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EPT-30-MASTER SERVICE MANUAL.pmd

1. Power wiring for compound motor 9 Control wiring for compound motor 9 1207 Wiring Throttle x 0 Sk throttle 1 icti vore 10 0 5 0 10 3 wire potentiometer and electronic throttles Type 2 11 0 5 throttle Type 77 15 I 1207 Wiring Emergency Reverse Check j 1207 Switches and Other Hardware 16 KeyS WIECH 16 Main Contactok A eK 16 Forward reyerse 16 F R and emergency reverse switches l6 Circuitry protection devices 16 1207 Installation Checkout eese 17 2a INSTALLATION AND WIRING 1207A controllers 19 1207 A 19 1207A Connections Low Current 2 22 2 2S 1207A Connections High rrr trea ap 1207A Wiring Standard Configuration Series Motor 22 Power wiring for Senes Motel Jodocus 23 Control wiring for series QUOTOP 23 SS Curtis PMC 1207 1207A Manual ii __ 2 6 FIGURES FIGURES FIG 1 Curtis PMC 1207 and 1207A motor controllers and handheld programmer titre pen 1 FIG 2 Mounting dimensions C
2. 30 to be worked on Remove the black plastic cover it will lift out Filename Changing Cylinder in EPT VESTIL MFG CO 5 09 07 TG Model EPT XXXX 30 15 126 014 Remove battery wiring taking note where each wire goes Filename Changing Cylinder in EPT VESTIL MFG CO 5 09 07 TG Model EPT XXXX 30 15 126 014 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 Filename Changing Cylinder in EPT 5 09 07 TG 15 126 014 With the batteries removed the cylinder hose will be revealed Cylinder Hose VESTIL MFG CO Model 30 Filename Changing Cylinder in EPT VESTIL MFG CO 5 09 07 TG Model EPT XXXX 30 15 126 014 The cylinder hose can be placed here to help prevent oil leakage Place hose hear Remove snap ring from pin on bottom of cylinder using a tool similar to this Filename Changing Cylinder in EPT VESTIL MFG CO 5 09 07 TG Model EPT XXXX 30 15 126 014 Once the snap ring is removed take the pin out that holds the bottom of the cylinder in place Remove lower pin Filename Changing Cylinder in EPT VESTIL MFG CO 5 09 07 TG Model EPT XXXX 30 15 126 014 Using a flat punch and hammer if required remove the top cylinder pin Take note of the location of the two bushings that
3. 5kQ 0 throttle KE FOT 16 15 14 18 12 11 10 9 1 7 15 1 12 FASTER PIN KEY 1207A 8 5kQ 0 Pin7 Pot Low 5k 0 0 5k 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 510 and full speed corresponds to 0Q In addition to accommodating the basic 5kQ 0 throttle the Type 1 throttle is the easiest with which to implement wigwag style throttle Using 20kQ potentiometer wired as shown in Figure 6a the pot wiper can be set such that the controller has 5kQ 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 6a Wiring for 20kQ 20 POT potentiometer used as a wigwag siyle throttle AAA 16 15 14 13 12 41 10 9 Type 1 8 7 6 5 4 3 2 1 FASTER FASTER N LA PIN KEY 1207A Pin8 5kQ 0 Pin7 PotLow Curtis PMC 1207 1207A Manual 26 S 3 2 INSTALLATION amp WIRING 1207A Controller between Pins 7 and 8 which increases the controller output The throttle mechanism must provide signals to the contro
4. 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 Filename Changing Batteries in EPT VESTIL MFG CO 4 17 07 TG Model EPT XXXX 30 15 126 010 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 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 seve
5. indicating that the control ler 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 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 5 DIAGNOSTICS amp TROUBLESHOOTING Table 2 TROUBLESHOOTING CHART ES LED CODE PROGRAMMER LCD DISPLAY EXPLANATION POSSIBLE CAUSE 1 2 HW FAILSAFE hardware fail safe error ji Controller defective 1 3 M SHORTED M output shorted M output shorted to ground Direction contactor not closing Direction contactor not closing fast enough Internal motor short to ground SRO SRO fault ES gm T Improper sequence of KSI brake and direction inputs Wrong SRO type selected Brake or direction switch circuit open Sequencing delay too short 2 1 THROTTLE FAULT 1 5 0 or wiper fault Throttle input wire open Throttle input wire shorted to ground
6. 4 MAINTENANCE MAINTENANCE There are no user serviceable parts inside Curtis PMC 1207 and 1207A control lers 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 periodi cally and if a handheld programmer is available this periodic cleaning pro vides 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 CAUTION ESY 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 avoid ing loose clothing and jewelry and using insulated wrenches CLEANING Although the 1207 1207A controller requires virtually no maintenance if prop erly installed the following minor maintenance is recommended in certain applications 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 controllers 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 recon necting the battery 4 Make sure the connec
7. 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 The internal watchdog timer must be reset periodically by correct sequential 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 A 13 APPENDIX B SPECIFICATIONS APPENDIX B SPECIFICATIONS N 2 Table B 1 SPECIFICATIONS 1207 CONTROLLERS Nominal input voltage range 24 36 V Maximum operating voltage 45V 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 cur
8. 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 emer gency 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 Curtis PMC 1207 1207A Manual 15 2 INSTALLATION amp 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 i
9. Ambient operating temperature range Heatsink overtemperature cutback Heatsink undertemperature cutback 16 V undervoltage point 500 V ac minimum 15 kHz 1207A 41XX 250 amps for 1 minute 200 amps for 2 minutes 150 amps for 5 minutes 100 amps for 1 hour 1207A 51XX 300 amps for 30 seconds 210 amps for 2 minutes 160 amps for 5 minutes 110 amps for 1 hour 24V 1 amp current limit at 2 amps internal diode to brake internal diode from brake to KSI 2 amps active clamp at 47 V 16 30 V 80 mA without programmer 130 mA with programmer 10 mA at 24 V 8v 25 C to 50 C 85 C 25 C Package splash resistant Weight 1 1kg 2 5 Ibs 122 165 x 66 4 8 6 5 x 2 6 J Output current rating test conditions 1 Controller cover installed 2 Controller mounted to 230 x 305 x 3 2 mm 9 x 12 x 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 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 contro
10. Machine Cover VH WPS 130 0000031 11 1 Battery Cover VH WPS 1300000010 1 Batter 2X12V 70H 12 Battery Charger VST224 15 1 1 Spring Washer 26 6588598 0 Nut M6 2 26 4 Battery Indicator DC24V 114 2008 Disconnect Switch KEY EPT30208 1 2000 DisconectSwth EPT302090 1 2010 FlatWasher 6 689 485 2 2011 BoltM6x25 GH T8a398 2 __ 202 Pin VH WPS 13000005 4 2013 PivtArm 1 VH WPS i30000060 2 2014 Bushing i6x10 53020204 4 216 MainBody VH WPS 13000000 1 2017 SnapRing 20 1 0201 7 1 2018 Bushing20x320 1 EPT 30 2018 2 219 Shaft VH WPS 13000007 1 200 Shat 1 5 13 5 50044 1 2021 SnapRing 22 1 GB8941 86 1 202 0 6859487 2 203 Bot 1 168 702 85 2 2024 S GB578586 2 2025 BearingSet VH WPS 13004008 4 2026 Wheel76x36 VH WPS 13004000 2 2027 2 168615046 22 2028 WheelFrame VH WPS 1300040100 2 209 Shaft 1 VH WPS 13004007 2 200 Bushing 1 VH WPS 13004006 4 2051 BearingPlate VH WPS 13004003 2 2033 BearingPlate VH WPS 13004002 2 2035 Bearing6205 GB894186 2 2026 1 686146 2 2037 Washer 8 685987 2 2038 FixedRi
11. PROGRAM and piacNosrics 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 MORE INFO key to display additional information about the selected item press the MORE INFO key again to return to the original list OPERATING MODES PROGRAM TEST DIAGNOSTICS SPECIAL PROGRAM SPECIAL DIAGNOSTICS O 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 PROGRAM 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 The INFO key when used in the Program mode displays a bar graph along with the minimum and maximum values possible for the selected param eter Parameters can be changed either from the main Program Menu or after the MORE INFO key has been pressed and the additional information is being displayed see example b
12. Pin 2 reverse contactor driver output Pin 3 forward contactor driver output Pin 4 main contactor driver output Pin 5 throttle 3 wire pot high Pin 6 throttle 3 wire pot wiper or 0 5 Pin 7 throttle pot low Pin 8 throttle 2 wire 5 0 or 0 5kQ input Pin 9 throttle 0 10V Pin 10 emergency reverse BB check output optional Pin 11 reverse input Pin 12 forward input Pin 13 emergency reverse input Pin 14 mode selection input Pin 15 brake input Pin 16 keyswitch input KSI Curtis PMC 1207 1207A Manual 4 7 2 INSTALLATION amp 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 7 B positive connection to battery field M A2 2 plug diode to motor armature Cables are fastened to the bus bars M8 o 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 1 noe 2 1 none VN
13. 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 ae EMERGENCY KEYSWITCH MODE FORWARD PED OUTPUT EMERGENCY REVERSE REVERSE FORWARD CONTACTOR 2 WIRE POT MAIN REVERSE 5 CONTACTOR CONTACTOR The throttle shown in Figure 3A is a 5k 2 0 type Various other throttles can also be accommodated and are discussed in the throttle wiring section Curtis PMC 1207 1207A Manual 23 ZA INSTALLATION amp 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
14. held SCROLL A small scroll bar at the left of the display window provides a rough indication of DISPLAY 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 MAIN C L 250 selected item Il b PLUG C L 70 scroll oar RAMP C L 250 ACCEL RATE 1 0 Curtis PMC 1207 1207A Manual 4 6 PROGRAMMER OPERATION The two CHANGE VALUE arrow keys are used to increase or decrease the value of a selected menu item Like the arrow keys the 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 CHANGE An LED on each CHANGE VALUE arrow key indicates whether the key is active VALUE F 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 The key has three functions 1 to display more information about the selected item 2 to access the Special Program and Special Diagnostics modes when used together with the
