading the appropriate display on the programmer or observing the fault codes issued by the Status LED. The Status LED is located on top of the controller. On 1207 models, it is under the sliding protective cover.

LED DIAGNOSTICS

During normal operation, with no faults present, the Status LED ﬂashes a single flash at approximately 1 flash/second. If the controller detects a fault, a 2-digit fault identiﬁcation code is flashed continuously until the fault is corrected. For example, code “3,2”—welded direction contactor—appears as:

¤¤¤ ¤¤ ¤¤¤ ¤¤ ¤¤¤ ¤¤

( 3 , 2 ) ( 3 , 2 ) ( 3 , 2 )

The codes are listed in Table 1. For suggestions about possible causes of the various faults, refer to the troubleshooting chart (Table 2).

Table 1

LED CODE EXPLANATION

LED off no power or defective controller

solid on defective controller

single flash ¤ controller operational; no faults

1,2 ¤ ¤¤ hardware fail-safe error 1,3 ¤ ¤¤¤ M- fault or motor output short 1,4 ¤ ¤¤¤¤ sequencing fault (SRO)

2,1 ¤¤ ¤ 5kΩ–0 or throttle wiper input fault 2,2 ¤¤ ¤¤ emerg. rev. circuit check fault (BB wiring) 2,3 ¤¤ ¤¤¤ high-pedal-disable fault (HPD) 2,4 ¤¤ ¤¤¤¤ throttle pot low open or shorted to B+ or B-

3,1 ¤¤¤ ¤ contactor or shunt driver overcurrent 3,2 ¤¤¤ ¤¤ welded direction contactor 3,3 ¤¤¤ ¤¤¤ [reserved for future use] 3,4 ¤¤¤ ¤¤¤¤ missing contactor or shunt

4,1 ¤¤¤¤ ¤ low battery voltage 4,2 ¤¤¤¤ ¤¤ overvoltage 4,3 ¤¤¤¤ ¤¤¤ thermal cutback 4,4 ¤¤¤¤ ¤¤¤¤ [reserved for future use]

LED CODES

Curtis PMC 1207/1207A Manual

44

NOTE

: Only one fault is indicated at a time, and faults are not queued up.

37

5 — DIAGNOSTICS & TROUBLESHOOTING

Operational faults—such as overtemperature—are cleared as soon as operation is brought within range. Non-operational faults—such as a throttle fault—usually require the brake or keyswitch to be cycled after the problem is remedied.

PROGRAMMER DIAGNOSTICS

With a programmer, diagnostics and troubleshooting is more direct than with the LED alone. The programmer presents complete diagnostic information in plain language—no codes to decipher. Faults are displayed in the Diagnostic Menu, and the status of the controller inputs/outputs is displayed in the Test Menu.

The following 4-step process is generally used for diagnosing and troubleshooting an inoperative vehicle: (1) visually inspect the vehicle for obvious problems; (2) diagnose the problem, using the programmer; (3) test the circuitry with the programmer; and (4) correct the problem. Repeat the last three steps as necessary until the vehicle is operational.

Example:

A vehicle that does not operate in “forward” is

brought in for repair.

STEP

1: Examine the vehicle and its wiring for any obvious

problems, such as broken wires or loose connections.

STEP

2: Connect the programmer, put it in diagnostic mode, and read the displayed fault information. In this example, the display shows “No Faults Present,” indicating that the controller has not detected anything out of the norm.

STEP

3: Put the programmer in test mode, and observe the status of the inputs and outputs in the forward direction. In this example, the display shows that the forward switch did not close when “forward” was selected, which means the problem is either in the forward switch or the switch wiring.

STEP

4: Check or replace the forward switch and wiring and repeat the test. If the programmer shows the forward switch closing and the vehicle now drives normally, the problem has been corrected.

Refer to the troubleshooting chart (Table 2) for suggestions covering a wide range of possible faults.

Curtis PMC 1207/1207A Manual

38

45

5 — DIAGNOSTICS & TROUBLESHOOTING

LED PROGRAMMER

CODE LCD DISPLAY

1,2

HW FA I L SAFE

1,3

M- SHORTED

1,4

SRO

2,1

THRO TTLE FAULT 1

2,2

BB WI R ING CHECK

2,3

HPD

2,4

THRO TTLE FAULT 2

3,1

CONT DRV R OC

3,2

DIR CONT WELDED

3,4

M I SS I NG CONTA CTOR

4,1

LOW B A TT ER Y VOLT AGE

4,2

OVER VOL TAGE

4,3

THERMAL CUTBACK

Table 2

TROUBLESHOOTING CHART

EXPLANATION POSSIBLE CAUSE

hardware fail-safe error 1. Controller defective.

M- output shorted 1. M- output shorted to ground.

2. Direction contactor not closing.

3. Direction contactor not closing fast enough.

4. Internal motor short to ground.

SRO fault 1. Improper sequence of KSI, brake, and

direction inputs.

2. Wrong SRO type selected.

3. Brake or direction switch circuit open.

4. Sequencing delay too short.

5kΩ–0 or wiper fault 1. Throttle input wire open.

2. Throttle input wire shorted to ground or B+.

3. Throttle pot defective.

4. Wrong throttle type selected.

emerg. reverse wiring fault 1. BB wire open.

2. BB check wire open.

HPD sequencing fault 1. Improper seq. of KSI, brake, throttle inputs.

2. Wrong HPD type selected.

3. Misadjusted throttle pot.

Pot Low broken or shorted 1. Pot Low wire open.

2. Pot Low wire shorted.

3. Wrong throttle type selected.

driver output overcurrent 1. Direction contactor coil shorted.

2. Shunt ﬁeld shorted.

welded direction contactor 1. Direction contactor stuck closed.

missing contactor or shunt 1. Direction contactor coil open.

2. Direction contactor missing.

3. Shunt ﬁeld open.

4. Wire to shunt or direction contactor open.

low battery voltage 1. Battery voltage <16 volts.

2. Corroded battery terminal.

3. Loose battery or controller terminal.

overvoltage 1. Battery voltage >48V (1207); >33V (1207A).

2. Vehicle operating with charger attached.

over-/under-temp. cutback 1. Temperature >85°C or <-25°C.

2. Excessive load on vehicle.

3. Improper mounting of controller.

4. Operation in extreme environments.

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46

39

6 — PROGRAMMER OPERATION

PROGRAMMER OPERATION

6

The LED in the corner of the key lights up to identify the mode of operation

The universal Curtis PMC handheld programmer (optional) allows you to program, test, and diagnose Curtis PMC programmable controllers. The programmer is powered by the host controller, via an RJ11 modular connector located in the adjustment panel on top of the controller (1207 models) or via a 4-pin Molex connector on the front panel (1207A models).

When the programmer is ﬁrst plugged into the controller, it displays the controller’s model number, date of manufacture, and software revision code. Following this initial display, the programmer displays a prompt for further instructions.

+ + + ++++++++++++++++++++

CURTIS PMC

+ + +

A 4-line LCD display is presented in this window

Choose the Program, Test,

PROGRAM

Scroll the 4-line display (up and down) with these two keys

Curtis PMC 1207/1207A Manual 40

SCROLL

DISPLAY

MORE INFO

A DIVISION OF CURTIS INSTRUMENTS INC.

TEST

DIAGNOSTICS

CHANGE

VALUE

or Diagnostics Mode with one of these three keys

Change the selected item’s value (up or down) with these two keys

Get more information about selected items with this key. Also, use this key in combination with other keys to put the programmer in Special modes.

47

6 — PROGRAMMER OPERATION

The programmer is operated via an 8-key keypad. Three keys select operating modes (Program, Test, Diagnostics), two scroll the display up and down, and two change the values of selected parameters. The eighth key, the

MORE INFO

key, is used to display further information about selected items within any of the three standard modes. In addition, when pressed together with the

DIAGNOSTICS

the

key, the

MORE INFO

key selects the Special Program mode or the

PROGRAM

or

Special Diagnostics mode.

