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Curtis PMC 1209B/1221B/1221C/1231C Manual

27

TROUBLESHOOTING & BENCH TESTING

TROUBLESHOOTING

AND BENCH TESTING

Some behaviors that may seem to suggest controller malfunction do not, in fact,
indicate a problem but rather are typical of normal operation. Before undertaking the
diagnostic tests, check to see whether your problem is addressed in the first section,
“Operational Notes.”

The diagnostic tests are designed to enable you to determine whether the trouble

is in the controller or in some other part of the motor control circuitry.

The controllers

themselves are sealed and not field serviceable; contact your local dealer or
Curtis office if the problem is in the controller.

The diagnostic section provides

enough detail to enable you to track circuitry problems to their source and repair them.

Finally, the bench tests will allow you to confirm controller operation in a simple,

low-power test configuration. Bench testing is primarily intended for checking out a
number of controllers on a regular basis.

OPERATIONAL NOTES

Noise

Controller operation is normally silent, with three exceptions: (1) A 1 kHz tone
may be heard during plug braking. This noise is normal and indicates that
plugging is taking place. The noise will stop when plug braking stops. (2) The
same noise may indicate overtemperature. The controller shifts frequency during
overtemperature from its normal 15 kHz to 1 kHz (1.5 kHz on

“

C

”

controllers),

providing an audible tone to alert the operator to the overtemperature condition.
(3) The frequency shifting feature on

“

C

”

controllers produces a 1.5 kHz tone

during the

fi

rst 15% duty cycle of the PWM output. This tone may be heard

during low throttle, slow speed maneuvering.

Inability of Material Handling Vehicle to Plug Brake to a Stop on a Steep Ramp

If a material handling vehicle is rolling backwards down a steep ramp in reverse
and the throttle is applied demanding forward drive, the controller will attempt
to plug the vehicle to a stop. If the ramp is so steep that the plugging current
setpoint is insuf

fi

cient to stop the vehicle, it will continue to be braked but will

nevertheless roll down the ramp. If the mechanical brakes are applied, and the
vehicle is stopped, the full drive current will be available when the throttle is
applied and the vehicle will proceed up the ramp.

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Summary of Contents for PMC 1200 Series

Page 1: ...S PMC 1200 SERIES CONTROLLERS PROTECTED BY U S PATENT NO 4626750 MOTOR CONTROLLERS 1209B 1221B 1221C 1231C Manual p n 98827 Rev D August 1999 MANUAL CURTIS PMC 235 East Airway Boulevard Livermore California 94568 USA Tel 925 961 1088 Fax 925 961 1099 www curtisinst com ...

Page 2: ...ctronic version of the manual is identical to the printed version published in August 1999 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 FAX 914 666 2188 CURTIS PMC 235 EAST AIRWAY BOULEVARD LIVERMORE CALIFORNIA 94550 USA 925 961 1088...

Page 3: ...901 12345678901 12345678901 12345678901 12345678901 12345678901 12345678901 12345678901 12345678901 12345678901 12345678901 12345678901 12345678901 12345678901 12345678901 12345678901 12345678901 12345678901 12345678901 12345678901 12345678901 12345678901 12345678901 12345678901 12345678901 12345678901 12345678901 12345678901 12345678901 12345678901 12345678901 12345678901 12345678901 12345678901 ...

Page 4: ...1234567890 1234567890 1234567890 1234567890 1234567890 1234567890 1234567890 1234567890 1234567890 1234567890 1234567890 1234567890 1234567890 1234567890 1234567890 1234567890 1234567890 1234567890 1234567890 1234567890 1234567890 1234567890 1234567890 1234567890 1234567890 4 MAINTENANCE AND ADJUSTMENT 24 Controller 24 Potbox 25 5 TROUBLESHOOTING AND BENCH TESTING 27 Operational Notes 27 In Vehicl...

Page 5: ...FIG 6 Mounting dimensions Curtis electronic throttle ET series 7 FIG 7 Typical installation 1209B 1221B 1221C controllers 8 FIG 8 Typical installation 1231C controller 9 FIG 9 Basic wiring configuration 1209B 1221B 1221C controllers 14 FIG 10 Basic wiring configuration 1231C controller 15 FIG 11 Control wiring for inhibiting plug braking in order to allow freewheeling 17 FIG 12 Standard throttle p...