15. implied by law is limited in duration to the warranty period
16. indication the parameter cannot be adjusted electronically If you press the key the programmer will display the mere message Protected by controller can t program 2 Curtis PMC 1207 1207 Manual 33 3 ADJUSTMENT OF PARAMETERS MECHANICAL ADJUSTMENT 7207 single mode controllers only Five screwdriver adjustable potentiometers trimpots allow mechanical ad justment of the main current limit plug current limit acceleration rate maxi mum 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 0 3 0 VES 9 O PS 3 0 VES 9 PS 3 ort opp M opp A or A8 ore 2 28 MAIN PLUG ACCEL CREEP LOW STATUS CURRENTLIMIT SPEED LIMIT 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 OFF NOTE On 1207 controllers with the MultiMode feature the trimpots are disabled at the factory Curtis PMC 1207 1207A Manual 34
17. is shown in Figure 4A Fig 44 Compound SWITCHES motor wiring diagram CONTACTORS MULTI EMERGENCY l Curtis 1207A BRAKE MODE REVERSE FORWARD REVERSE SHUNT REV FWD MAIN controller NC ox THROTTLE 5kQ 0 TYPICAL x KEYSWITCH POLARITY PROTECTION DIODE MAIN CONTACTOR PRECHARGE RESISTOR 250 Q 5 W FORWARD CONTACTOR REVERSE CONTACTOR 3 28 00 The configuration shown in Figure 4 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 NOTE The emergency reverse check feature wiring shown by dashed line is a factory option Curtis PMC 1207 1207A Manual 24 4 2A INSTALLATION amp WIRING 1207A Controller Power Wiring for Compound Motor The field must be wired between B and A2 and the armature between M and A2 The internal plug diode in the 1207A is connected between M 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 4a If the shunt is rated for higher than 2 amperes a contactor must be used to control the
18. keep the cylinder centered Filename Changing Cylinder in EPT VESTIL MFG CO 5 09 07 TG Model EPT XXXX 30 15 126 014 The cylinder can now be removed If a cylinder is being replaced this procedure can be reversed to install the new one If the seals are being replaced follow the next steps Filename Changing Cylinder in EPT VESTIL MFG CO 5 09 07 TG Model EPT XXXX 30 15 126 014 To replace the seals the rod end of the cylinder must be unscrewed Place the cylinder in a vice and with a flat punch and hammer tap the end loose counterclockwise Filename Changing Cylinder in EPT 5 09 07 TG VESTIL MFG CO Model EPT XXXX 30 15 126 014 The rod assembly should pull out once the end is unscrewed With a small screwdriver remove the bottom seal Filename Changing Cylinder in EPT VESTIL MFG CO 5 09 07 TG Model 30 15 126 014 Filename Changing Cylinder in EPT VESTIL MFG CO 5 09 07 TG Model EPT XXXX 30 15 126 014 Remove the other O ring seal in a similar fashion Remove bushings from the top of the cylinder rod Two bushings on each side Filename Changing Cylinder in EPT VESTIL MFG CO 5 09 07 TG Model EPT XXXX 30 15 126 014 Remove the cylinder end by pulling it off the rod Filename Changing Cylinder in EPT VESTIL MFG CO 5 09 07 TG Model 30 15 126 014 This shows the all the cylinder parts dis
19. or B Throttle pot defective Wrong throttle type selected 2 2 BB WIRING CHECK emerg reverse wiring fault Romse Be BB wire open BB check wire open 2 3 HPD HPD sequencing fault Improper seq of KSI brake throttle inputs Wrong HPD type selected Misadjusted throttle pot 2 4 THROTTLE FAULT 2 Pot Low broken or shorted Pot Low wire open Pot Low wire shorted Wrong throttle type selected 3 1 CONT DRVR OC driver output overcurrent Direction contactor coil shorted Shunt field shorted 332 DIR CONT WELDED welded direction contactor Direction contactor stuck closed 3 4 MISSING CONTACTOR missing contactor or shunt Direction contactor coil open Direction contactor missing Shunt field open Wire to shunt or direction contactor open 4 1 LOW BATTERY VOLTAGE low battery voltage Battery voltage lt 16 volts Corroded battery terminal Loose battery or controller terminal 4 2 OVERVOLTAGE overvoltage Battery voltage gt 48V 1207 gt 33V 1207A Vehicle operating with charger attached 4 3 xz THERMAL CUTBACK over under temp cutback peo pu i see S rS ris e Eon Temperature gt 85 C or lt 25 C Excessive load on vehicle Improper mounting of controller Operation in extreme environments A Curtis PMC 1207 1207A Manual 39 6 PR
20. parts that wear under normal usage conditions wearing parts bearings hoses wheels seals brushes batteries and the battery charger The warranty period for drive and lift components is 1 year For wearing parts the warranty period is 90 days Both warranty periods begin on the date when Vestil ships the product to the warrantee If you purchased the product from an authorized distributor the periods begin when the distributor ships the product which extends the warranty by up to an additional 30 days If a defective part is covered by the warranty what will Vestil do to correct the problem Vestil will provide an appropriate replacement for any covered part An authorized representative of Vestil will contact you to discuss your claim What is not covered by the warranty 1 Labor costs or Freight 2 Any of the following automatically void the warranty Product misuse Negligent operation or repair Corrosion or use in corrosive conditions Inadequate or improper maintenance Failure to exercise good judgment Damage sustained during shipping Accidents involving the product Unauthorized modifications Do NOT modify the product IN ANY WAY without first receiving written authorization from Vestil Modifications may render the pallet truck or stacker unsafe to use or might cause excessive and or abnormal wear Do any other warranties apply to the product Vestil Manufacturing Corp makes no other express warranties Any warranty
21. 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 modula tion 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 Curtis PMC 1207 1207A Manual A 10 APPENDIX A GLOSSARY feature disabled i e a single mode controller you can adjust the maximum speed mechanically via the trimpot labeled Low on top of the controller The maximum creep speed setting is also adjustable via these two methods see Creep speed The maximum emerg
22. start mode it will continue to do so until the opposite direction is selected for more than one second When the brake is first released the ramp start current limit level will be 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 A 9 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
23. 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 maneuver ing 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 not reduced in order to provide full vehicle braking under all therma
24. terminal down Add more length to this wire if necessary and re terminate with a ring terminal Locate Pin 11 on Molex connector at the motor controller Try to drive the unit in forward there should be 24 volts at this pin If there is voltage and the unit does not move the motor controller may be bad consult diagnostics page factory If there is no voltage trace the wiring back towards the tiller head and check voltage on each side of connectors Continue this until bad connection is found If the connections are all good and there is no voltage coming out of throttle assembly then the throttle assembly may be bad Verify there is 24 volts going into the assembly and that there is a good ground If there is still no output voltage for pin 11 replace throttle assembly See Fig 1 04 26 07 Possible cause s Broken wire or loose connection bad motor controller Problem Unit will not reverse belly switch does not function forward ok Bad throttle assembly Broken wire or loose connection bad motor controller Belly switch does not function forward ok reverse ok Bad belly switch Unit will not reverse The unit only Stuck Switch goes forward for about 1 second and dies when the handle is pulled down When the handle is re set and pulled down the unit will move forward again then die VESTIL MFG Co 15 126 013 Action Locate Pin 12 on Molex connector at the mot
25. 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 Fig 2 Mounting DNE lt 165 6 50 dimensions Curtis PMC 1207 lt ______ 127 5 00 lt 22 0 85 controller 28 1 10 122 4 80 G SLIDING 66 2 60 COVER 6 6 0 26 dia 3 pics lt 152 6 00 6 5 0 25 21x 16x 1 5 0 83 x 0 63 x 0 06 8 4 0 33 dia hole thru 60 2 35 4 8 0 19 E 1 Dimensions in millimeters and inches Curtis PMC 1207 1207A Manual 3 2 INSTALLATION amp 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 control ler 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 A s A AA E AA D AAAA Pin 1 shunt field driver output n c for series motors
26. 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 5vac source Filename EPT Belly Switch trouble shoot VESTIL MFG CO 4 24 07 TG Model 30 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 the batteries are fully charged and the units belly switch is not functioning the following procedure will show how to A Replace the tiller assembly wh
27. use NOTE Only one fault is indicated at a time and faults are not queued up Curtis PMC 1207 1207A Manual 37 5 DIAGNOSTICS amp 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
28. 0 15 126 011 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 12 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 itis 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 Omm deep socket or small wrench 4mm wrench or crescent wrench Regular flat bladed screw driver Filename Changing Charger in EPT VESTIL MFG CO 4 17 07 TG Model EPT XXXX 30 15 126 011 Model 30 Remove the two screws shown below and take off the yellow cover Filename Changing Charger in EPT VESTIL MFG