The display window presents a 4-line LCD display. The display is visible even in bright sunlight. You can adjust the display contrast in the Special Program mode.

When one of the menu keys is pressed, the LED at the corner of the key lights up, identifying the mode of programmer operation. For example, if the

TEST

key is pressed, the LED at the corner of the key indicates that the programmer is now in the Test mode, and the Test Menu is displayed.

Four lines of a menu are displayed at a time. The item at the top of the display window is the selected item. To select an item, scroll within the menu until the desired item is positioned at the top of the display window. The selected item is always the top line. (In the Program mode, the selected item is highlighted by a ﬂashing arrow.) To modify a parameter or obtain more information about it, it must be scrolled to the top position in the display window.

To scroll up and down within a menu, use the two The a key is held down, the scrolling speed increases the longer the key is held.

SCROLL DISPLAY

A small scroll bar at the left of the display window provides a rough indication of the position of the four displayed items within the entire menu. That is, when the bar is at the top of the window, the top of the menu is displayed. As you scroll through the menu, the bar moves downward. When the bar is at the very bottom of the window, you have reached the end of the menu. This sample display is from the Program Menu:

Curtis PMC 1207/1207A Manual

SCROLL DISPLAY

scroll bar

SCROLL DISPLAY

arrow keys.

arrow keys can be pressed repeatedly or be held down. When

M1 MA I N C / L > 2 5 0 M1 P LUG C/ L 7 0 M1 RAMP C / L 250 M1 ACCEL RA TE 1 . 0

selected item

41

48

6 — PROGRAMMER OPERATION

CHANGE

VALUE

PROGRAM

The two CHANGE selected menu item. Like the

VALUE arrow keys are used to increase or decrease the value of a

SCROLL DISPLAY arrow keys, the CHANGE VALUE arrow

keys can be pressed repeatedly or be held down. The longer a key is held, the faster the parameter changes. This allows rapid changing of any parameter.

An LED on each

CHANGE VALUE arrow key indicates whether the key is active

and whether change is permissable. When the value of a parameter is being increased, the LED on the “up”

CHANGE VALUE key is on until you reach the

maximum value for that parameter. When the LED goes off, you cannot increase the value.

MORE INFO key has three functions: (1) to display more information about

The the selected item, (2) to access the Special Program and Special Diagnostics modes (when used together with the

PROGRAM and DIAGNOSTICS keys), and (3)

to initiate certain commands (such as the Self Test).

“More information” is available in all of the programmer operating modes. After using the selected item, press the

MORE INFO key to display additional information about the

MORE INFO key again to return to the original list.

OPERATING MODES:

PROGRAM, TEST, DIAGNOSTICS, SPECIAL PROGRAM, SPECIAL DIAGNOSTICS

In the

Program

mode, accessed by pressing the PROGRAM key, all the adjustable

parameters and features of the controller are displayed (four at a time), along with their present settings. The setting of the selected item—the item at the top of the display, with the flashing arrow—can be changed, using the two

CHANGE VALUE

keys.

The LEDs on these keys indicate whether there is still room for change. That is, when the upper limit of a parameter’s range is reached, the LED on the “up” key no longer lights up, indicating that the present value cannot be increased; when the lower limit is reached, the LED on the “down” key no longer lights up.

MORE INFO key, when used in the Program mode, displays a bar graph

The along with the minimum and maximum values possible for the selected parameter. Parameters can be changed either from the main Program Menu or after

MORE INFO key has been pressed and the additional information is being

the displayed (see example below).

selected parameter

Curtis PMC 1207/1207A Manual

bar graph

minimum value

MODE1 ACCELERAT I ON R ATE , SECS

MIN 0.2 MAX 3.0

1.3

units

set value

maximum value

42

49

TEST

6 — PROGRAMMER OPERATION

Some parameters on some controllers have dependencies on other parameters. This means that the available settings for one parameter may be dependent on the limits of another parameter. If you attempt to set a parameter (A) outside the limits imposed by another parameter (B), a message will be displayed indicating that parameter A is dependent on parameter B.

The Program Menu is presented at the end of this section.

NOTE

: Some items

may not be available on all models.

In the

Test

mode, accessed by pressing the

TEST

key, real-time information is displayed about the status of the inputs, outputs, and controller temperature. For example, when the status of the forward switch is displayed, it should read “On/Off/On/Off/On/Off” as the switch is repeatedly turned on and off. In the Test mode, the item of interest does not need to be the top item on the list; it only needs to be among the four items visible in the window. The Test mode is useful for checking out the operation of the controller during initial installation, and also for troubleshooting should problems occur.

The

MORE INFO

key, when used in the Test mode, causes additional informa-

tion to be displayed about the selected item (top line in the window).

The Test Menu is presented at the end of this section.

NOTE

: Some items may

not be available on all models.

In the active faults detected by the controller are displayed.

information to be displayed about the selected item.

DIAGNOSTICS

end of this section.

The which are self-explanatory. Through the Special Program Menu, you can revert to earlier settings, save controller settings into the programmer memory, load the

*

PROGRAMMORE INFO

controller settings from the programmer into a controller, clear the controller’s diagnostic history, adjust the contrast of the programmer’s LCD display, select the language to be displayed by the programmer, and display basic information (model number, etc.) about the controller and the programmer.

while continuing to hold the on the

Curtis PMC 1207/1207A Manual

Diagnostics

The

MORE INFO

mode, accessed by pressing the

DIAGNOSTICS

key, currently

key, when used in the Diagnostics mode, causes additional

A list of the abbreviations used in the Diagnostics display is included at the

Special Program

To access the Special Program mode, ﬁrst press the

PROGRAM

mode allows you to perform a variety of tasks, most of

MORE INFO

key, press the

MORE INFO

PROGRAM

key. Then,

key. The LED

key will light, just as when the programmer is in Program mode.

43

50

6 — PROGRAMMER OPERATION

To distinguish between the Program and Special Program modes, look at the menu items in the display.

CONTROLLER CLONING

Two of the Special Program Menu items—“Save Controller Settings in Programmer” and “Load Programmer Settings into Controller”—allow you to “clone” controllers. To do this, simply program one controller to the desired settings, save these settings in the programmer, and then load them into other similar (same model number) controllers, thus creating a family of controllers with identical settings.

*

The

MORE INFO

key is used initially to access the Special Program mode, and once you are within the Special Program mode, it is used to perform the desired tasks. To adjust the contrast in the display window, for example, select “Contrast Adjustment” by scrolling until this item is at the top of the screen, and then press

MORE INFO

to ﬁnd out how to make the adjustment.

The Special Program Menu is presented at the end of this section.

In the

Special Diagnostics

mode, the controller’s diagnostic history ﬁle is

displayed. This ﬁle includes a list of all faults observed and recorded by the

NOTE

controller since the history was last cleared. (

: The maximum and minimum

temperatures recorded by the controller are included in the Test Menu.) Each

DIAGNOSTICSMORE INFO

fault is listed in the diagnostic history ﬁle only once, regardless of the number of times it occurred.

To access Special Diagnostics, ﬁrst press the

continuing to hold the

DIAGNOSTICS

the

key will light, just as when the programmer is in Diagnostics

MORE INFO

key, press the

MORE INFO

DIAGNOSTICS

key. Then, while

key. The LED on

mode.

The

MORE INFO

key, when used within the Special Diagnostics mode, causes

additional information to be displayed about the selected item.

To clear the diagnostic history ﬁle, put the programmer into the Special

Program mode, select “Clear Diagnostic History,” and press the

MORE INFO

key for instructions. Clearing the diagnostic history ﬁle also resets the maximum/ minimum temperatures in the Test Menu.

