The Curtis 933/3 “fuel” gage Electric Fork Lift Truck "Fuel“ Gage and Battery Controller Your truck has just been equipped with the finest “fuel” gage on the mar- ket. Curtis “fuel” gages were used by the astronauts on the Lunar Rover, on three separate tours of the moon. For the first time you'll know exactly the stateof-charge of your battery. You'll be able to use your judgment instead of guessing and taking chances, One of the features of the Curtis 933/3 is that lft lock-out is no longer on a blind timer. It is under your control. After the warning light goes on. you're on ENERGY RESERVE. You're not racing time, you can decide exact ly what you're going to do and when you are going to do it It’s only after you've actually used up the reserve that lock-out will occur to protect the truck. (Lock-out will occur when indicator enters red ball.) Drivers tell us that the Curtis “fuel” gage has helped them do a better job. and helped make their work easier and more efficient. This section will give you some idea how the 933/3 works and what it does. We welcome your comments and suggestions. This installation manual covers only the standard 933/3 “Fuel” Gage and Battery Controller. A variety of adjustment features and options are available, enabling adaptability to virtually any application. (I"FUEL” GAGE: Displays the battery's state-of-charge providing the oper- ator and supervisor with information on which to base their operations decisions. Uses a needle to indicate state-of-charge all the way from full to empty, which are represented by the internationallytecognized green si nal for full/go and red signal for empty/stop. Ci Reserve Warning Light: Indicates to driver that the “energy reserve” point has been reached - approximately 5% battery capacity is available prior to the Itt being inhibited. The need for a battery change is signalled at the optimum point in the discharge cycle to maximize battery life and reduce main:enance and energy costs. 1 Lift Lockout: Prevents damage to battery and truck due to the di charging of the battery beyond its “energy reserve". Lockout in the CU TIS 933/3 is achieved by use of Silicon Controlled Rectifier (SCR) - no interruption of lift while in operation, therefore reduced chance of welded contacts from breaking high pump motor currents. D Adjustable Luchuut Puint, Favtury set for full scale termination at 20% depth of discharge, with a useradjustable pot on the CURTIS 933/3 Controller for higher and lower termination points to suit special cond tions, e.g., peak season overtime, temporary equipment shortage, otc 1 Automatic Reset: Tests for properly charged battery. The “fuel” gage resets only if the battery is properly charged. A pot on the CURTIS 933/3 Controller al ows the user to select a reset level within the range of from 70% charged to full to accommodate special circumstances. CMe Cena How to install it Dee ae Gare aed eee A ceThe Curtis 933/3 “FUEL” GAGE & BATTERY CONTROLLER NOTE: Certain constraints may require a deviation from the ideal installation. To be considered an acceptable installation, the voltage at terminals 1 and 8 must be within 19 of the baterry voltage at ite terminals under all operating conditions. BATTERY CONTROLLER BATTERY CONNECTOR VEHICLE’S FIRST i NEGATIVE TERMINAL (See 5B) INSTALLATION INSTRUCTIONS The CURTIS 933/3 “Fuel” Gage and Battery Controller is a rugged, precision olectronic instrument. Please fol- low these installation instructions carefully for best results, First, make sure that the CURTIS 933/3 is the comrect volt age for the truck: Le., 93/3 D24 for a 24-volt truck, D36 for a 36-volt truck, ete. 1) Unplug the battery. 2) Install the “Fue!” Gage in a location in easy view of the driver. The Gage mounts in a standard 21/16" diameter cutout and will replace most pre-existing volt- meters. 3) Select a location for the Controller. It can be mounted ‘on its side or back. The Controller is placed out of the driver's reach under the instrument panel or seat, or in ‘a cleared area of the control panel. 4) Drill two 1/4” holes, 3-3/4" apart and mount the Controller with two 1/4” bolts. 