29. 005 lt Washer 26 PU Wheel 1 Oil Seal 0140 180 12 Bearing O Ring Gear O Ring Gear Box Gear Gear Axle Ke Ball Bearing 30 3017 1 1 1 1 1 1 Snap Ring Plug PEPT 30 3019 1 1 1 1 111 Cap Screw M6x15 3021 Washer 6 PT 30 30 3022 Cap Screw M6x20 EPT 30 3022 Cap Screw M6x20 Gear Cap Screw 6 60 Bearing Snap Ring Clutch Plate Clutch Gear Ke Scraping Plate Clutch Gear Cap Screw M6x20 N EPT 30 3033 U iO 2047 30 EPT 2547 30 POWERED PALLET TRUCK PARTS IDENTIFICATION WIRING DIAGRAM NO DESCRIPTION QTY MOTOR Controller Contactor F R Pump Motor Hydraulic Contactor Bellly Switch Battery Meter Fuse 150A Fuse 5A KEY SWITCH ASSY Horn Drive Motor Control Bottons BATTERY 12V 70AH 1 2 4 raat 1 MOTOR Controller 1 2 ContactorF R_ 1 3 PumpMotr 1 4 Hydraulic Contactor 1 5 Belly Switch 1 6 Battery Meter 1 7 Fuse 150A 2 8 FusebA 1 9 SWITCH ASSY 1 aroen 11 11 1 12 Control Bottons 1 14 BATTERY 12 70 1 E Serial No Model LIMITED WARRANTY Vestil Manufacturing Corporation Vestil warrants each EPT model electric pallet truck and Stacker models SE HP S CB S 62 to be free of defects in material and workmanship during the warranty period Our warranty obligation is_to provide a replacement
30. 07 Controller Power Wiring for Compound Motor The field must be wired between B and A2 and the armature between M and A2 The internal plug diode in the 1207 is connected between M 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 EMERGENCY KEYSWITCH FORWARD pate OUTPUT EMERGENCY BRAKE REVERSE REVERSE POT FORWARD LOW CONTACTOR SHUNT 2 WIRE POT MAIN REVERSE 5 kQ CONTACTOR CONTACTOR The throttle shown in Figure 4 is 5kQ 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 9 2 INSTALLATION amp WIRING 1207 Controller WIRING Throttle Wiring for various throttles is described belo
31. ARD E KERR OUTPUT EMERGENCY BRAKE REVERSE REVERSE POT FORWARD LOW CONTACTOR 2 WIRE POT MAIN REVERSE 5 kQ CONTACTOR CONTACTOR The throttle shown in Figure 3 is a 5 0 type Various other throttles can also be accommodated and are discussed in the throttle wiring section Curtis PMC 1207 1207A Manual 7 2 INSTALLATION amp 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 Suid SWITCHES motor wiring diagram CONTACTORS MULTI EMERGENCY a 222 Curtis PMC 1207 BRAKE MODE REVERSE FORWARD REVERSE SHUNT REV FWD MAIN controller NC THROTTLE 5kQ 0 TYPICAL 2 KEYSWITCH POLARITY PROTECTION DIODE MAIN CONTACTOR PRECHARGE RESISTOR 250 5 W FORWARD CONTACTOR REVERSE CONTACTOR 3 28 00 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 8 493 2 INSTALLATION amp WIRING 12
32. BW REV 06 12 2007 EPT 30 SERIES MASTER SERVICE AND PARTS MANUAL EPT 30 SERIES VESTIL MFG 2999 N WAYNE ST PO BOX 507 ANGOLA INDIANA 46703 PH 800 348 0868 800 526 3133 MADE IN P R C 4 INDEX Motor 99 4 3 71 Ept 30 change out instructions for eT M 72 77 Cla DOE 78 85 Charger Conversion to Soneil Brand 86 97 dieti 98 113 Belly Switch Troubleshooting 114 130 Program 252 5 131 Troubleshooting Guide 132 136 WV T M E 137 EPT 30 SERIES PARTS 138 143 MANUAL CURTIS 120 1207A MultiMode MOTOR CONTROLLERS 1999 CURTIS INSTRUMENTS INC DESIGN OF CURTIS PMC 1200 SERIES CONTROLLERS PROTECTED BY U S PATENT NO 4626750 1207 1207A Manual p n 16081 Rev D August 1999 1207 1207A Manual p n 16081 Rev D August 1999 1999 CURTIS INSTRUMENTS INC 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 publishe
33. CO 4 17 07 TG Model EPT XXXX 30 15 126 011 Battery Charger Remove the black plastic cover it will lift out as shown below Filename Changing Charger in EPT VESTIL MFG CO 4 17 07 TG Model EPT XXXX 30 15 126 011 ove ba y wirin 8 Es posts even 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 Y Do the same for the red post as shown here remove 2 Red wires Filename Changing Charger in EPT VESTIL MFG CO 4 17 07 TG Model EPT XXXX 30 15 126 011 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 YS There 4 nuts holding the charger in place that can easily be removed with a deep well 10mm socket or small 10 mm wrench Filename Changing Charger in EPT VESTIL MFG CO 4 17 07 TG Model EPT XXXX 30 15 126 011 Remove nuts I P7LLSA TICON AUALIVE IVHSHA 5 Filename Changing Charger in EPT VESTIL MFG CO 4 17 07 TG Model EPT XXXX 30 15 126 011 Once the battery charger is removed it can be exchanged for the new one Reverse the process and reconnect the wiring Filename Changing Charger in EPT to Soneil VESTIL MFG CO 5 16 07 TG Mode
34. 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 Filename Changing Charger in EPT to Soneil VESTIL MFG CO 5 16 07 TG Model 30 15 126 015 Model EPT XXXX 30 Remove the two screws shown below and take off the yellow cover Filename Changing Charger in EPT to Soneil VESTIL MFG CO 5 16 07 TG Model 30 15 126 015 The battery charger is located on the left side of the unit Battery Charger Filename Changing Charger in EPT to Soneil VESTIL MFG CO 5 16 07 TG Model EPT XXXX 30 15 126 015 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 batt
35. D 10 0 i i 0 10 20 30 40 50 60 70 80 90 100 THROTTLE percent Curtis PMC 1207 1207A Manual A 8 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 300 throttle map for control 90 T ler with maximum speed i set at 6096 and creep speed 80 T 50 set at 10 70 MAXIMUM SPEED 60 30 5 60 9 2 504 5 CREEP SPEED ut l 1096 uo 40 10 wee 30 f eT 204 So i s 10 0 0 10 20 30 40 50 60 70 80 90 100 THROTTLE percent 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 5096 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 for 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 STEP 1 select a direction for more than 1 second STEP 2 return to neutral and STEP 3 re select the same direction Once the vehicle is operating in ramp
36. OGRAMMER OPERATION PROGRAMMER OPERATION The universal Curtis PMC handheld programmer optional allows you to program test and diagnose Curtis PMC programmable controllers The pro grammer 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 controllers 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 LCD display is presented in this window The LED in the corner of the key lights up to identify the mode of operation Choose the Program Test TEST DIAGNOSTICS or Diagnostics Mode with one of these three keys Scroll the 4 line display up and down o with these two keys a DISPLAY VALUE Change the selected Ww item s value up or down with these two keys Get more information about selected items with MORE INFO this key Also use this key in combination with other keys to put the programmer in Special modes Curtis PMC 1207 1207A Manual 40 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 s
37. VN 0 0 02 3 0 2 3 0 4 0 4 gt 2008 2008 O4 2208 208 OFF 4 OFF 4 OFF 4 OFF 4 OFF 4 MAIN PLUG ACCEL CREEP LOW STATUS CURRENT LIMIT SPEED LIMIT Manually Adjustable Potentiometers Five screwdriver adjustable potentiometers trimpots allow manual adjustment of the main and plug current limits acceleration rate maximum creep speed and maximum speed labeled Low as de scribed 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 grammer its potentiometer must be set to 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 Curtis PMC 1207 1207A Manual 5 2 INSTALLATION amp WIRING 1207 Controller WIRING Standard Configuration Series Motor The basic wiring for series motors with field reversing is shown in Figure 3 Fig Standard SWITCHES wiring diagram CONTACTORS MULTI EMERGENCY series motor BRAKE MODE REVERSE FORWARD REVERSE REVERSE FORWARD MAIN Curtis PMC 1207 OAS 7 2 controller NEM THROTTLE 5kQ 0 TYPICAL KE
38. W FAILSAFE Hardware failsafe activated LOW BATTERY VOLTAGE Low battery voltage lt 16V M SHORTED M output fault MISSING CONTACTOR Missing contactor NO KNOWN FAULTS No known faults OVERVOLTAGE Overvoltage 1207 gt 48V 1207A gt 33V SRO Static return to off SRO activated THERMAL CUTBACK Cutback due to over under temp THROTTLE FAULT1 Throttle input fault THROTTLE FAULT2 Throttle low input fault Curtis PMC 1207 1207A Manual 48 G 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 single mode 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 alr
39. YSWITCH POLARITY IN PROTECTION CONTROL FUSE CONTACTOR FORWARD CONTACTOR REVERSE i PRECHARGE RESISTOR CONTACTOR 250 5 W 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 The emergency reverse check feature wiring shown by dashed line is a factory option Curtis PMC 1207 1207A Manual 6 2 INSTALLATION amp 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 KEYSWITCH MODE FORW
40. and the next photo fig 28 red tab slides over the top of this when installing the top assembly back on the handle Fig 29 Filename EPT Belly Switch trouble shoot VESTIL MFG CO 4 24 07 TG Model EPT XXXX 30 This is the top front where the two connectors are Make sure they are on each side of the stand offs so the wires do not get pinched Fig30 This shows sliding the red tabs over the black nub Fig31 this is basically the reverse of Fig9 Filename EPT Belly Switch trouble shoot VESTIL MFG CO 4 24 07 TG Model EPT XXXX 30 filename EPTdefaultvalues Program Menu Values for the EPT electric pallet truck 1207A controller These are the desired parameters for the EPT EPT XXXX 30 Rev 05 01 07 TG Option Program cones THROTTLE 2 HIGH PEDAL DIS 0 QUICK START 0 04 26 07 15 126 013 TROUBLESHOOTING GUIDE Warning Before performing any task always block drive wheel off of the ground Consult the factory for problems at time of installation or for any problems not addressed below Problem Possible cause s Action Unit doesn t move when controls Battery voltage low lt 17 Charge batteries are used Problem with motor controller Consult diagnostics check for LED flash code on page factory side of controller Fuse blown Remove back shroud and check fuses 3 fuses Unit will not charge Charger malfunction Verify output voltage on charge
41. assembled Replace the seals and reverse the process to re assemble the cylinder and place it back in the pallet truck Take caution not to damage the new seals when installing Filename EPT Belly Switch trouble shoot VESTIL MFG CO 4 24 07 TG Model EPT XXXX 30 Instructions for Changing the Tiller Assembly 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