Curtis PMC 1207/1207A Manual

44

51

6 — PROGRAMMER OPERATION

PEACE-OF-MIND PROGRAMMING

Each time the programmer is connected to the controller, it acquires all the controller’s parameters and stores them in its temporary memory. You can revert back to these original settings at any time during a programming session via the Special Program Menu. Select “Reset All Settings” by scrolling it to the top of the display window, press the

MORE INFO

key, and follow the instructions displayed. Any inadvertent changing of parameters can be “undone” using this procedure— even if you can’t remember what the previous settings were—as long as the

programmer has not been unplugged and power has not been removed from the controller.

Programmer Self Test

You can test the programmer by displaying two special test screens. Press

MORE INFO

the you can toggle between the two test screens by pressing the

key while the programmer is powering up. During the Self Test,

SCROLL DISPLAY

keys. The ﬁrst screen turns on every LCD element, and the second screen displays all the characters used in the various menus. As part of the Self Test, you can also test the keys be pressing each one and observing whether its corner LED lights up. To exit the Self Test, unplug the programmer or turn off the controller, and then repower it without holding the

MORE INFO

key.

Curtis PMC 1207/1207A Manual

⇐

SCROLL DISPLAY

⇒

()

!"#$%&'

0123456789: ;<=>?

@A B C D E FG H I J K LM NO

QPRSTUVWXYZx

+, - . /

*

>

Ω°

45

52

6 — PROGRAMMER OPERATION

PROGRAMMER MENUS

Items are listed for each menu in the order they appear in the actual menus displayed by the handheld programmer.

Program Menu

EMR REV C / L THROTTLE TYPE RAMP SHAPE CREEP SPEED EMR REV SPEED SEQUENCING DLY VARI ABLE PLUG HIGH PEDAL DIS SRO ANT I -T I EDOWN QU I CK START M1 MAI N C/ L M1 PLUG C/ L M1 RAMP C / L M1 ACCEL RATE M1 MAX SPEED M2 MAI N C/ L M2 PLUG C/ L M2 RAMP C / L M2 ACCEL RATE M2 MAX SPEED NEUT BRAKE C / L NEUTRAL BRAKE

(not all items available on all controllers)

Emergency reverse current limit Throttle type* Throttle map Creep speed, as percent PWM duty cycle Emerg. reverse speed, as % PWM duty cycle Sequencing delay, in seconds Throttle-variable plug braking: on or off High pedal disable (HPD): type† Static return to off (SRO): type‡ Anti-tiedown: on or off Quick-start throttle factor Mode 1 main current limit Mode 1 plug current limit Mode 1 ramp start current limit Mode 1 acceleration rate, in seconds Mode 1 maximum speed, as % PWM output Mode 2 main current limit Mode 2 plug current limit Mode 2 ramp start current limit Mode 2 acceleration rate, in seconds Mode 2 maximum speed, as % PWM output Neutral brake current limit Neutral brake: on or off

(Notes are on the next page.)

Curtis PMC 1207/1207A Manual 46

53

6 — PROGRAMMER OPERATION

Program Menu Notes

(For more detail on these options, see Appendix A: Glossary of Features and Functions.)

*

Throttle types

Type 1: 5kΩ–0 Type 2: 0–5V, 0–10V, 3-wire pot, and electronic throttles

Type 3: 0–5kΩ throttles

†

HPD types

Type 0: no HPD Type 1: HPD on brake input

Type 2: HPD on KSI

‡

SRO types

Type 0: no SRO Type 1: SRO on brake input Type 2: SRO on KSI plus brake input plus a direction input Type 3: SRO on KSI plus brake input plus

forward input

Test Menu

THROTTLE % BATT VOLTAGE HEAT S INK°C MAX TEMP°C MIN TEMP°C BRAKE I NPUT SPEED I N EMR REV I NPUT

FORWARD INPUT REVERSE I NPUT MA I N CONTACTOR

FWD CONT REV CONT

*

Maximum/minimum temperatures recorded

(not all items available on all controllers)

Throttle reading, as percent of full Battery voltage Heatsink temperature Maximum temperature seen * Minimum temperature seen * Brake switch: on/off Mode switch: on (Mode 1) / off (Mode 2) Emergency reverse switch: on/off Forward switch: on/off Reverse switch: on/off Main contactor: on/off Forward contactor: on/off Reverse contactor: on/off

since Diagnostic History was last cleared.

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54

47

Special Program Menu

6 — PROGRAMMER OPERATION

RESET ALL SETT INGS CONT SETT I NGS > PROG

PROG SETT I NGS> CONT CLEAR DIAG HISTORY CONTRAST ADJUSTMENT

LANGUAGE SELECTION

PROGRAMMER INFO CONTROLL ER I NFO

Revert to original settings Save controller settings in programmer Load programmer settings in controller Clear diagnostic history memory Adjust display contrast Select displayed language Display programmer information Display controller information

Diagnostics and Special Diagnostics “Menu”

This is not a menu as such, but simply a list of the possible messages you may see displayed when the programmer is operating in either of the Diagnostics modes. The messages are listed in alphabetical order for easy reference.

BB WIR ING CHECK CONT DRVR OC DIR CONT WELDED HPD HW F A I LS AF E

LOW BATTERY VOLTAGE M- SHORTED MISSING CONTACTOR NO KNOWN FAULTS OVERVOLTAGE

SRO

THERMAL CUTBACK

THROTTLE FAULT1

THROTTLE FAULT2

BB wiring check failed Contactor driver overcurrent Direction contactor welded High-pedal-disable (HPD) activated Hardware failsafe activated Low battery voltage (<16V) M- output fault Missing contactor No known faults Overvoltage (

1207

:

>48V;

1207A

:

>33V) Static-return-to-off (SRO) activated Cutback, due to over/under temp Throttle input fault Throttle low input fault

Curtis PMC 1207/1207A Manual

48

55

APPENDIX A: GLOSSARY

APPENDIX A

GLOSSARY OF FEATURES AND FUNCTIONS

Acceleration/deceleration rate

The acceleration rate is the time required for the controller to increase from 0% to 100% duty factor. The shape of the acceleration curve is controlled by the dynamic throttle response, which is linear.

If you have a MultiMode™ controller, the acceleration rates in Mode 1 and in Mode 2 are independently adjustable via the handheld programmer. If you have a 1207 controller with the MultiMode™ feature disabled (i.e., a singlemode controller), you can adjust the acceleration rate mechanically via the appropriate trimpot located on top of the controller.

Anti-tiedown

Before enabling Mode 1 operation, the anti-tiedown function checks that the mode selection switch has been released after the last cycling of the brake switch. This feature discourages operators from taping or otherwise “tying down” the mode switch. If Mode 1 is already selected before the brake is released, the controller remains in Mode 2 until the mode switch is released and pressed again.

Arcless contactor switching

The controller output duty factor is quickly reduced to zero any time a direction is de-selected, so that the controller current will be reduced to zero direction contactor drops out.

BB (= Belly Button; see Emergency reverse)

Brake

The brake must be released (brake input “high”) for the controller to operate. This is a safety interlock used on most material handling vehicles.

Curtis PMC 1207/1207A Manual

before the

Cycling the brake or KSI clears most faults and enables operation.

A-1

56

APPENDIX A: GLOSSARY

Contactor drivers and circuits

These controllers can accommodate up to four external contactors: forward, reverse, main, and shunt. Some vehicles may have no main contactor, or the main contactor may be wired directly to the KSI or brake signal, bypassing the controller.

Various protections provided for the contactor drivers ensure that the

contactors operate correctly; see Fault detection.

The shunt winding of a compound motor can be wired directly to the shunt driver, provided that the maximum current does not exceed the driver’s current rating.