5) WIRING: Use No. 18 AWG heavy-duty wire or larger. Follow the wiring instructions carefully to prevent dam- age to the Controller's circuitry (A) Connect a wire from Terminal No. 1 on the Controller to the vehicle's first positive terminal clos- ‘est to the truck battery connector (before all switch- ‘es and fuses) For testing use Curtis 1142 Testor and 1141 FasTest Accessory. (B) Connect a wire from Terminal No. 8 on the Controller to the vehicle's first negative terminal closest to the truck battery connector (before all ‘switches and fuses) {C) Connect a wire from Terminal No. 3 on the Controller to Terminal No. 3 on the Gage. (0) Connect a wire from Terminal No. 4 on the Controller to Terminal No. 4 on the Gage. (©) Connect a wire from Terminal No. 5 on the Controller to Terminal No. 5 on the Gage. (F) Locate the lift coils negative side. Make sure it con- ects directly to battery negative. If there is a ‘switch, refer to Step (J) {G) Remove wire(s). If more than one, tie them electri- cally together and tape them. (H) Connect a wire from Terminal No. 6 on the Controller to the now vacant terminal on the lift con- tactor coil (1) Connect a jumper between Controller Terminals No. 7 & No. 8. (0) Disconnect wire(s) between the switch and battery negative. If more than one, tie them electrically together and tape them. Connect a wire from the ‘witch's vacant terminal to the Controller Terminal No. 6. Refer to Step (I). 6) Plugin a fully charged battery. The 933/3 “Fue” Gage ‘mil'teset t0 FULL A now factory unit will reset t0 full despite battery state-of charge. How to install it ECR ea ae GEC a aes Our extraordinary service policyUsing the Curtis 933/3 Controller Potentiometers (Pots) Approximately 90% of Curtis users in the field have found that the factory settings of the DISCHARGE and RESET pots on the 933/3 Controller - DISCHARGE at "N"; RESET at “B” - have been more than satisfactory in meeting typical battery power consumption patterns. cone Op However, one of the distinguishing features of the 933/3 that makes it the world’s leading instrument of its kind ate the useradjustable Controller pots, permit- ting selection of the points at which lockout occurs (DIS CHARGE) and at which the gage resets to “Fill” when a charged battery is installed on the equipment (RESET). For those special occasions that may require adjustment of the 933/3 in meeting atypical conditions (for example, the need to use a partially charged battery, or to extend the work period and discharge the battery deeper than usually, quick and simpla action can be taken, as described herein. Adjustment of the pots is done by first unscrewing by hand the outer pot protector and then turning by hand the pot with the arrow to the desired calibrated marking. The pot makes a single revolution. The arrow aids in precision setting of the pot. The alphabetic set- tings and linear markings are accurately calibrated and are precision-repeatable unit to unit. The RESET pot on all Curtis 933/3 units leaves the factory set at RESET “B”, which means the Curtis “Fuel” Gage will reset to “Full” if the voltage of a newly installed battery is above 2.09 VPC. Turning the pot clockwise from “B” to "E” increases the voltage per cell required to reset the gage. Turning it counter-clockwise toward "A” decreases the voltage per cell required to reset the gage. Example: With the new generation batteries, particularly those of the high acid type. open cir cuit voltage can be a bit higher than in lower acid batteries. in such cases, to properly align the 933/3 to the particular battery characteristics, simply adjust the RESET pot to a level above the “C* marking for reset to occur when the battery's voltage is above 2.12 VPC, the higher open ci cuit voltage. Example: In those circumstances when shutdowns cannot be tolerated because of the negative effect on productivity and it is necessary to use a partially charged battery, the gage reset level can be decreased from 2.09 VPC to as low as 2.00 VPC. Though the gage initially reads “Full” once it resets, as the equipment is used it will quickly catch up with the battery and provide a co~ rect reading of the actual state-of-charge of the partially charged battery. Keep in mind that RESET adjustments must be made prior to connecting the battery to the equipment. RESET adjustments made after battery/equipment connection have no effect. The RESET action is instantaneous. The gage will reset or not within seconds. If reset does not occur and it is necessary to readjust the pot setting, first unplug the battery and equipment, wait at least 10 seconds, adjust pot to new setting, and replug. GTC ae ed How to adjust it - 2 Our extraordinary service policyThe DISCHARGE pot on all Curtis 933/3 units leaves the factory set at DISCHARGE “N’. which means the discharge profile is set for a final end point of 1.73 VPC, where lockout will ‘occur. This profile has proven to be the most common. Turning the pot clockwise from "N’ to “P" decreases the depth of discharge and, in turn, the ‘operating time of the equipment. Turning it counter-clockwise from “N° to “K" increases the depth of the discharge and, in turn, the operating time of the equipment. Example: On occasion, equipment is required for work beyond its normally assigned work cycle and time does not permit changing of battery. In these cases, lift lockout can be delayed by increasing the depth of discharge from the standard 1.73 VPC ("N" setting) to as low as 1.56 VPC ("beyond K" setting). Example: Equipment and battery are sized for the type of work they are used for. On occasion, ‘equipment designated for heavy work might be used for light tasks. Lighter work means low- current drain which, in turn, means the recommended 80% depth of discharge lockout point will be at a higher voltage level. In these cases, to properly align the low-current work profile and the required higher lift lockout point, the DISCHARGE pot can be adjusted to the “O" (1.78 VPC) or the "P” (1.82 VPC) settings. Itis IMPORTANT to NOTE that adjustments of the DISCHARGE pot can be made at any time during a work cycle prior to lift lockout. However, DISCHARGE pot adjustments made late in a work cycle have little or no effect in delaying lift lockout in that particular work cycle. In most cases, DISCHARGE pot adjustments are made prior to or at the beginning of a work cycle to effectively change the discharge profile of that work cycle. Once lift lockout does occur, the gage must be reset before DISCHARGE pot adjustments can have an effect. TABLE OF POT SETTINGS AND ASSOCIATED VOLTAGES PER CELL DISCHARGE RESET Pp 1,82 VPC E 2.18 VPC ° 1,78 D 2,15 N (Factory set) 1.73 c 2.12 M 1,68 B (Factory set) 2,08 L 1.63 A 2,06 K 187 beyond A 2,00 beyond K 1,56 * The DISCHARGE voltage of the 933/3 is not an instantaneous voltage, nor a measure of the open circuit voltage at the time of lift lockout. Gace aa ae Our extraordinary service policysss The Extraordinary If something goes wrong with the Curtis 933/3 “Tue” gage and battery i f . controller for electric fork lft trucks, whether it's your fault or ours Curtis Service Policy whether youre covered by the guarantee or not, one phone call from you and a FACTORY SERVICE REPLACEMENT UNIT is on its way to you before you have a chance to pack and return your unit to us. If i's covered by the Guarantee, i's free. Ifnot. there isa flat nominal charge, provided your old Unit is stil repairable. Either way, we replace immediately, repair later, and Tat the paperwork catch up when i's ready i CD BATTERY BOOK ONE: Lead Acid Traction Batteries: Written and pub- Curtis Pros ducts lished by Curtis Instruments staff, Battery Book One is required reading for Mean Savings anyone working with electric fork lift trucks. 1 Model 1141 FasTest Accessory: Checks out all the functions of the 933/3 in 60 seconds when used with the 1142 Tester. 1 Model 1142 Tester: Checks out all the functions of the 933/3 on the ‘truck in 30 minutes, without vehicle operation. 1 Model 1156 Gage: LED display for 933/3 for use in cold storage and ‘work areas of limited light. ows Model 1156 Model 1141 Model 1142 Tel. (914}-666-2971 Fax (914)-666-2188 INSTRUMENTS, INC. 200 Kisco Avenue, Mt. Kisco, N.Y. 10549 GUARANTY REGISTRATION Curtis 933/3 “Fuel” Gage and Battery Controller ‘OUR GUARANTY: Curtis instruments, Inc. guarantees to the purchaser of each new Model 933/3 Fork Lift Truck “Fuel” Gage and Battery Contooller for one year from the date of installation that any defect in material or workmanship will be repaired or replaced free of charge. For the guaranty to be valid, the purchaser must register his purchase by return of the attached guaranty card. This company has no other obligation or liability in connection with the gage or controller. To obtain service, return to authorized dealer or return direct to Curtis Instruments, Inc., 200 Kisco Ave., Mt. Kisco, New York - charges prepaid CURTIS INSTRUMENTS, INC. Please record installation of Mode! 933/3. Serial No, NAME on our truck, manufactured by comANY TELEPHONE NO. Model No. Serial No. |RSS The 933/3 was purchasedon___ == | cry. —“‘“Ssé™S™S™S™*”*””OOOOO™OCOC~™ from Sate zP Oa celle re Mera Ta