42. controller The throttle map parameter is called ramp shape see Ramp shape for more information Throttle response The dynamic throttle response duty factor as 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 5 0 and 0 5kQ 2 wire rheostats 3 wire pots 0 5 throttles 0 10 throttles 1207 only and the Curtis 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 opera tion Adjustments and settings are independent of throttle type However throttle fault conditions will vary by throttle type Curtis PMC 1207 1207A Manual A 12 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
43. ctrically 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 10 If itis 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 Filename Changing Batteries in EPT VESTIL MFG CO 4 17 07 TG Model 30 15 126 010 Changing Batteries in 30 estimated time 15 minutes Remove the black plastic cover it will lift out Filename Changing Batteries in EPT VESTIL MFG CO 4 17 07 TG Model EPT XXXX 30 15 126 010 Filename Changing Batteries in EPT VESTIL MFG CO 4 17 07 TG Model EPT XXXX 30 15 126 010
44. d 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 5vac 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 Filename Changing Cylinder in EPT VESTIL MFG CO 5 09 07 TG Model EPT XXXX 30 15 126 014 Verify this is the unit
45. d 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 4a and 9a on pages 8 24 and 28 Bookmarks have been added to the electronic version to speed the process of going directly to a particular part of the document CURTIS INSTRUMENTS INC 200 KISCO AVENUE MOUNT KISCO NEW YORK 10549 USA 914 666 2971 914 666 2188 CURTIS PMC 235 EAST AIRWAY BOULEVARD LIVERMORE CALIFORNIA 94550 USA 925 961 1088 925 961 1099 ADDITIONAL OFFICES located in Bulgaria China England France Germany India Italy Japan Netherlands Puerto Rico Russia Sweden and Switzerland CONTENTS CONTENTS OVER VIEW ipe ee 1 2 INSTALLATION AND WIRING 1207 controllers 1207 3 1207 Connections Low Current 00 4 1207 Connections High Current quss 5 1207 Adjustment Panels y 1207 Wiring Standard Configuration Series Motor 6 Power wiring for series 7 Control wiring for series ioa qus Seit adio ea Roe 7 1207 Wiring Compound Motor Configuration
46. de 1 plug current limit 1 RAMP C L Mode 1 ramp start current limit 1 ACCEL RATE Mode 1 acceleration rate in seconds 1 MAX SPEED Mode 1 maximum speed as PWM output 2 MAIN C L Mode 2 main current limit 2 PLUG C L Mode 2 plug current limit 2 RAMP C L Mode 2 ramp start current limit 2 ACCEL RATE Mode 2 acceleration rate in seconds 2 MAX SPEED Mode 2 maximum speed as PWM output NEUT BRAKE C L Neutral brake current limit NEUTRAL BRAKE Neutral brake on or off Notes are on the next page Curtis PMC 1207 1207A Manual 46 49 6 PROGRAMMER OPERATION Program Menu Notes For more detail on these options see Appendix A Glossary of Features and Functions Throttle types 1 5kQ 0 2 0 5 0 10 3 wire pot and electronic throttles 3 0 5 throttles HPD types Type 0 no HPD Type 1 HPD on brake input Type 2 HPD on KSI t 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 not all items available on all controllers THROTTLE BATT VOLTAGE HEAT SINK C MAX TEMP C Throttle reading as percent of full Battery voltage Heatsink temperature Maximum temperature seen MIN TEMP C Minimum temperature seen BRAKE INPUT Brake switch on off SPEED IN M
47. djustable 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 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 Curtis PMC 1207 1207A Manual 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 maxi
48. e attached to the switch as shown below Also verify the belly switch is not stuck in You should be able to push on the switch and the actuator will move freely in and out you should here a click as you do this If the switch is stuck in contact Vestil Manufacturing for replacement options Fig20 Solder connection Bell Switch actuator L connection VEM v e Replace any broken missing components To assemble press the red belly switch cover back on the tiller head seating the red holes over the gray tabs Basically the opposite of the procedure in Fig 17 but without a screwdriver Fig 21 Filename EPT Belly Switch trouble shoot VESTIL MFG CO 4 24 07 TG Model EPT XXXX 30 The spring can be pushed into position Fig 22 This is the spring is shown not seated completely Push the spring into the pocket and over the gra Filename EPT Belly Switch trouble shoot VESTIL MFG CO 4 24 07 TG Model 30 Filename EPT Belly Switch trouble shoot VESTIL MFG CO 4 24 07 TG Model EPT XXXX 30 Install Philips screw Fig26 Re installing the tiller cover is basically reversing steps Fig 11 thru 7 with the following precautions steps Make sure red tabs on each side goes on top of black nubs when installing tiller cover on the handle Fig 27 Filename EPT Belly Switch trouble shoot VESTIL MFG CO 4 24 07 TG Model 30 Black nub for right side shown here
49. e freed up Verify 24 volts at coil when lower is pushed if no voltage trace wiring back to tiller head looking for voltage on each side of the connectors until the bad connection is found If voltage is present at the coil and the unit does not lower remove the connector to the coil and measure the coil resistance It should be around 39 ohms If it s open or shorted replace the coil Remove the wire to the solenoid coil on the pump motor Measure the resistance it should be around 19 ohms If it is nearly zero ohms replace the solenoid 4 39 Problem Unit will not reverse belly switch does not function forward ok VESTIL MFG Co 04 26 07 Possible cause s Broken wire or loose connection bad throttle assembly bad motor controller 15 126 013 Action Locate Pin 12 on Molex connector at the motor controller Try to drive the unit in reverse there should be 24 volts at this pin If there is voltage and the unit does not move the motor controller may be bad consult factory If there is no voltage trace the wiring back towards the tiller head and check voltage on each side of connectors Continue this until bad connection is found If the connections are all good and there is no voltage coming out of throttle assembly then the throttle assembly may be bad Verify there is 24 volts going into the assembly and that there is a good ground If there
50. eady 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 before the 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 Cycling the brake or KSI clears most faults and enables operation Curtis PMC 1207 1207A Manual 1 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 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 thrott
51. ecial 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 family of controllers with identical settings 2 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 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 controller since the history was last cleared NOTE The maximum minimum temperatures recorded by the controller are included in the Test Menu Each MORE INFO DIAGNOSTICS 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 MORE INFO key Then while continuing to hold the INFO key press the DiaGNosTics key The LED on the key will ligh
52. ed 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 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 Curtis PMC 1207 1207A Manual 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
53. eld programmer Curtis PMC 1207 1207A Manual A 2 427 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 em
54. elected parameters The eighth key the key is used to display further information about selected items within any of the three standard modes In addition when pressed together with the PROGRAM or the DIAGNOSTICS key the key selects the Special Program mode or the 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 SCROLL DISPLAY arrow keys The SCROLL DISPLAY arrow keys can be pressed repeatedly or be held down When a key is held down the scrolling speed increases the longer the key is
55. elow selected parameter MODE1 ACCELERATION set value RATE SECS 1 3 bar graph MIN 0 2 minimum value S maximum value units Curtis PMC 1207 1207A Manual 42 6 PROGRAMMER OPERATION TEST DIAGNOSTICS MORE INFO PROGRAM Some parameters on some controllers have dependencies on other param eters 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 i
56. ency 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 step 1 KSI on 5 2 brake released brake input high and 5 3 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 requir
57. er 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 disconnect ing 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
58. er gency 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 func tioning 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 Curtis PMC 1207 1207A Manual 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 e
59. er The checkout procedure is easier with a programmer Otherwise observe the Status LED for codes Put the vehicle up on blocks to get the drive wheel s off CAUTION 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 NS 1 Ifa 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 key The display should indicate No Faults 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 con tinue 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 c
60. ery field A2 plug diode to motor armature Cables are fastened to the bus bars by M8 6 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 21 2A INSTALLATION amp WIRING 1207A Controller WIRING Standard Configuration Series Motor The basic wiring for series motors with field reversing is shown in Figure 3a Fig 3a Standard P SWITCHES wiring diagram CONTACTORS MULTI EMERGENCY series motor BRAKE MODE REVERSE FORWARD REVERSE REVERSE FORWARD Curtis PMC 1207A a lt 7 7 2 controller LE TN THROTTLE 5kQ 0 TYPICAL X KEYSWITCH POLARITY PROTECTION DIODE CONTROL FUSE MAIN CONTACTOR FORWARD CONTACTOR REVERSE CONTACTOR PRECHARGE RESISTOR 250 5 W 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 The emergency reverse check feature wiring shown by dashed line is a factory option Curtis PMC 1207 1207A Manual 22 2 INSTALLATION amp WIRING 1207A Controller