Creep speed at first throttle

Creep speed is activated when a direction is ﬁrst selected. The output maintains creep speed until the throttle is rotated out of the throttle deadband (typically 10% of throttle). Creep speed is adjustable from 0 to 25% of the controller duty factor; the adjustment can be made mechanically (via the appropriate trimpot on top of the 1207 controller) or electronically (via the handheld programmer).

Current limiting

Curtis PMC controllers limit the motor current to a preset maximum. This feature protects the controller from damage that might result if the current were limited only by motor demand. PWM output to the power section is reduced smoothly until the motor current falls below the set limit level.

In addition to protecting the controller, the current limit feature also protects the rest of the system. By eliminating high current surges during vehicle acceleration, stress on the motor and batteries is reduced and their efﬁciency enhanced. Similarly, there is less wear and tear on the vehicle drivetrain, as well as on the ground on which the vehicle rides (an important consideration with golf courses and tennis courts, for example).

If you have a MultiMode™ controller, the main current limit, plug current limit, and ramp start current limit in Mode 1 and in Mode 2 are independently adjustable via the handheld programmer. If you have a 1207 controller with the MultiMode™ feature disabled (i.e., a single-mode controller), you can adjust the main and plug current limits mechanically via the appropriate trimpots located on top of the controller.

In addition, the emergency reverse current limit can be set via the handheld programmer.

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APPENDIX A: GLOSSARY

Current multiplication

During acceleration and during reduced speed operation, the Curtis PMC controller allows more current to flow into the motor than flows out of the battery. The controller acts like a dc transformer, taking in low current and high voltage (the full battery voltage) and putting out high current and low voltage. The battery needs to supply only a fraction of the current that would be required by a conventional controller (in which the battery current and motor current are always equal). The current multiplication feature gives vehicles using Curtis PMC controllers dramatically greater driving range per battery charge.

Deceleration rate

The deceleration rate is the time required for the controller to decrease from 100% duty factor to zero. The deceleration rate is ﬁxed, and cannot be adjusted. The shape of the deceleration curve is controlled by the dynamic throttle response, which is linear.

Emergency reverse

Emergency reverse is activated when the brake is released, KSI is activated, and the emergency reverse switch (the BB, or “belly button” switch) is pressed. After the BB switch is released, normal controller operation is not resumed until neutral (no direction) is selected or until the brake is cycled (brake, then brake release). However, repeatedly pressing the BB switch will reactivate the emergency reverse function each time.

Because emergency reverse immediately powers the reverse contactor, some

arcing may occur.

Fault detection

An internal microcontroller automatically maintains surveillance over the functioning of the controller. When a fault is detected, the appropriate fault code is signalled via the LED, externally visible on top of the controller. The diagnostic codes ﬂashed by the LED are listed in Section 5, Troubleshooting.

If the fault is critical, the controller is disabled. More typically, the fault is a remediable condition and temporary—for example, an undervoltage fault is cleared when the condition is removed.

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A-3

APPENDIX A: GLOSSARY

The automatic fault detection system includes:

contactor coil open / shorted driver (F/R and shunt contactors) contactor driver overcurrent / contactor coil short contactor welded emergency reverse circuit check M- output fault memory checks upon start-up overvoltage cutoff power supply out of range (internal) throttle fault undervoltage cutback watchdog (external and internal) watchdog (internal)

Fault recording

Fault events are recorded in the controller’s memory. Multiple occurrences of the same fault are recorded as one occurrence.

The fault event list can be loaded into the programmer for readout. The Special Diagnostics mode provides access to the controller’s diagnostic history ﬁle—the entire fault event list created since the diagnostic history ﬁle was last cleared. The Diagnostics mode, on the other hand, provides information about only the currently active faults.

Fault recovery

Almost all faults require a cycling of the KSI or brake input to reset the controller and enable operation.

Curtis PMC 1207/1207A Manual

(including recovery from disable)

The only exceptions are these:

FAULT RECOVERY

anti-tiedown release and re-select Mode 1

contactor overcurrent when condition clears

emergency reverse BB re-applied

or brake cycled HPD lower throttle to below HPD threshold overvoltage when battery voltage drops below overvoltage SRO when proper sequence is followed thermal cutback when temperature comes within range throttle fault clears when condition gone undervoltage when battery voltage rises above undervoltage

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APPENDIX A: GLOSSARY

High-pedal-disable (HPD)

The HPD feature prevents the vehicle from being started while the throttle is applied. The controller can be programmed to have HPD based on either brake input or KSI.

Brake-type HPD

To start the vehicle, the controller must receive a brake input (brake released) before receiving a throttle input. Controller operation will be disabled immediately if pedal demand (throttle input) is greater than 25% duty factor at the time the brake is released (brake input “high”). Normal controller operation is regained by reducing the throttle demand to less than 25%.

Sequencing delay, which can be set with the handheld programmer, provides a variable delay before disabling the controller. If the brake is applied while the throttle is above the HPD threshold (25%), HPD is not activated if the brake is then released before the delay time elapses.

KSI-type HPD

The HPD feature can be activated by KSI input instead of brake input, if preferred. To start the vehicle, the controller must receive a

KSI input before

receiving a throttle input.

KSI

KSI ( starts diagnostics. In combination with the brake input, KSI enables all logic functions.

the key permanently turned on.

LED

A Status LED located on top of the controller ﬂashes a fault identiﬁcation code if a fault is detected by the controller. The fault codes are listed in Table 1. The code will continue to ﬂash until the fault condition has been cleared during active fault detection. This will typically happen after cycling KSI for power-up fault conditions, and cycling the brake for faults detected during operation. 1207 models, the Status LED is on the adjustment panel under the sliding protective cover.

Curtis PMC 1207/1207A Manual

Key Switch Input) provides power to the logic board, and initializes and

Some vehicles may have no keyswitch (KSI simply tied to B+) or may have

NOTE

: In

A-5

60

MOSFET

APPENDIX A: GLOSSARY

A MOSFET (

Metal Oxide Semiconductor Field Effect Transistor) is a type of

transistor characterized by its fast switching speeds and very low losses.

MultiMode ™

The MultiMode™ feature of these controllers allows the vehicle to be operated with two distinct sets of characteristics. The two modes can be programmed to be suitable for operation under different conditions, such as slow precise maneuvering in Mode 2 and faster, long distance travel in Mode 1. The following parameters can be set independently in the two modes:

— main current limit — plug current limit — ramp start current limit — acceleration rate — maximum speed

The operating mode is selected by means of the mode selection switch. If Mode 1 is not selected, the controller operates by default in Mode 2. When the controller returns to Mode 2 from Mode 1, it automatically changes the main current limit, the plug current limit, the ramp start current limit, the acceleration rate, and the maximum speed to their Mode 2 values.

If the anti-tiedown feature is active, Mode 1 must be re-selected each time the brake is released.

Neutral brake

The optional neutral brake feature provides automatic plug braking in neutral. If this option is not selected, the vehicle is free to coast in neutral. The neutral brake plug current limit is programmable.

Overtemperature

At overtemperature (from 85°C to 95°C), the drive current limit is linearly decreased from full set current down to zero. (Plug current, however, is reduced—in order to provide full vehicle braking under all thermal conditions.) The operating PWM frequency is shifted to 1.5 kHz when the controller is operating in the overtemperature range.

Overvoltage protection

Overvoltage resets the microprocessor, inhibits PWM, and opens the contactors, thereby shutting down the controller. Overvoltage can result during battery charging or from an improperly wired controller. Controller operation resumes

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not

A-6

61

APPENDIX A: GLOSSARY

when the voltage is brought within the acceptable range. The cutoff voltage and re-enable voltage are percentages of the battery voltage, and are set at the factory.