Page 6: ...0 5kΩ pot 20 FIG 16 Throttle ramp shapes 21 FIG 17 Adjustment pots 25 FIG 18 Guide to troubleshooting procedures 29 FIG 19 Setup for bench testing 35 FIG A 1 Block diagram Curtis PMC 1209B 1221B 1221C 1231C controllers A 1 FIG B 1 Pulse width modulation B 1 TABLES TABLE 1 Recommended precharge resistors 10 TABLE C 1 Electrical specifications 1209B 1221B C 1 TABLE C 2 Electrical specifications 1221...

Page 7: ...tor control of the vehicle s motor drive speed Key features of these controllers include Infinitely variable drive and brake control Power MOSFET design provides high efficiency for reduced motor and battery losses and silent operation High pedal disable HPD function monitors throttle status during turn on and prevents operation until throttle has been returned to neutral optional feature Thermal ...

Page 8: ... LEAD ACID BATTERIES Charging or discharging generates hydrogen gas which can build up in and around the batteries Follow the battery manufacturer s safety recommendations Wear safety glasses Undervoltage cutback function protects against low battery voltage includ ing low voltage caused by external loads Throttle pot fault circuitry shuts off the motor in the event of an open circuit fault in the...

Page 9: ...astened with four screws to a clean flat metal surface that provides an adequate heat sink The mounting surface is an integral part of the overall heatsinking of the controller and affects its ability to dissipate heat The case outline and mounting dimensions are shown in Figure 2 2 Fig 2 Mounting dimensions Curtis PMC 1209B 1221B 1221C controllers 6 0 25 male push on 2 plcs 7 0 28 dia 15 0 60 MOD...

Page 10: ...ace 1231C The controller should be fastened to a clean flat metal surface that provides an adequate heat sink The mounting surface is an integral part of the overall heatsinking of the controller and affects its ability to dissipate heat B O P T I O N A L H E A T S I N K B A S E B A2 M Dimensions in millimeters and inches 175 6 9 173 6 8 220 8 6 Mounting Clamp 6 supplied 94 3 7 Mounting Clamp 1 4 ...

Page 11: ...rtis office If a Curtis PMC potbox is used it must be mounted so as to allow connection between the potbox lever arm and the vehicle accelerator linkage The lever arm provides a series of holes so that the accelerator pedal throw can be converted into the correct amount of potentiometer rotation Use of a second return spring on the pedal in addition to the potbox return spring is required to preve...

Page 12: ...ON COM N O N C N C N O COM WITH MICROSWITCH PB 6 WITHOUT MICROSWITCH PB 5 WITH MICROSWITCH PB 9 WITHOUT MICROSWITCH PB 10 42 1 65 52 2 06 Fig 5 Curtis PMC footpedal FP 2 Dimensions in millimeters and inches 15 244 9 6 112 4 4 112 4 4 1 8 m 6 ft WIRING BLACK throttle input BLUE switch common Note The green wire is not used with WHITE throttle input ORANGE switch normally open 1209B 1221B 1221C 1231...

Page 13: ...erenced to B and must be capable of driving an input impedance of 5kΩ Curtis offers two bi directional wigwag electronic throttle assemblies de signed for use with the 0 5V input the ET series and the CH series They require a 24 36V supply voltage The ET XXX throttle assembly provides a 0 5V output and forward reverse relay coil drivers Dimensions for the ET series throttles are shown in Figure 6 ...

Page 14: ...your local dealer or Curtis office OTHER HARDWARE The recommended hardware for a typical 1209B 1221B or 1221C controller installation is shown in Figure 7 and for a 1231C installation in Figure 8 CONTROL WIRING FUSE POWER WIRING FUSE POLARITY PROTECTION DIODE KEYSWITCH POTBOX FORWARD REVERSE SWITCH SPDT center off F R FORWARD REVERSE CHANGEOVER CONTACTOR Albright SW202 shown MAIN CONTACTOR Albrigh...

Page 15: ...and the coil suppression diodes connected to the forward reverse contactors in B applications are somewhat delicate components Care should be taken to prevent damaging them during installation HARDWARE INSTALLATION CONTROL WIRING FUSE POWER WIRING FUSE KEYSWITCH POTBOX MAIN CONTACTOR Albright SW200 shown TRACTION BATTERY B B PRECHARGE RESISTOR see Table 1 page 10 for recommended size COIL SUPPRESS...

Page 16: ...nternal filter capacitors causes a high inrush current to flow briefly when the contactor closes To extend contact life a precharge resistor is recommended the resistor precharges the capacitors and reduces the inrush current through the contacts If an inexpensive can type solenoid is used the resistor is mandatory to prevent contact welding The recommended precharge resistance values and power ra...