61. ery terminals with tools Do the same for the red post as shown here remove 2 Red wires Filename Changing Charger in EPT to Soneil VESTIL MFG CO 5 16 07 TG Model 30 15 126 015 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 m gt 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 a IVHSSA 4 gt 3 Filename Changing Charger in EPT to Soneil VESTIL MFG CO 5 16 07 TG Model EPT XXXX 30 15 126 015 Remove the 4 nuts LLISA TAGON 11 9 IVHSAA Once the battery charger is removed it be exchanged for the new AMSLIVE Filename Changing Charger in EPT to Soneil 5 16 07 TG 15 126 015 There are two hook and loop strips on the back of the char Remove the adhesive backing from the 2 strips er VESTIL MFG CO Model EPT XXXX 30 Filename Changing Charger in EPT to Soneil 5 16 07 TG 15 126 015 With the adhesive side inward carefull Try to center the charger in the opening and put the charger into position VESTIL MFG CO Model EPT XXXX 30 press it firmly into position Filename Changing C
62. for a defective original part a part used to make the product as shipped to the warrantee after we receive a proper request for warranty service Proper request means that we must receive 1 a photocopy of your Customer Invoice that displays the shipping date AND 2 a written request for warranty service that includes your name and phone number Send requests by any of the following methods Mail Fax Email Vestil Manufacturing Corporation 260 665 1339 sales vestil com 2999 North Wayne PO Box 507 Phone Angola IN 46703 260 665 7586 In the written request list the parts you believe are defective and include the address where replacements should be delivered After Vestil receives your request an authorized representative will contact you to determine whether your claim is covered by the warranty also see If a defective part is covered below Before providing warranty service Vestil may require you to send the entire product or the defective part or parts to its facility in Angola Indiana Who may request service Only the warrantee may request service You are a warrantee if you purchased the product from Vestil or from an authorized distributor AND Vestil has been fully paid What is covered under the warranty The warranty covers the following original drive and lift components drive motors and lift motors hydraulic pumps electronic controllers switches and cylinders It also covers original
63. forward reverse a paired single pole double throw 2xSPDT 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 contac tors 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 1207 1207A Manual 30 4 7 2A INSTALLATION amp WIRING 1207A Controller 1207A INSTALLATION CHECKOUT Before operating the vehicle carefully complete the following checkout proce dure 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 programm
64. g the Self Test you can toggle between the two test screens by pressing the 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 re power it without holding the key SCROLL DISPLAY 1 4 0123456789 lt gt ABCDEFGHI JKLMNOREEE PQRSTUVWXYZx gt Q gt Curtis 1207 1207A Manual 45 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 all items available on all controllers EMR REV C L Emergency reverse current limit THROTTLE TYPE Throttle type RAMP SHAPE Throttle map CREEP SPEED Creep speed as percent PWM duty cycle EMR REV SPEED Emerg reverse speed as PWM duty cycle SEQUENCING DLY Sequencing delay in seconds VARIABLE PLUG Throttle variable plug braking on or off HIGH PEDAL DIS High pedal disable HPD typet SRO Static return to off SRO typet ANTI TIEDOWN Anti tiedown on or off QUICK START Quick start throttle factor 1 MAIN C L Mode 1 main current limit 1 PLUG C L Mo
65. harger in EPT to Soneil VESTIL MFG CO 5 16 07 TG Model 30 15 126 015 With the charger in place feed the wires back to the batteries in the same manner they were removed off of the old charger Filename Changing Charger in EPT to Soneil VESTIL MFG CO 5 16 07 TG Model 30 15 126 015 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 Far right side terminal 7 terminal Negative post connection shown here Filename Changing Charger in EPT to Soneil 5 16 07 TG VESTIL MFG CO Model EPT XXXX 30 15 126 015 Plug 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 Filename Changing Charger in EPT to Soneil VESTIL MFG CO 5 16 07 TG Model EPT XXXX 30 15 126 015 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
66. he 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 path Wiring is shown in Figure 8a Fig 8 Wiring for 3 wire Since BUT potentiometer throttle ON OFF Type 2 CANNA IG JI sm JD an s F Pin7 Pot Low Pine 0 5 Input Pin5 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 in Figure 9a Fig 9A Wiring for B Curtis ET XXX electronic i T throttle Type 2 KEYSWITCH PIN KEY 1207A 16 KSI Input 209 quo Pini2 Forward miei Pint Reverse WHT BRN Pin6 0 5 Input GREEN Ly ORANGE i MEE Vp BLACK NN BLACK WHITE Ls WHITE y 8 Curtis PMC 1207 1207A Manual 28 A 2 INSTALLATION amp WIRING 1207A Controller 0 5kQ Throttle Type 3 The 0 5kQ throttle 3 in the programming menu is a 2 wire resistive throttle that c
67. ich contains the belly switch and throttle controls B Troubleshoot belly switch mechanism itself The following tools will be required 5mm allen wrench Philips bladed screw driver Small Regular flat bladed screw driver Filename EPT Belly Switch trouble shoot VESTIL MFG CO 4 24 07 TG Model EPT XXXX 30 30 fig 1 verify this is the unit you are working on Make sure key switch is off Fi Filename EPT Belly Switch trouble shoot VESTIL MFG CO 4 24 07 TG Model EPT XXXX 30 This is the top side of the tiller Fig3 This is the driver side of the tiller looking at the belly switch Fig 4 Filename EPT Belly Switch trouble shoot VESTIL MFG CO 4 24 07 TG Model EPT XXXX 30 This is the bottom side of the tiller handle 3 allen head screws need to be removed Fig5 5mm allen screws 3 places Filename EPT Belly Switch trouble shoot VESTIL MFG CO 4 24 07 TG Model EPT XXXX 30 Lift the front top edge of the tiller cover up Carefully pull the belly switch back off of the tiller while tipping the front up Fig 9 Filename EPT Belly Switch trouble shoot VESTIL MFG CO 4 24 07 TG Model EPT XXXX 30 The tiller assembly cover should come off just be careful not to drop it and rip out the wiring from the connectors At this point the tiller throttle assembly can be replaced with a new one by just unplugging the two connectors Or if the problem appears to be in the be
68. 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 Filename Changing Cylinder in EPT VESTIL MFG CO 5 09 07 TG Model EPT XXXX 30 15 126 014 Instructions for Changing the Cylinder in EPT XXXX 30 estimated time 45 min READ ALL INSTRUCTIONS BEFORE PROCEEDING Only qualified personnel should work on this equipment 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 Warning Working with or near lea
69. is still no output voltage for pin 12 replace throttle assembly EPT 2047 30 EPT 2547 30 POWERED PALLET TRUCK EPT 2547 30 F VH WPS 130 ave 1003 wp 1001 7e 1006 1005 7 M7 1007 1009 1008 i ba 00 x 1011 MX x 1012 1023 lt gt fi 1014 m T 1015 pP AT Ci 1016 1022 1021 Z gt 1017 1029 id 1019 gt ape PARTS IDENTIFICATION FORK ASSEMBLY ITEM DESCRIPTION PART NO QTY 1001 For assomoy vetwes ts0 019000 1 1004 Screw Mexa5 GBs78886 2 1008 Snap Ring p vetwes tao reves S eRe 1008 Front Wheel Bearing VH WPS 130 012104 2 1009 SetPinOsx 0 GB87986 1 61 1010 Wheel Frame VH WPS i30012101 2 shan ve weS 130010001 2 i012 V Snat VH WPS 130012000 2 1013 PushRod VH WPS 30012008 2 _ 1044 Nu GBetzi86 121 1015 Glevis End VH WPS i30012004 2 1017 EPTSO37 5 ee POPPY POT POPP no 1020 97616 3020 1 2 NT 5 EPT 2047 30 EPT 2547 30 POWERED PALLET TRUCK EPT 2547 30 VH WPS 130 2001 PARTS IDENTIFICATION TAIL BOX ASSEMBLY ITEM NO DESCRIPTION PART NO QTY
70. l EPT XXXX 30 15 126 015 Instructions for Changing the Battery Charger in 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 1 1 5 source Battery
71. l 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 Curtis PMC 1207 1207A Manual A 6 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 Plug current limit on the 1207 1207A controls the field current The armature current in plug 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 a
72. le 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 handh
73. ler head by removing 3 screws from bottom Slightly loosen up the two scews that hold the switch in place this may free the switch If it is still stuck contact the factory for a replacement switch 04 26 07 Problem Possible cause s Unit will not raise motor does not Loose wire run Bad solenoid Upper limit switch out of adjustment Unit will not raise motor runs Lower solenoid stuck on Unit will not lower Loose wire bad coil Unit keeps blowing fuses when the Shorted solenoid for motor raise raise button is pressed VESTIL MFG CO 15 126 013 Action Verify 24 volts at coil when raise is pushed if no voltage trace wiring back to till her head looking for voltage on each side of the connectors until the bad connection is found If voltage is present at the solenoid and the unit does not raise remove the two wires to the coil and measure the coil resistance It should be around 19 ohms If it s open or shorted replace the solenoid Bypass upper limit switch and see if the unit raises DO NOT TAKE IT ALL THE WAY UP If it does raise verify the limit switch is normally closed and will open when activated If the limit switch is ok try to adjust the switch accordingly so that the units raise height is approximately 7 to 8 Check to see if the lowering switch is stuck on If it is remove the tiller head via 3 screws on bottom and replace switch or tap on switch to see if it can b