Plug braking

Plug braking takes place when a series motor is driven electrically in a direction opposite from the direction it is turning. The 1207/1207A controls the

ﬁeld current to obtain smooth and controlled plug braking torque. During plug braking, the maximum current limit is automatically changed to the plug current limit, and the PWM frequency is changed to 1.5 kHz. on the 1207/1207A controls the

ﬁeld current. The armature current in plug

NOTE

: Plug current limit

mode will be higher than the ﬁeld current.

There are two types of plug braking control — ﬁxed and variable. The ﬁxed plug current limit is set to a ﬁxed level. The variable plug current limit varies the current limit to correspond to the throttle position.

If you have a MultiMode™ controller, the plug current limits in Mode 1 and in Mode 2 are independently adjustable via the handheld programmer. If you have a 1207 controller with the MultiMode™ feature disabled (i.e., a singlemode controller), you can adjust the plug current limit mechanically via the appropriate trimpot located on top of the controller.

PWM

Pulse width modulation (PWM), also called “chopping,” is a technique that switches battery voltage to the motor on and off very quickly, thereby controlling the speed of the motor. Curtis PMC 1200 series controllers use high frequency PWM—15 kHz—which permits silent, efficient operation.

Quick-start

Upon receiving a quick throttle demand from neutral, the controller will exceed normal acceleration momentarily in order to overcome inertia. The “quick-start” algorithm is applied each time the vehicle passes through neutral and is not in plug mode. If the vehicle is in plug, the quick-start function is disabled, allowing normal plug braking to occur.

The quick-start throttle factor is adjustable via the handheld programmer.

Ramp shape (throttle map)

“Ramp shape” is a programmable parameter that determines the static throttle map of the 1207/1207A controller. Eleven preprogrammed ramp shapes are available, in 5% steps between 20% and 70% (20, 25, 30, 35, 40, 45, 50, 55, 60,

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A-7

APPENDIX A: GLOSSARY

65, and 70%). The ramp shape number refers to the PWM output at half throttle, as a percentage of its full range. For example, if maximum speed is set at 100% and creep speed is set at 0, a ramp shape of 50% will give 50% output at half throttle. The 50% ramp shape corresponds to a linear response. The six “even number” ramp shapes for maximum and creep speeds set at 100% and 0 are shown in Figure A-1.

Fig. A-1 Ramp shape

(throttle map) for controller with maximum speed set at 100% and creep speed set at 0.

Fig. A-2 Ramp shape

(throttle map) for controller with maximum speed set at 100% and creep speed set at 10%.

100

90 80 70 60 50 40

PWM (percent)

30

CREEP SPEED

20

(0)

10

0

MAXIMUM SPEED (100%)

100908070605040302010 0

THROTTLE (percent)

RAMP SHAPE

70% 60% 50% 40% 30% 20%

Changing either the maximum speed setting or the creep speed setting changes the output range of the controller. Ramp shape output is always a percentage of that range. Ramp shapes with the creep speed setting raised to 10% are shown in Figure A-2.

100

90 80 70 60 50 40

PWM (percent)

30 20 10

0

MAXIMUM SPEED (100%)

CREEP SPEED (10%)

100908070605040302010 0

THROTTLE (percent)

RAMP SHAPE

70% 60% 50% 40% 30% 20%

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APPENDIX A: GLOSSARY

In Figure A-3, the creep speed is kept at 10% and the maximum speed setting dropped to 60%.

Fig. A-3

Ramp shape (throttle map) for controller with maximum speed set at 60% and creep speed set at 10%.

100

90 80 70 60 50 40

PWM (percent)

30 20 10

0

CREEP SPEED (10%)

MAXIMUM SPEED

THROTTLE (percent)

(60%)

100908070605040302010 0

RAMP SHAPE

70% 60% 50% 40% 30% 20%

In all cases, the ramp shape number is the PWM output at half throttle, as a percentage of its full range. So, for example, in Figure A-3, a 50% ramp shape gives 35% PWM output at half throttle (halfway between 10% and 60%). A 30% ramp shape gives 25% PWM at half throttle (30% of the range {which is 50%, from 10% to 60%}, starting at 10% output, or {[.30 x 50%] + 10%} = 25%).

Ramp start

The ramp start feature allows the vehicle to be started with a higher plug current limit to prevent rolling downhill. Ramp start increases the plug current limit the selected direction only. When the opposite direction is selected, ramp start will be canceled and a 3-step sequence must be followed to re-activate it:

Once the vehicle is operating in ramp start mode, it will continue to do so until the opposite direction is selected for more than one second.

obtained when either direction is selected in plug braking mode. In ramp start mode, either direction selected will allow the ramp start current limit level. This condition remains until the other direction is selected for more than one second. The new direction then becomes the decision direction, and the 3-step ramp start sequence is required to regain the ramp start current limit level in plug.

Curtis PMC 1207/1207A Manual

for

STEP

1. select a direction for more than 1 second,

STEP

2. return to neutral, and

STEP

3. re-select the same direction.

When the brake is ﬁrst released, the ramp start current limit level will be

A-9

64

APPENDIX A: GLOSSARY

The ramp start current limit is adjustable via the handheld programmer. The

Mode 1 and Mode 2 ramp start current limits can be set independently.

Reset

Almost all faults require a cycling of the KSI or brake input to reset the controller and enable operation; see Fault recovery for exceptions.

Sequencing delay

Sequencing delay allows the brake to be cycled within a set time (the sequencing delay), in order to prevent inadvertent activation of HPD or SRO. This feature is useful in applications where the brake switch may bounce or be momentarily cycled during operation. The delay can be set with the handheld programmer from 0 to 3 seconds, where 0 corresponds to no delay.

Shunt field control

The shunt ﬁeld of a compound motor can be directly controlled by using the shunt winding driver (if the current requirement meets the contactor driver speciﬁcations). The shunt is activated while a direction is selected, as long as the controller is

not in plug braking mode. A programmable delay is available for the shunt drive. This delays the shunt turn-on until some time after the reversing contactors have shuttled. The delay can be set with the handheld programmer from 0 to 0.5 seconds, where 0 corresponds to no delay.

Smooth, stepless operation

Like all Curtis PMC 1200 Series controllers, the 1207 and 1207A models allow superior operator control of the vehicle’s drive motor speed. The amount of current delivered to the motor is set by varying the “on” time (duty cycle) of the controller’s power MOSFET transistors. This technique—pulse width modulation (PWM)—permits silent, stepless operation.

Speed settings

The maximum speed setting deﬁnes the upper-limit speed as a percentage of PWM output at full throttle. If you have a MultiMode™ controller, the maximum speed settings in Mode 1 and in Mode 2 are independently adjustable via the handheld programmer. If you have a 1207 controller with the MultiMode™

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APPENDIX A: GLOSSARY

feature disabled (i.e., a single-mode controller), you can adjust the maximum

LOW

speed mechanically via the trimpot labeled “

” on top of the controller.

The maximum creep speed setting is also adjustable via these two methods;

see Creep speed. The maximum emergency reverse speed is adjustable only via the programmer.

Static-return-to-off (SRO)

The SRO feature prevents the vehicle from being started when “in gear.” SRO checks the sequencing of brake input—or of KSI

and brake input—relative to a direction input. The brake input must come on before a direction is selected. If a direction is selected before or simultaneously (within 50 msec) with the brake input, the controller is disabled. There are three types of SRO: SRO relative to brake input alone (Type “1” in the programming menu); SRO relative to both KSI and brake input (Type “2”); and SRO relative to KSI, brake, and

forward inputs (Type “3”). The handheld programmer can be used to set the controller to operate with any of these types of SRO, or with no SRO (SRO Type “0”).