Page 17: ...to wire it for freewheeling the best switch to use is a double pole double throw DPDT hesitation switch a toggle switch with a mechanism that forces it to stop in the center neutral position before going into the opposite direction If a standard switch is moved quickly from one direction to the other it may not be in neutral long enough to actuate HPD and the motor will plug brake instead of freew...

Page 18: ...ld be added to the control circuit This diode must be sized appropriately for the maximum total contactor coil currents Control Wiring Fuse To protect the control circuitry from accidental shorts a small fuse typically 10 amps connected in series with the B feed to the control circuitry wiring is recommended Power Wiring Fuse To protect the power wiring circuit a fuse appropriate for the controlle...

Page 19: ...or The cables used for the battery and motor connections must be heavy enough to carry the high current required Rubber insulated welding cable is convenient to work with because of its flexibility Connections to the controller bus bars should be made with lugs suitable for the cable used fastened by M8 5 16 bolts and nuts When tightening the bolts two opposing wrenches should be used Failure to u...

Page 20: ...le applied Reversing is accomplished via a forward reverse changeover contactor or two single pole double throw 2 SPDT contactors Coil suppression diodes should be used on the main and forward reverse contactors WIRING Fig 9 Basic wiring configuration Curtis PMC 1209B 1221B 1221C controllers A2 M B B FORWARD REVERSE MAIN F R S2 A2 S1 A1 F R F R POTBOX MAIN KEYSWITCH INTERLOCKS THROTTLE MICROSWITCH...

Page 21: ...e controller KSI is used to turn the controller on and off KSI is turned on by connecting it to battery B Any positive voltage greater than about 8 volts will turn on the controller but usually the full vehicle battery voltage is used In its simplest form KSI is operated by a keyswitch that turns the vehicle off and prevents unauthorized use The keyswitch should also turn off the main contactor an...

Page 22: ...ct the direction desired The contactor coils should have suppression diodes con nected across them to improve switch contact life This is the recommended wiring for controllers with the HPD option in applications where plug braking is desired If your controller does not have the HPD option however we recommend that you use the alternate wiring shown in Figure 11 and described below instead of the ...

Page 23: ...the potbox footpedal cable to the two push on terminals of the controller as shown in Figures 9 and 10 It doesn t matter which wire goes on which terminal The wires can be extended as required IMPORTANT All vehicles should have throttle actuated microswitches to protect against runaways in the event the forward reverse switch becomes stuck in either direction If your potbox doesn t have such a mic...

Page 24: ...sm can be designed to make a standard pot turn in the same direction regardless of which direction the twist grip is turned A third method of accommodating bi directional twist grip throttles uses a standard potentiometer and a controller with a nonstandard throttle input As shown in Figure 13 a standard 20 kΩ pot is used with its end terminals wired together The resistance goes from 5 kΩ at neutr...

Page 25: ...Figure 14 It requires a 24 36V supply voltage and a controller with the optional 0 5V throttle input Fig 14 Curtis electronic throttle ET series with a controller having the optional 0 5V throttle input A2 M B B FORWARD REVERSE MAIN KEYSWITCH INTERLOCKS FUSE POLARITY PROTECTION DIODE GREEN ORANGE BLACK BLACK WHITE WHITE WHT BRN WHT GRN ...

Page 26: ...orized personnel to run the vehicle outdoors at full speed The speed reduction shown in the curve is approximate The actual vehicle top speed will depend on the motor characteristics and the vehicle load You should determine by experiment the proper resistor value to give the desired speed reduction NOTE With reduced speed operation only top speed is reduced full power is maintained for starting a...

Page 27: ...PWM output response relative to the throttle position The more ramp shaping the throttle circuitry has the more control the operator has over low speed Therefore there is a smaller change in output duty cycle relative to a specific amount of change in throttle output An example set of throttle ramp shaping responses is shown in Figure 16 The various ramp shaping options shown in the figure are not...

Page 28: ...ssume that your system has the recommended precharge resistor in parallel with the main contactor C If A and B do not check out troubleshoot the wiring connections Do not proceed until the trouble is corrected and A and B check out D With the forward reverse switch in neutral turn on the keyswitch If the motor runs without the throttle being applied turn the keyswitch off and recheck the wiring If...

Page 29: ...top speed H On vehicles that are intended to plug brake test the plug braking by driving forward at moderate speed and shifting into reverse without letting up on the throttle The vehicle should smoothly brake to a stop and accelerate in reverse I On vehicles that are intended to have plug braking inhibited verify that the maneuver in H produces freewheel coasting ...