74. ller in the minimum time at minimum cost The panels manufactured by Curtis Instru ments 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 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 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 Opera
75. ller 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 OV 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 7 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 Fig 7a Wiring for 0 5V throttle Type 2 0 5V throttle sensor 0 0 5V SENSOR SENSON Oe PIN KEY 1207A Pin7 Pot Low Pin6 0 5 Input SENSOR GROUND b Ground referenced 0 5 throttle 16 15 14 13 12 11 10 9 Shunt impedance 150 to ground PIN KEY 1207A Pin7 Pot Low PE 4 7 KQ Pine 0 5 Input gt B Pin5 Pot High Curtis PMC 1207 1207A Manual 27 2A INSTALLATION amp WIRING 1207A Controller 3 Wire Potentiometer 5000 10 Throttle T
76. lly switch itself further breakdown of the assembly can continue to search for the problem Fig 10 Filename EPT Belly Switch trouble shoot VESTIL MFG CO 4 24 07 TG Model 30 Remove Philips screw on throttle Fig12 Throttle wheel will then pull off Take note of the orientation of the wheel on the shaft Correct orientation is shown here Fig 13 VESTIL MFG CO Filename EPT Belly Switch trouble shoot Model EPT XXXX 30 4 24 07 TG Do the same on the other side taking note of the orientation of the two plastic bushings If the throttle wheel had a tendency to stick contact Vestil Manufacturing for replacement bushings Fig 14 Filename EPT Belly Switch trouble shoot VESTIL MFG CO 4 24 07 TG Model EPT XXXX 30 To remove the red cover use a small screwdriver and carefully lift the plastic up over the gray tab Fig 16 Do the same on the other side and remove Fig 17 Filename EPT Belly Switch trouble shoot VESTIL MFG CO 4 24 07 TG Model 30 This should expose a spring This spring has a specific orientation When assembled the spring sets in the red cup on the inside of the red belly cover Fig 18 fits over the gray plastic nub Fig ran are Filename EPT Belly Switch trouble shoot VESTIL MFG CO 4 24 07 TG Model EPT XXXX 30 Another picture of the nub spring not shown At this point verify the solder joints are in tact and the two wires ar
77. mum 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 166 throttle map for control MAXIMUM SPEED 100 ler with maximum speed pel aus set at 100 and creep 80 di 50 was speed set at 0 704 P uu cups 40 p P 30 c dis 8 60 x uA au hee 20 PA ra 504 Fd reg 2 407 BO Ps a 30 wt CREEP L 20 4 SPEED 72570 10 LLL Lm H 0 10 20 30 40 50 60 70 80 90 100 THROTTLE percent 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 Fig A 2 Ramp shape 100 throttle map for control MAXIMUM SPEED 100 8 RAMP SHAPE 901 OLE 70 ler with maximum speed 2 a set at 100 and creep 807 dem 50 7 speed set at 10 70 eee 40 26 gt 30 60 s 2d KERR TEDS 20 5 amp 50 a gt Kon and 407 j a d d 30 Lut e c ees 10 T CREEP SPEE
78. n 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 250Q 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 2xSPDT 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 contac tors 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 ba
79. ng 1 VH WPS 13004000 2 209 LinikRod 1 VH WPS 13004004 2 200 Bot X GB T2673 1986 2 2041 FiedPlate 1 VHWPS 130 020013 1 2042 WwaserO8 685987122 2048 l EPT 2047 30 EPT 2547 30 POWERED PALLET TRUCK EPT 2547 30 H VH WPS 130 PARTS IDENTIFICATION HANDLE ASSEMBLY ITEM NO DESCRIPTION PART NO CH 4 000004 308 Spring CH200006 2 GB70 85 3100 ContolHande vHSCH2 1 EPT 2047 30 EPT 2547 30 POWERED PALLET TRUCK 2547 30 a PARTS IDENTIFICATION 2 e POWER PACK ASSEMBLY ITEMNO DESCRIPTION PART NO QTY 4102 Shaft 20 WPS 130 4102 4103 Manifold WPS 130 4103 4101 1 4104 4105 4106 1 SCHEMATIC ane 4100 Power Pack Assembl WPS 130 4100 EPT 2547 30 CYLINDER 4302 4201 PARTS IDENTIFICATION CYLINDER ASSEMBLY ur at ITEMNO DESCRIPTION PART NO QTY 4204 Piston 7 WPS 130 42200 1 4205 PistonRod 5 130 4205 T AN WPS 130 4304 40 4402 WPS 130 4402 4403 WPS 130 4403 i SealKit WPS 130 CYL SK 1 EPT 2047 30 EPT 2547 30 POWERED PALLET TRUCK EPT 2547 30 DRIVE WHEEL ASSEMBLY 3014 PARTS IDENTIFICATION MOTOR ITEMNO DESCRIPTION PART NO ee E __ _ Motor DC 700W 24V Ke Washer 3004 Pin 25 16 EPT 30 3004 3005 Cap Screw M6x15 EPT 30 3
80. nly open wiper faults It is the responsibility of the vehicle manufacturer to provide any additional throttle fault detection necessary for the application The 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 2 44 2 INSTALLATION amp WIRING 1207 Controller 0 5 Throttle Type 3 The 0 5kQ throttle Type 3 in the programming menu is a 2 wire resistive throttle that connects between the 5k 2 0 0 5k Q 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 0Q and full speed corre sponds to 5kQ Fig 11 Wiring for 0 50 throttle Type 37 FASTER Pin8 5kQ 0 Pin7 Pot Low Broken wire protection is provided by the controller sensing the current flow from the 0 5kQ 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
81. ntrol 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 beds eel fle A A 00000000 1 shunt field driver output for series motors Pin 2 reverse contactor driver output Pin 3 forward contactor driver output Pin 4 main contactor driver output Pin 5 throttle 3 wire pot high Pin 6 throttle 3 wire pot wiper or 0 5 Pin 7 throttle pot low Pin 8 throttle 2 wire 5kQ 0 or 0 5 input Pin 9 n c Pin 10 emergency reverse BB check output optional Pin 11 reverse input Pin12 forward input Pin 13 emergency reverse input Pin14 mode selection input Pin15 brake input 16 keyswitch input KSI Curtis PMC 1207 1207A Manual 20 2A INSTALLATION amp WIRING 1207A Controller Programmer Connector WE 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 00000000 B negative connection to battery B positive connection to batt
82. ode switch on Mode 1 off Mode 2 EMR REV INPUT Emergency reverse switch on off FORWARD INPUT Forward switch on off REVERSE INPUT Reverse switch on off MAIN CONTACTOR Main contactor on off FWD CONT Forward contactor on off REV CONT Reverse contactor on off Maximum minimum temperatures recorded since Diagnostic History was last cleared Curtis PMC 1207 1207A Manual 47 6 PROGRAMMER OPERATION Special Program Menu RESET ALL SETTINGS Revert to original settings CONT SETTINGS PROG Save controller settings in programmer PROG SETTINGSs CONT Load programmer settings in controller CLEAR DIAG HISTORY Clear diagnostic history memory CONTRAST ADJUSTMENT Adjust display contrast LANGUAGE SELECTION Select displayed language PROGRAMMER INFO Display programmer information CONTROLLER INFO 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 WIRING CHECK BB wiring check failed CONT DRVR OC Contactor driver overcurrent DIR CONT WELDED Direction contactor welded HPD High pedal disable HPD activated H
83. on high efficiency for reduced motor and battery losses V Compact size lt Overvoltage undervoltage protection V Thermal protection and compensation circuitry provides undertemperature cutback constant current limit and linear rollback in overtemperature thus preventing sudden power loss regardless of thermal conditions More Features 1 Curtis PMC 1207 1207A Manual 1 OVERVIEW v Intelligent handheld programmer optional provides a full set of parameter and function settings V Diagnostic and test information for the controller and other system com ponents readily available both on board and through the programmer V 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 V 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 V Inputsequencing options include neutral start and static return to off SRO V Microprocessor controlled contactor sequencing provides true arcless contactor switching V Smooth controlled plug braking with either variable throttle dependent or fixed plug current limit lt Neutral braking option provides automatic plug braking in neutral V MultiMode input selects between two different o
84. onnects between the 5kQ 0 0 5kQ pin Pin 8 and the Pot Low pin Pin 7 as shown in Figure 10a It doesn t matter which wire goes on which pin Zero speed corresponds to OQ and full speed corresponds to 5kQ Fig 104 Wiring for 0 50 throttle Type 3 5kQ POT 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 FASTER 1 PIN KEY 1207A Pin8 5kQ 0 7 PotLow 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 Fig 114 Alternative SWITCHES wiring for 1207A CONTACTORS Pech MULTI EMERGENCY emergency reverse BRAKE MODE REVERSE FORWARD REVERSE REVERSE FORWARD MAIN 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 outpu
85. ontroller 28 FIG 9A Wiring for Curtis ET XXX electronic throttle 1207A controller 28 FIG 10a Wiring for 0 5 throttle 1207A controller 29 FIG 11a Alternative wiring for emergency reverse check 1207A controller 29 TABLES TABTE Je DED 60desi 5n 37 TABLE 25 Troubleshooting 39 Curtis PMC 1207 1207A Manual vi 1 OVERVIEW OVERVIEW Curtis PMC 1207 1207A programmable motor speed controllers provide effi cient 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 diag nostic information quickly and easily Fig 1 Curtis 1207 and 1207A electronic motor controllers and handheld programmer Like all Curtis PMC motor controllers the 1207 and 1207A models offer superior operator control of the vehicle s motor drive speed Features include V Power MOSFET design providing infinitely variable drive and plug brake control silent high frequency operati
86. 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 external watchdog timer guards against a complete failure of the micropro cessor which would incapacitate the internal watchdog timer This independent system check on the microprocessor meets the EEC s requirement for backup fault detection The external watchdog timer safety circuit shuts down the controller and the microprocessor if the software fails to generate a periodic external pulse train