If your controller is programmed so that both KSI and brake input are required (SRO Type “2”), the following sequence must be followed to enable the controller:

1, KSI on;

STEP

2, brake released (brake input “high”); and

STEP

3,

STEP

direction selected. The interval between steps 1 and 2 is the same as between steps 2 and 3; that is, KSI input must precede brake input by at least 50 msec. Once the controller is operational, turning off either KSI or the brake causes the controller to turn off; re-enabling the controller requires the 3-step sequence.

Similarly, if your controller is programmed so that KSI, brake, and

forward inputs are all required (SRO Type “3”), they must be provided in that sequence in order to enable the controller. Note, however, that operation is allowed if a reverse input precedes the brake input; this can be useful when operating a walkie on ramps.

Sequencing delay, which can be set with the handheld programmer, provides a variable delay before disabling the controller. If the brake is applied while direction is selected, SRO is not activated if the brake is then released before the delay time elapses.

Curtis PMC 1207/1207A Manual

66

Temperature compensation for current limits

Full temperature compensation provides constant current limits throughout the normal operating range (heatsink temperatures of -25°C to +85°C). The tem- perature sensor is also used to calculate and display the heatsink temperature on the handheld programmer.

A-11

APPENDIX A: GLOSSARY

Temperature extreme current-limit cutback (see Overtemperature,

Undertemperature)

Temperature extreme data storage

The maximum and minimum temperatures read at the heatsink at any time during powering of the controller are stored in the controller’s memory. These values (which can be accessed via the programmer’s Test Menu) are cleared each time the controller’s diagnostic history ﬁle is cleared.

Throttle map

The throttle map (duty factor as a function of

throttle position) is adjustable, so

that you can provide the proper feel for the many types of vehicles that use the 1207 controller. The throttle map parameter is called “ramp shape”; see Ramp shape for more information.

Throttle response

The dynamic throttle response (duty factor as a function of

time) is shaped by the acceleration rate setting. Dynamic throttle response is linear. The newest throttle input is mapped to the throttle map, and the controller then automatically accelerates (or decelerates) through a straight line until the new throttle demand is obtained.

Throttle types

The 1207 and 1207A controllers accept a variety of throttle inputs, through various combinations of their four throttle input pins. The most commonly used throttles can all be hooked up directly: 5kΩ–0 and 0–5kΩ 2-wire rheostats, 3-wire pots, 0–5V throttles, 0–10V throttles (1207 only), and the Curtis ET-XXX electronic throttle.

Throttle full range produces 0–100% duty factor at the controller output (unless limited by other conditions). Throttle fault detect is performed on the throttle input signals and virtually eliminates the possibility of runaway operation. Adjustments and settings are independent of throttle type. However, throttle fault conditions will vary by throttle type.

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APPENDIX A: GLOSSARY

Undertemperature

When the controller is operating at less than -25°C, the current limit is cut back to approximately one-half of the set current. The operating PWM frequency is shifted to 1.5 kHz when the controller is operating at undertemperature.

Undervoltage protection

Undervoltage protection automatically disables the controller output if battery voltage is detected below the undervoltage point at start-up, or when the battery voltage is pulled below the undervoltage point by an external load. The undervoltage cutback point is set in ROM, and is not adjustable.

During normal operation, the controller duty factor will be reduced when the batteries discharge down to less than the undervoltage level. If the motor current is such that the batteries are being pulled below the minimum point, the duty factor will be reduced until the battery voltage recovers to the minimum level. In this way the controller “servos” the duty factor around the point which maintains the minimum allowed battery voltage.

If the voltage continues to drop below the undervoltage level to a severe undervoltage condition (due to battery drain or external load), the controller continues to behave in a predictable fashion, with its output disabled.

Watchdog (external, internal)

The cessor, which would incapacitate the system check on the microprocessor meets the EEC’s requirement for backup fault detection.

the microprocessor) if the software fails to generate a periodic external pulse train. This pulse train can only be created if the microprocessor is operating. If not periodically reset, the watchdog timer times out after 150 msec and turns off the controller. The external watchdog also directly disengages all contactors and directly shuts down the PWM drive to the MOSFETs. It can only be reset by cycling KSI.

execution of the software. If not reset, the internal timer times out and the microprocessor is “warm booted.” This causes the microprocessor to shut down its outputs (thus shutting down the controller) and attempt to restart.

Curtis PMC 1207/1207A Manual

external watchdog timer guards against a complete failure of the micropro-

internal watchdog timer. This independent

The external watchdog timer safety circuit shuts down the controller (and

The internal watchdog timer must be reset periodically by correct sequential

A-13

68

APPENDIX B

SPECIFICATIONS

APPENDIX A: GLOSSARY

APPENDIX B: SPECIFICATIONS

Table B-1

SPECIFICATIONS: 1207 CONTROLLERS

Nominal input voltage range 24 – 36 V Maximum operating voltage 45 V Overvoltage point 48 V Minimum operating voltage 16 V (= undervoltage point) Electrical isolation to heatsink 500 V ac (minimum) PWM operating frequency 15 kHz

Output current* 1207-11XX 1207-21XX

250 amps for 1 minute 300 amps for 30 seconds 200 amps for 2 minutes 210 amps for 2 minutes 150 amps for 5 minutes 160 amps for 5 minutes 100 amps for 1 hour 110 amps for 1 hour

Contactor voltage = battery voltage Contactor current (maximum) 1 amp (current limit at 2 amps) Contactor coil spike protection internal diode to brake; internal diode from brake to KSI Shunt driver current (maximum) 2 amps Shunt driver spike protection active clamp at 47 V

KSI input voltage 16– 45 V KSI input current (typical) 80 mA without programmer; 130 mA with programmer Logic input current (typical) 10 mA at 24 V Logic input threshold 8 V

Ambient operating temperature range -25°C to 50°C Heatsink overtemperature cutback 85°C Heatsink undertemperature cutback -25°C

Package splash resistant Weight 1.1 kg (2.5 lbs) Dimensions 122 × 165 × 60 mm (4.8" × 6.5" × 2.35")

*

Output current rating test conditions:

1. Controller cover installed

2. Controller mounted to 230 × 305 × 3.2 mm (9" × 12" × 0.125") aluminum plate heatsink

3. Airflow at 4.8 km/h (3 mph) perpendicular to bottom of aluminum plate

4. Duty factor held at 60%

5. Initial heatsink temperature at 20°C

6. Ambient temperature at 20°C

7. Current held at tested rating for 120% of time before thermal cutback

Curtis PMC 1207/1207A Manual

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B-1

69

APPENDIX A: GLOSSARY

APPENDIX B: SPECIFICATIONS

Table B-2

SPECIFICATIONS: 1207A CONTROLLERS

Nominal input voltage 24 V Maximum operating voltage 30 V Overvoltage point 33 V Minimum operating voltage 16 V (= undervoltage point) Electrical isolation to heatsink 500 V ac (minimum) PWM operating frequency 15 kHz

Output current* 1207A-41XX 1207A-51XX

250 amps for 1 minute 300 amps for 30 seconds 200 amps for 2 minutes 210 amps for 2 minutes 150 amps for 5 minutes 160 amps for 5 minutes 100 amps for 1 hour 110 amps for 1 hour

Contactor voltage 24 V Contactor current (maximum) 1 amp (current limit at 2 amps) Contactor coil spike protection internal diode to brake; internal diode from brake to KSI Shunt driver current (maximum) 2 amps Shunt driver spike protection active clamp at 47 V

KSI input voltage 16– 30 V KSI input current (typical) 80 mA without programmer; 130 mA with programmer Logic input current (typical) 10 mA at 24 V Logic input threshold 8 V

Ambient operating temperature range -25°C to 50°C Heatsink overtemperature cutback 85°C Heatsink undertemperature cutback -25°C

Package splash resistant Weight 1.1 kg (2.5 lbs) Dimensions 122 × 165 × 66 mm (4.8" × 6.5" × 2.6")

*

Output current rating test conditions:

1. Controller cover installed

2. Controller mounted to 230 × 305 × 3.2 mm (9" × 12" × 0.125") aluminum plate heatsink

3. Airflow at 4.8 km/h (3 mph) perpendicular to bottom of aluminum plate

4. Duty factor held at 60%

5. Initial heatsink temperature at 20°C

6. Ambient temperature at 20°C

7. Current held at tested rating for 120% of time before thermal cutback

Curtis PMC 1207/1207A Manual

B-2

A-15

70

APPENDIX A: GLOSSARY

APPENDIX B: SPECIFICATIONS

1207/1207A AUXILIARY PANELS

Auxiliary panels are available for the 1207 and 1207A controllers, consisting of a range of contactor and fuse assemblies mounted on small aluminum panels. These auxiliary panels are designed to let you install your controller in the minimum time, at minimum cost. The panels, manufactured by Curtis Instruments (UK) Ltd., are available through all Curtis ofﬁces.

