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.

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

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

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

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

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

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

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

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

OVERVIEW

1 — OVERVIEW

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 — 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 — INSTALLATION & WIRING: 1207 Controller

INSTALLATION AND WIRING: 1207

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)

SLIDING

COVER

Curtis PMC 1207/1207A Manual

152 (6.00)

(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)

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)

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

plug diode to motor armature

B+B-

Cables are fastened to the bus bars by M8 (

⁄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.

OFF

30 4

OFF

Manually Adjustable Potentiometers

OFF

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 “

.”

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.

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

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

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

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

–0 (TYPICAL)

FORWARD

REVERSE

SHUNT

M- A2

B+B-

FORWARD

CONTACTOR

CONTACTORS

FWD

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

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.

Curtis PMC 1207/1207A Manual

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

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

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

Curtis PMC 1207/1207A Manual

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

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

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

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”).

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

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

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

Curtis PMC 1207/1207A Manual

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.

2A — INSTALLATION & WIRING: 1207A Controller

INSTALLATION AND WIRING: 1207A

Fig. 2

dimensions, Curtis PMC 1207A controller.

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

dimensions are shown in Figure 2

122

(4.80)

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)

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)

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

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

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)

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+

B+B-

Cables are fastened to the bus bars by M8 (

positive connection to battery/ﬁeld

plug diode to motor armature

⁄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

Fig. 3

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

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

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

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

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

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