87. or controller Try to drive the unit in reverse there should be 24 volts at this pin If there is voltage and the unit does not move the motor controller may be bad consult diagnostics page factory If there is no voltage trace the wiring back towards the tiller head and check voltage on each side of connectors Continue this until bad connection is found If the connections are all good and there is no voltage coming out of throttle assembly then the throttle assembly may be bad Verify there is 24 volts going into the assembly and that there is a good ground If there is still no output voltage for pin 12 replace throttle assembly See Fig 1 Locate Pin 13 on Molex connector at the motor controller Try to drive the unit in reverse and hit the belly switch there should be 24 volts at this pin If there is voltage and the unit does not move the motor controller may be bad consult diagnostics page factory If there is no voltage trace the wiring back towards the tiller head and check voltage or continuity on each side of connectors Continue this until bad connection is found If the connections are all good and there is no voltage then the switch may be bad Verify there is 24 volts going into the switch If there is still no output voltage for pin 13 replace the switch The belly switch is stuck on Tap the orange assembly to see if the switch can be freed If this doesn t work disassemble the til
88. orrected it may be necessary to cycle the brake in order to clear the fault code 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 Curtis PMC 1207 1207A Manual 3 2A INSTALLATION amp WIRING 1207A Controller verify the wiring to the forward reverse switches forward reverse con tactors and motor The motor should run proportionally faster with increasing throttle If not refer to Section 5 5 Ifyou 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 1175 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 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
89. ottle 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 Pin 9 exceeds 16 volts the controller will shut down Nore In Figure 8 b the throttle s voltage input signal is in reference to Pot Low Fig 8 Wiring for 0 10V throttle Type 2 a 0 10V throttle sensor 16 15 14 13 12 11 10 9 o SERIE SENSO SENSOR OUTPUT Pin9 0 10V Input SENSOR GROUND Pin7 Pot Low b Ground referenced 0 10V throttle Shunt impedance 150 to ground Pin9 0 10V Input PEE 51 7 Pot Low B Pin5 Pot High Curtis PMC 1207 1207A Manual 12 2 INSTALLATION amp WIRING 1207 Controller 3 Wire Potentiometer 5000 10 Throttle A 3 wire potentiometer with a total resistance value anywhere between 500Q and 10kQ 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 s
90. ou are using a programmer put it into the diagnostic mode by pressing the DIAGNOSTICS key The display should indicate No Faults 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 con tinue 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 Curtis PMC 1207 1207A Manual 17 2 INSTALLATION amp 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 con tactors 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 programm
91. ource to the potentiometer and Pot Low provides the return path Fig 9 Wiring for 3 wire JWIREBGT potentiometer throttle ON OFF Type 2 16 15 14 13 11 10 9 8 7 6 5 4 3 2 1 Pin7 Pot Low Pin6 0 5 Input Pin5 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 shuts down NOTE The Pot Low pin Pin 7 must not be tied to ground Curtis PMC 1207 1207A Manual 13 2 INSTALLATION amp 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 B4 ET XXX electronic throttle 2 KEYSWITCH ET XXX 16 KSI Input Pin12 Forward il Pini Reverse WHT BRN 7 5 Pin7 Low 2E 7 Pine 0 5 Input 1 1 B GREEN i i ORANGE BLACK ae BLACK WHITE b WHITE re There is no fault detection built into the and the controller will detect o
92. perating modes thus allowing optimization of vehicle characteristics for different driving condi tions V Emergency reverse belly button switch with a single input lt Ramp start feature provides full power for starting on ramps V Simple contactor and switch wiring with coil drivers monitored for faults thus ensuring fail safe operation V Flexible throttle circuitry accommodates a variety of throttle types V Programmable ramp shape static throttle map provides flexibility in selecting throttle response feel V Connections made by solid copper power busses with a polarized Molex connector for control signals V Solid well protected construction with an aluminum mounting plate and injection molded cover 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 2 2 INSTALLATION amp WIRING 1207 Controller INSTALLATION AND WIRING 1207 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
93. r will only get a reading when connected to batteries should be approximately 28 volts Bad batteries Load test batteries Unit will not go forward reverse Broken wire or loose connection Locate Pin 2 on Molex connector at works belly switch just kills unit motor controller Trace wiring to does not go forward and time contactor and verify connection out Contactor bad motor controller bad When forward is depressed there should be 24 volts on this wire from Molex connector to the contactor if not the motor controller may be bad consult diagnostics page factory If 24 volts is present at contactor verify ground connection If ground is good remove both wires and check with ohm meter resistance should be approximately 38 ohms If it s open or zero the contactor should be replaced Unit will not go reverse belly Broken wire or loose connection Same as above except locate Pin 3 switch works i e when the contactor bad motor controller on Molex connector on motor handle is in operating range and bad controller and follow procedure rotating throttle in reverse and the belly switch is hit the unit moves forward and times out VESTIL Mra Co 1 04 26 07 Problem Possible cause s Unit will not go forward or reverse but belly switch still functions properly Broken wire or loose connection bad motor controller Throttle assembly bad Unit will not move fo
94. re 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 1 5 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 Filename Changing Charger in EPT VESTIL MFG CO 4 17 07 TG Model EPT XXXX 3
95. reases the resistance between Pins 7 and 8 which increases the controller output The throttle Fig 6 Wiring for 20kQ potentiometer used as a 20 kQ POT wiguag style throttle LANAANAA 16 J 15 14 13 J 12 J 11 10 9 17 A FASTER FASTER 8 7 gt PIN KEY 1207 Pin8 5kQ 0 Pin7 Pot Low Curtis PMC 1207 1207A Manual 10 47 2 INSTALLATION amp 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 5k 2 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 generated and the controller is disabled Nore 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 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 10 input Pin 9 Zero speed corresponds to OV and full speed corre sponds to either 5V or 10V measured relative to B Po
96. rent 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 1kg 2 5 Ibs 122 165 60 4 8 x 6 5 x 2 35 2 Output current rating test conditions 1 Controller cover installed Controller mounted to 230 x 305 x 3 2 mm 9 x 12 x 0 125 aluminum plate heatsink Airflow at 4 8 km h 3 mph perpendicular to bottom of aluminum plate Duty factor held at 6096 Initial heatsink temperature at 20 C Ambient temperature at 20 C Current held at tested rating for 120 of time before thermal cutback NOOB WP Curtis PMC 1207 1207A Manual B 1 APPENDIX B SPECIFICATIONS Table 2 SPECIFICATIONS 1207A CONTROLLERS Nominal input voltage 24V Maximum operating voltage 30V Overvoltage point 33V Minimum operating voltage Electrical isolation to heatsink PWM operating frequency Output current Contactor voltage Contactor current maximum Contactor coil spike protection Shunt driver current maximum Shunt driver spike protection KSI input voltage KSI input current typical Logic input current typical Logic input threshold
97. rward or Blown fuse reverse and the Belly switch will not function unit does turn on as indicated by the battery gage lighting up Broken wire or loose connection Unit will not go forward the belly switch functions reverse works Broken wire or loose connection bad motor controller Bad throttle assembly VESTIL MFG Co 15 126 013 Action Locate Pin 6 on Molex connector at the motor controller Try to drive the unit in forward there should be 0 to 5 volts 5 v is full throttle at this pin If there is voltage and the unit does not move the motor controller may be bad consult diagnostics page factory If there is no voltage trace the wiring back towards the tiller head and check voltage on each side of connectors Continue this until bad connection is found If the connections are all good and there is no voltage coming out of throttle assembly then the throttle assembly may be bad Verify there is 24 volts going into the assembly and that there is a good ground If there is still no output voltage for pin 6 replace throttle assembly See Fig 1 Verify fuses are good replace if blown Locate Pin 7 on Molex connector at the motor controller Trace wire back up to tiller head and verify continuity all the way to the throttle assembly Repair any loose connections If there is continuity up to the throttle assembly then check the ground wire that comes off of B on the motor controller 3
98. s 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 oo 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 CODES LED CODE EXPLANATION LED off no power or defective controller solid on defective controller single flash 9 controller operational no faults 1 22 nu hardware fail safe error 13 ooo fault or motor output short 1 4 ooon sequencing fault SRO 2 1 oo n 5k 2 0 or throttle wiper input fault 2 2 oo oo emerg rev circuit check fault BB wiring 2 9 oo ooo high pedal disable fault HPD 2 4 oo nun throttle pot low open or shorted to B or B Pl ooo contactor or shunt driver overcurrent 3 2 ooo nu welded direction contactor 3 3 ooo ooo reserved for future use 3 4 ooo ooo missing contactor or shunt 4 1 ooon low battery voltage 4 2 overvoltage 4 3 aooo nnn thermal cutback 4 4 ooo reserved for future