Page 30: ...ill help avoid putting stress on the bus bars which could crack the seals Always use insulated wrenches 2 Inspect all seals at the front and back of the controller If necessary use a moist rag to wipe these areas clean enough so that you can see the seals Look for cracks and other signs of seal damage If the seals are intact clean the controller thoroughly either by washing it off or by wiping it ...

Page 31: ...ntroller maintenance inspect for integrity of connections and mounting and clean with a moist rag as required Adjustment Curtis PMC potboxes are factory set and rarely require user attention To test and adjust connect an ohmmeter to the potbox wires and use this procedure 1 With the spring holding the lever arm against the return stop the resistance should be less than 50 ohms Slowly move the leve...

Page 32: ...sturb the adjustment Make sure that the lever is still seated down on the pot shaft below the slight bevel on the end of the shaft 3 Check the resistance with the lever pushed all the way to the other stop It should be between 4500 and 5500 ohms If it is outside this range the potbox is faulty and should be replaced 4 For potboxes equipped with a microswitch check for correct switch operation Use ...

Page 33: ...tion is normally silent with three exceptions 1 A 1 kHz tone may be heard during plug braking This noise is normal and indicates that plugging is taking place The noise will stop when plug braking stops 2 The same noise may indicate overtemperature The controller shifts frequency during overtemperature from its normal 15 kHz to 1 kHz 1 5 kHz on C controllers providing an audible tone to alert the ...

Page 34: ... problem Curtis PMC 1209B 1221B and 1221C controllers protect themselves by reducing power to the motor if their internal temperature exceeds 75 C 167 F The 1231C controller begins reducing power at 85 C 185 F Power output will be reduced for as long as the overheat condition remains and full power will return when the unit cools In typical applications overheating will rarely be a problem However...

Page 35: ...50 ohms with pedal UP and 4500 5500 ohms with pedal DOWN Check for shorts between potbox wires and vehicle frame Resistance should be at least 1 megohm Check voltage at upper throttle input terminal on controller Voltage should be 2 7 volts with pedal UP and 7 0 volts with pedal DOWN a few tenths of a volt if YES if YES TEST 4 Check for controller output if YES 4 A B C if NO if NO if NO Check volt...

Page 36: ...these check out the controller is malfunctioning If you see full battery voltage at this point then the contactor has welded and must be replaced TEST 2 Check for main contactor operation and KSI 2 A Turn the key on place the forward reverse switch in forward or reverse and apply the throttle until its microswitch operates In these procedures we assume the throttle is equipped with the recommended...

Page 37: ...at 0 full off 5 kΩ full on and also to 5kΩ 0 configurations If your installation uses a controller with a throttle input other than 0 5kΩ or 5kΩ 0 find out what its range is and use a procedure comparable to the one below to make sure your throttle is working correctly 3 A With the keyswitch off pull off the connectors going to the throttle input of the controller Connect an ohmmeter to the two wi...

Page 38: ...ltage at the appropriate throttle input terminal the upper terminal for 0 5kΩ pots the lower terminal for 5kΩ 0 pots by connecting the voltmeter lead to the controller s B terminal The keyswitch must be on and a direction selected for this test THROTTLE INPUT VOLTAGE in volts STANDARD 0 5kΩ POT 5kΩ 0 POT UPPER TERMINAL LOWER TERMINAL Zero throttle 2 7 3 1 Full throttle 7 0 7 4 Compare your reading...

Page 39: ...ble at auto parts stores and their accuracy is adequate for this test 4 E Turn on the keyswitch with the forward reverse switch in neutral and then select a direction and watch the ammeter while applying the throttle 4 F If you see no current flowing in the M lead the problem is an open circuit in the motor or the wiring between the motor and the controller Check the forward reverse switch If your...

Page 40: ...r testing these controllers on the bench You will need a POWER SUPPLY with a voltage equal to the rating of the controller you want to test You can use either a string of batteries or a regulated line operated power supply Because only low power tests will be described a 10 amp fuse should be wired in series with the batteries to protect both operator and controller against accidental shorts A bat...

Page 41: ... controller s throttle output TEST LOAD to match battery voltage MAIN CONTACTOR POWER SWITCH KEYSWITCH 10A FUSE 12V 12V 12V 5W 250Ω RESISTOR a TEST LOAD consisting of incandescent light bulbs wired in series to get the same voltage as your power supply For example with a 36 volt battery use three 12 volt bulbs a general purpose VOLT OHMMETER or DIGITAL VOLT METER ...