All panels are ﬂush rear mounting. Please contact the Curtis ofﬁce nearest

you for further conﬁguration details.

Curtis PMC 1207/1207A Manual

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71

Filename: Changing Batteries in EPT VESTIL MFG. CO. 4/17/07 TG Model: EPT-XXXX-30

15-126-010

Instructions for Changing the Batteries in EPT-XXXX-30; estimated time, 15 min.

READ ALL INSTRUCTIONS BEFORE PROCEEDING!

Lock out all potential energy sources before attempting this installation; turn off the unit and remove the key.

Only qualified personnel should work on this equipment!

Warning!

! Working with or near lead acid batteries is dangerous. Batteries contain sulfuric

acid and produce explosive gases. A battery explosion could result in loss of eyesight or serious burns.

! Do not smoke or allow a spark or flame near batteries. Charge batteries in

locations which are clean, dry, and well-ventilated. Do not lay tools or anything metallic on top of any battery. All repairs to a battery must be made by experienced and qualified personnel.

! When working with batteries, remove personal items such as rings, bracelets,

necklaces, and watches. Batteries can produce enough energy to weld jewelry to metal, causing a severe burn.

! Always have fresh water and soap nearby in case battery acid contacts skin, clothing,

or eyes.

! Operating the battery with a low battery voltage can cause premature motor

contact failure.

! Do not expose the lift or charger to rain or adverse conditions. ! Replace defective cords or wires immediately. ! Check the battery’s water level frequently if this applies to your battery type. ! Make sure the battery charger is unplugged from 115vac source.

Battery Charger Operating Instructions

Plug the charger into a standard 115V receptacle. If an extension cord must be used, keep it as short and as large as possible. A small cord will decrease the output of the charger due to the voltage drop in the line. This will increase the charging time. It can also cause the 115V cord to overheat.

When properly connected, the charge LED will indicate the status of charge current

flowing to the battery, as follows: Power LED is always green when charger is

plugged in. The status light is as follows:

Red only – the charger is providing full output to the battery.

Yellow – the charger is “topping off” the battery.

Green – the charger is providing a “float,” or maintenance, charge.

Remember to unplug the charger before moving the equipment. Failure to do so could cause damage to cords, receptacles and other equipment.

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Filename: Changing Batteries in EPT VESTIL MFG. CO. 4/17/07 TG Model: EPT-XXXX-30

15-126-010

Troubleshooting:

If the unit does not operate, check all of the wiring connections to make sure they’re

both mechanically and electrically sound – specifically at the battery, and the motor.

A fully-charged lead acid battery in good condition at room temperature should read

12.65 volts. At 11.9 volts it is considered to be fully discharged and in need of charging. When checking battery voltage, wait at least 1\2 hour after the charger has been turned off before checking the battery’s voltage.

If the batteries aren’t being charged by the charger, check the output charger fuse. Verify fuse is good with an ohmmeter, or close visual (ohm meter best). Fuse is a 10Amp 250 Volt; GBD 10A. If it is good, check the battery’s state of charge with a voltmeter. The charger must be connected to the battery in order to read the output voltage of the battery charger. Depending on the state of charge of the batteries, the voltage should be somewhere around 27 to 28 volts dc.

If it is determined the batteries are dead, and need replaced, continue with the following procedure.

Tools Required: 14mm wrench, or crescent wrench Regular flat bladed screw driver

73

Filename: Changing Batteries in EPT VESTIL MFG. CO. 4/17/07 TG Model: EPT-XXXX-30

15-126-010

Changing Batteries in EPT-XXXX-30; estimated time 15 minutes.

Remove the black plastic cover, it will lift out.

74

Filename: Changing Batteries in EPT VESTIL MFG. CO. 4/17/07 TG Model: EPT-XXXX-30

15-126-010

Remove battery wiring taking note where each wire goes.

75

Filename: Changing Batteries in EPT VESTIL MFG. CO. 4/17/07 TG Model: EPT-XXXX-30

15-126-010

Batteries need to be lifted straight up. Tie wraps can aid in this process as shown here, or two small piece of nylon rope. Caution: do not use metal and short the battery terminals together!

Once the batteries are removed, they can be exchanged for the new ones. Reverse the process, and reconnect the wiring.

76

Filename: Changing Batteries in EPT VESTIL MFG. CO. 4/17/07 TG Model: EPT-XXXX-30

15-126-010

77

Filename: Changing Charger in EPT VESTIL MFG. CO. 4/17/07 TG Model: EPT-XXXX-30

15-126-011

Instructions for Changing the Battery Charger in EPT-XXXX-30; estimated time, 30 min.

READ ALL INSTRUCTIONS BEFORE PROCEEDING!

Lock out all potential energy sources before attempting this installation; turn off the unit and remove the key.

Only qualified personnel should work on this equipment!

Warning!

! Working with or near lead acid batteries is dangerous. Batteries contain sulfuric

acid and produce explosive gases. A battery explosion could result in loss of eyesight or serious burns.

! Do not smoke or allow a spark or flame near batteries. Charge batteries in

locations which are clean, dry, and well-ventilated. Do not lay tools or anything metallic on top of any battery. All repairs to a battery must be made by experienced and qualified personnel.

! When working with batteries, remove personal items such as rings, bracelets,

necklaces, and watches. Batteries can produce enough energy to weld jewelry to metal, causing a severe burn.

! Always have fresh water and soap nearby in case battery acid contacts skin, clothing,

or eyes.

! Operating the battery with a low battery voltage can cause premature motor

contact failure.

! Do not expose the lift or charger to rain or adverse conditions. ! Replace defective cords or wires immediately. ! Check the battery’s water level frequently if this applies to your battery type. ! Make sure the battery charger is unplugged from 115vac source.

Battery Charger Operating Instructions for New Charger after Installation

Plug the charger into a standard 115V receptacle. If an extension cord must be used, keep it as short and as large as possible. A small cord will decrease the output of the charger due to the voltage drop in the line. This will increase the charging time. It can also cause the 115V cord to overheat.

When properly connected, the charge LED will indicate the status of charge current

flowing to the battery, as follows: Power LED is always green when charger is

plugged in. The status light is as follows:

Red only – the charger is providing full output to the battery.

Yellow – the charger is “topping off” the battery.

Green – the charger is providing a “float,” or maintenance, charge.

Remember to unplug the charger before moving the equipment. Failure to do so could cause damage to cords, receptacles and other equipment.

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Troubleshooting:

If the unit does not operate, check all of the wiring connections to make sure they’re

both mechanically and electrically sound – specifically at the battery, and the motor.

A fully-charged lead acid battery in good condition at room temperature should read

12.65 volts. At 11.9 volts it is considered to be fully discharged and in need of charging. When checking battery voltage, wait at least 1\2 hour after the charger has been turned off before checking the battery’s voltage.