99. 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 KEYSWITCH MODE FORWARD Tec OUTPUT EMERGENCY BRAKE REVERSE REVERSE POT FORWARD LOW CONTACTOR SRUNI 2 WIRE POT REVERSE 5 kQ CONTACTOR The throttle shown in Figure 4 is a 5kQ 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 25 SSS 2A INSTALLATION amp 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 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 5kQ 0 Throttle Type 1 The 5kQ 0 throttle called a 1 throttle in the programming menu of the handheld programmer is a 2 wire resistive throttle that connects between the Fig 5a Wiring for
100. splay Press the appropriate cance value key or down 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 program mer 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 key If the limit is related to another parameter that information 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 Use of the programmer is described more fully in Section 6 f 5 1207 single mode controllers only If a programmer is connected when a parameter is adjusted mechani cally see next page the effect of the change can be seen in the programmer display To adjust one of these five parameters with the programmer its potentiometer must be set to the OFF position on the adjustment panel If you attempt to use the programmer to adjust a parameter whose potentiometer is not set to the OFF position its value will not change You will also note that the LEDs in the corners of both the chance value keys do not light up another
101. ss 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 Key Switch Input provides power to the logic board and initializes and starts diagnostics In combination with the brake input KSI enables all logic functions Some vehicles may have no keyswitch KSI simply tied to B or may have 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 NOTE In 1207 models the Status LED is on the adjustment panel under the sliding protective cover Curtis PMC 1207 1207A Manual A 5 APPENDIX A GLOSSARY MOSFET A MOSFET Metal Oxide Semiconductor Field Effect Transistor is a type of transistor characterized by its fast
102. t just as when the programmer is in Diagnostics 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 key for instructions Clearing the diagnostic history file also resets the maximum minimum temperatures in the Test Menu Curtis PMC 1207 1207A Manual 44 4 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 the key while the programmer is powering up Durin
103. t 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 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 Fig 7 Wiring for 0 5V throttle Type 2 a 0 5V throttle sensor aa Ill M M SENSOR SENSOR OUTPUT Pin7 Pot Low SENSOR GROUND 6 0 5V Input b Ground referenced 0 5V throttle 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 7 Pot Low 4 7 KQ Pine 0 5 Input N B Pin5 Pot High Curtis PMC 1207 1207A Manual 11 2 INSTALLATION amp 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 5 throttle input 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 thr
104. t wire is connected to Pin 10 as shown by the dashed lines in the two basic wiring diagrams Figures 3A and 44 Alternatively a 9 1kQ resistor can be wired directly across the emergency reverse switch to provide the dc bias as shown by the dashed line in Figure 10a Curtis PMC 1207 1207A Manual 29 2A INSTALLATION amp 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 250Q 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
105. tem 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 Diagnostics mode accessed by pressing the key currently active faults detected by the controller are displayed The MORE INFO key when used in the Diagnostics mode causes additional information to be displayed about the selected item A list of the abbreviations used in the Diagnostics display is included at the end of this section The Special Program mode allows you to perform a variety of tasks most of which are self explanatory Through the Special Program Menu you can revert to earlier settings save controller settings into the programmer memory load the 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 To access the Special Program mode first press the MORE INFO key Then while continuing to hold the key press the key The LED on the key will light just as when the programmer is in Program mode Curtis PMC 1207 1207A Manual 43 6 PROGRAMMER OPERATION To distinguish between the Program and Special Program modes look at the menu items in the display G CONTROLLER CLONING Two of the Sp
106. the brake and apply the throttle The vehicle should now operate normally d 7 the vehicle off the blocks and drive it in a clear area It should have smooth acceleration and good top speed 8 Testthe 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 disconnect ing one of the emergency reverse wires The vehicle should be disabled and a fault indicated Curtis PMC 1207 1207A Manual 32 3 ADJUSTMENT OF PARAMETERS ADJUSTMENT OF PARAMETERS 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 me chanically by means of the built in screwdriver adjustable potentiometers ADJUSTMENT VIA THE PROGRAMMER To change a parameter using the programmer press the key and scroll down the Program Menu until the desired parameter is the top line of the di
107. ting the battery with 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 1 5 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 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 ele
108. tions to the bus bars are tight Use two well insulated wrenches for this task in order to avoid stressing the bus bars DIAGNOSTIC HISTORY The handheld programmer can be used to access the controller s diagnostic history file Connect the programmer press the INFO key and then while Curtis PMC 1207 1207A Manual 35 4 MAINTENANCE continuing to hold the key press the key The program mer 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 mro 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 ro again The programmer will prompt yo
109. to close the protective sliding cover Curtis PMC 1207 1207A Manual 18 2A INSTALLATION amp WIRING 1207A Controller INSTALLATION AND WIRING 1207A A 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 Fig 24 Mounting dimensions 165 6 50 Curtis PMC 1207A p 127 6 00 22 0 85 controller W 28 1 1 Status LED CE 122 b 4 80 66 2 6 6 7 0 265 dia 3 plcs lt 152 6 00 gt k 6 3 0 25 21x 16x 1 5 0 83 x 0 63 x 0 06 8 4 0 33 dia hole thru 66 2 60 4 8 0 19 NE Dimensions in millimeters and inches Curtis PMC 1207 1207A Manual 19 2A INSTALLATION amp 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 control ler provides the low power logic co
110. ttery feed These devices are both shown in the wiring diagrams Curtis PMC 1207 1207A Manual 16 M S 3 2 INSTALLATION amp WIRING 1207 Controller 1207 INSTALLATION CHECKOUT Before operating the vehicle carefully complete the following checkout proce dure 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 ie Put the vehicle up on blocks to get the drive wheel s off CAUTION 55 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 2 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 y
111. u to acknowledge or cancel See Section 6 of this manual for more detail on program mer 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 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 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 Curtis PMC 1207 1207A Manual 36 5 DIAGNOSTICS amp TROUBLESHOOTING DIAGNOSTICS AND TROUBLESHOOTING The 1207 1207A controllers provide diagnostics information to assist techni cians 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 Statu
112. urtis PMC 1207 controller 2 3 FIG 3 Standard wiring diagram series motors Curtis PMC 1207 controller 2 6 FIG 4 Compound motor wiring diagram Curtis PMC 1207 0 8 FIG 5 Wiring for 5k 2 0 throttle 1207 controller 10 FIG 6 Wiring for 20kQ potentiometer used as a wigwag style throttle 1207 controller 10 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 5 throttle 1207 controller 15 FIG 2A Mounting dimensions Curtis PMC 1207A controller see 19 FIG Standard wiring diagram series motors Curtis PMC 1207A controller 21 FIG 44 Compound motor wiring diagram Curtis PMC 1207A controller 24 FIG 5a Wiring for 5kQ 0 throttle 1207A controller 26 Curtis PMC 1207 1207A Manual V FIGURES TABLES Wiring for 20kQ 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 c
113. vent 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 including recovery from disable Almost all faults require a cycling of the KSI or brake input to reset the controller and enable operation 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 Curtis PMC 1207 1207A Manual A 4 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 immedi ately 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 re gained by reducing the throttle demand to le
114. w 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 5kQ 0 Throttle Type 1 The 5kQ 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 5kQ 0 0 5kQ 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 5kQ measured between the two pins and full speed corresponds to 09 Fig 5 Wiring for 560 0 throttle Type 1 5 16 13 J 12 11 10 9 A s 7 gt FASTER PIN KEY 1207 in8 5kQ 0 in7 Pot Low In addition to accommodating the basic 5k 2 0 throttle the Type 1 throttle is the easiest with which to implement a wigwag style throttle Using a 20kQ potentiometer wired as shown in Figure 6 the pot wiper can be set such that the controller has 5kQ 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 dec

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