Page 42: ...lamps should increase in brightness D If the controller has HPD test this feature as follows 1 Turn off the keyswitch 2 Move the potbox lever to about halfway 3 Turn the keyswitch switch on Verify that the lamps do not come on until the potbox lever is moved most of the way toward OFF and then moved back up E Test the controller s throttle fault protection feature by pulling off one of the potbox ...

Page 43: ...y and service life are improved 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 The maximum motor current can be factory set to a lower value than the standard maximum if requested In addition the current limit is field adjustable see Section 4 for adjustme...

Page 44: ...IONAL FEATURE By preventing the vehicle from being turned on with the throttle applied HPD ensures the vehicle starts smoothly and safely If the operator attempts to start the vehicle when the throttle is already applied the controller and the vehicle will remain off For the vehicle to start the controller must receive an input to KSI before receiving a throttle input In addition to providing rout...

Page 45: ...t to meet customer requirements In addition the plug current limit is adjustable via an externally accessible trimpot see Section 4 for adjustment instructions Two types of plug braking control are available variable and fixed Variable plug braking allows the amount of plug braking to be adjusted via the throttle When direction is reversed the plug braking current increases as a function of the th...

Page 46: ...n normal operation Overheating can occur however if the controller is undersized for its application or otherwise overloaded If the internal temperature of the 1209B 1221B and 1221C controllers exceeds 75 C 167 F the main and plug current limits decrease steadily until they are reduced to zero at 95 C 200 F Thermal cutback for the 1231C controller begins at 85 C 185 F At the reduced performance le...

Page 47: ...t of an open circuit fault in the throttle or its wiring The standard configuration is a two wire pot ranging from 0 ohms for full off to 5000 ohms for full on if the controller detects an abnormally high throttle input more than about 1 5 times the normal input resistance it shuts off its output to the motor thus preventing a runaway The controller returns to normal operation when the fault e g b...

Page 48: ...rrent filtering and voltage spike suppression The plug diode provides a path for armature current to flow during plug braking Fig A 1 Block diagram Curtis PMC 1209B 1221B 1221C 1231C controllers 14V REGULATOR UNDER VOLTAGE DETECT SWITCH PLUG DIODE PLUG DETECT PULSE WIDTH MODULATOR CURRENT LIMIT COMPARATORS CURRENT LIMIT REFERENCE CURRENT LIMIT DISABLE SHUT DOWN GATE DRIVE LIMIT INTEGRATOR ACCELERA...

Page 49: ...sponse of this circuit gives a stable limiting action The throttle output from the limit integrator is also fed to the oscillator to determine the operating frequency On C models the controller operates at 1 5 kHz for throttle requests less than 15 output and at 15 kHz for throttle requests greater than 15 output The undervoltage detector gives an output when the battery voltage is too low The red...

Page 50: ...xed plug option provides one level of plug braking current independent of throttle position provided it is at least minimally applied For the fixed plugging option the plug current limit reference is derived from the current limit reference 5 The variable plug option provides variable plug braking current corresponding to the position of the throttle This allows much smoother braking under control...

Page 51: ...tor builds up storing energy in the motor s magnetic field When the transistors are off the stored energy causes the motor current to continue to flow through the freewheel diode The control current ramps up and down as the switch turns on and off Average current which determines motor torque is controlled by the ratio of on off times Smooth stepless control of the power delivered to the motor is ...

Page 52: ...hers available NOMINAL VOLTAGE UNDER BATTERY CURRENT 2 MIN 5 MIN 1 HOUR DROP VOLTAGE MODEL VOLTAGE LIMIT RATING RATING RATING 100 AMPS CUTBACK NUMBER volts amps amps amps amps volts volts 1209B 46XX 24 36 500 500 350 225 0 15 16 55XX 36 48 450 450 300 200 0 30 21 64XX 48 72 400 400 275 175 0 30 30 6A5XX 48 80 450 450 300 200 0 25 33 72XX 72 120 275 275 175 100 0 70 45 1221B 48XX 24 36 600 600 425 ...

Page 53: ... to 1 5 maximum battery voltage STANDBY CURRENT less than 30 mA STANDARD THROTTLE INPUT 0 5kΩ 10 others available NOMINAL VOLTAGE UNDER BATTERY CURRENT 2 MIN 5 MIN 1 HOUR DROP VOLTAGE MODEL VOLTAGE LIMIT RATING RATING RATING 100 AMPS CUTBACK NUMBER volts amps amps amps amps volts volts 1221C 74XX 72 120 400 400 250 150 0 50 43 1231C 77XX 72 120 550 550 375 225 0 30 43 86XX 96 144 500 500 375 225 0...

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