If the batteries aren’t being charged by the charger, check the output charger fuse. Verify fuse is good with an ohmmeter, or close visual (ohm meter best). Fuse is a 10Amp 250 Volt; GBD 10A. If it is good, check the battery’s state of charge with a voltmeter. The charger must be connected to the battery in order to read the output voltage of the battery charger. Depending on the state of charge of the batteries, the voltage should be somewhere around 27 to 28 volts dc.

If it is determined the battery charger is dead, and needs replaced, continue with the following procedure.

Tools Required: 10mm deep socket, or small wrench 14mm wrench, or crescent wrench Regular flat bladed screw driver

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Model: EPT-XXXX-30

Remove the two screws shown below and take off the yellow cover.

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The battery charger is located on the left side of the unit.

Battery Charger

Remove the black plastic cover, it will lift out as shown below.

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Remove battery wiring from the negative post as shown with 13mm wrench. There will be one large black wire, and one smaller black wire. The smaller black wire is connected to the battery charger. Caution; do not short out battery terminals with tools!

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Do the same for the red post as shown here; remove 2 Red wires.

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Carefully pull the two battery charger wires out of the battery compartment taking note as to how they were routed. When the new charger is installed, the wires will have to be ran the same way back to the battery.

There are 4 nuts holding the charger in place that can easily be removed with a deep well 10mm socket, or small 10 mm wrench.

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4 10mm nuts

Remove the 4 nuts.

Remove nuts

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Once the battery charger is removed, it can be exchanged for the new one. Reverse the process, and reconnect the wiring.

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Instructions for Changing the Battery Charger in EPT-XXXX-30; estimated time, 30 min.

READ ALL INSTRUCTIONS BEFORE PROCEEDING!

Only qualified personnel should work on this equipment! Lock out all potential energy sources before attempting this installation; turn off the unit and remove the key.

Warning!

! Working with or near lead acid batteries is dangerous. Batteries contain sulfuric

acid and produce explosive gases. A battery explosion could result in loss of eyesight or serious burns.

! Do not smoke or allow a spark or flame near batteries. Charge batteries in

locations which are clean, dry, and well-ventilated. Do not lay tools or anything metallic on top of any battery. All repairs to a battery must be made by experienced and qualified personnel.

! When working with batteries, remove personal items such as rings, bracelets,

necklaces, and watches. Batteries can produce enough energy to weld jewelry to metal, causing a severe burn.

! Always have fresh water and soap nearby in case battery acid contacts skin, clothing,

or eyes.

! Operating the battery with a low battery voltage can cause premature motor

contact failure.

! Do not expose the lift or charger to rain or adverse conditions. ! Replace defective cords or wires immediately. ! Check the battery’s water level frequently if this applies to your battery type. ! Make sure the battery charger is unplugged from 115vac source.

Battery Charger Operating Instructions for New Charger after Installation

Plug the charger into a standard 115V receptacle. If an extension cord must be used, keep it as short and as large as possible. A small cord will decrease the output of the charger due to the voltage drop in the line. This will increase the charging time. It can also cause the 115V cord to overheat.

Remember to unplug the charger before moving the equipment. Failure to do so could cause damage to cords, receptacles and other equipment.

The following procedure will explain how to replace the existing charger with a Soneil charger.

Tools Required: 10mm deep socket, or small wrench 14mm wrench, or crescent wrench Regular flat bladed screw driver

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Model: EPT-XXXX-30

Remove the two screws shown below and take off the yellow cover.

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The battery charger is located on the left side of the unit.

Battery Charger

Remove the black plastic cover, it will lift out as shown below.

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Remove battery wiring from the negative post as shown with 13mm wrench. There will be one large black wire, and one smaller black wire. The smaller black wire is connected to the battery charger. Caution; do not short out battery terminals with tools!

Do the same for the red post as shown here; remove 2 Red wires.

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Carefully pull the two battery charger wires out of the battery compartment taking note as to how they were routed. When the new charger is installed, the wires will have to be ran the same way back to the battery.

There are 4 nuts holding the charger in place that can easily be removed with a deep well 10mm socket, or small 10 mm wrench.

4 10mm nuts

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Remove the 4 nuts.

Remove nuts

Once the battery charger is removed, it can be exchanged for the new one.

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There are two “hook and loop” strips on the back of the charger.

2 strips

Remove the adhesive backing from the 2 strips.

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With the adhesive side inward, carefully put the charger into position.

Try to center the charger in the opening, and press it firmly into position.

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With the charger in place, feed the wires back to the batteries in the same manner they were removed off of the old charger.

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Place the positive wire on the far right side to the red marked post. Place the negative wire on the far left side. Orientation; standing on fork side of EPT facing unit.

Far left side terminal

Negative post connection shown here.

Far right side terminal

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On/Off switch

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Plug in the charger and make sure the on/off switch is on; shown here as on.

Plug this end into a standard 115 volt outlet and charger batteries for at least 8 hours or overnight. The charger will not overcharge the batteries, so leaving the unit plugged in over a weekend is ok. The charger should only be used in doors!

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Troubleshooting:

If the unit does not operate, check all of the wiring connections to make sure they’re

both mechanically and electrically sound – specifically at the battery, and the motor.

Charge the unit overnight. A fully-charged lead acid battery in good condition at room temperature should read

12.65 volts. At 11.9 volts it is considered to be fully discharged and in need of charging. When checking battery voltage, wait at least 1\2 hour after the charger has been turned off before checking the battery’s voltage.

If the batteries aren’t being charged by the charger, check the output charger fuse. First, remove the yellow cover, 2 screws on top. The fuse is on the bottom of the charger. Verify the fuse is good with an ohmmeter, or close visual (ohm meter best). Fuse is a 10Amp 250 Volt; GDA 10A.

If it is good, plug the charger in and check the lights next to the fuse.

Red: Power On Yellow: Charging Green: Full Charge Green Flashing: Batteries are not connected to charger

Verify the on off switch is set to on.

With the charger connected to the battery read the output voltage of the battery charger. Depending on the state of charge of the batteries, the voltage should be somewhere around 26 to 29 volts dc typically.

If the charger is functioning properly, install the black tray over the batteries and the yellow shroud over the back.

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Instructions for Changing the Cylinder in EPT-XXXX-30; estimated time, 45 min.

READ ALL INSTRUCTIONS BEFORE PROCEEDING!

Lock out all potential energy sources before attempting this installation. Make sure the forks are fully lowered; turn off the unit and remove the key.

Only qualified personnel should work on this equipment!

Warning!

! Working with or near lead acid batteries is dangerous. Batteries contain sulfuric

acid and produce explosive gases. A battery explosion could result in loss of eyesight or serious burns.

! Do not smoke or allow a spark or flame near batteries. Charge batteries in

locations which are clean, dry, and well-ventilated. Do not lay tools or anything metallic on top of any battery. All repairs to a battery must be made by experienced and qualified personnel.

! When working with batteries, remove personal items such as rings, bracelets,

necklaces, and watches. Batteries can produce enough energy to weld jewelry to metal, causing a severe burn.

! Always have fresh water and soap nearby in case battery acid contacts skin, clothing,

or eyes.

! Operating the battery with a low battery voltage can cause premature motor

contact failure.

! Do not expose the lift or charger to rain or adverse conditions. ! Replace defective cords or wires immediately. ! Check the battery’s water level frequently if this applies to your battery type. ! Make sure the battery charger is unplugged from 115vac source.

Troubleshooting:

If the cylinder is leaking, and needs replaced or seals replaced; continue with the

following procedure.

Tools Required: 14mm wrench, 16mm wrench, or crescent wrench Regular flat bladed screw driver

“Dental Pick” for o-rings

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Verify this is the unit, EPT-XXXX-30; to be worked on.

Remove the black plastic cover, it will lift out.

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Remove battery wiring taking note where each wire goes.

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Vestil EPT-30 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual