IPC Gansow CT 230 BT 85 Operating manual

05/09/2011
TECHNICAL DEPT.
CT 230
T ECHNICAL S ERVICE M ANUAL
Stavale
DATE
PLDC01938
REVISION DATE
01/06/2011
IPC GANSOW - via Cartesio 39 42040 Villa Bagno RE
Tel. [phone] - Fax [phone] - [email protected]

CT230 Technical Specifications
CT230
Version BT 85 BT 105
Electrical system Voltage
Battery capacity
Running time
Battery level indicator
Low battery protection
Scrubbing head Scrubbing width 850 mm 1050 mm
Number of
brushes/microfiber
Brush diameter 435 mm 530 mm
Brush speed
Microfiber diameter
Microfiber speed
Brush head adjustment
Maximun pressure
Raising system
Transmission
Motors power 2 x 400W
2 x 500W
Productivity 5400 m²/h 6825 m²/h
Brush (standard) Material
Bristle section
Brush connection
Brush disconnection
Solution tank Capacity
Material
Filter
Water flow adjustment
Discharge hole
Recovery tank Capacity
Material
Discharge hose
Vacuum Vacuum motor power
Stage
Value in water columm
Max air flow
Motor position
Motor accessibility
Motor protection filter
Type of float
Squeegee Shape
Width 1010 mm 1280 mm
Mainbody material
Blade material
Pressure adjustment
Raising system
Blade replacement
open the recovery tank
fixed on the recovery tank - upper
Polyurethan
200 rpm
High Density Polythene
Ø 50 mm hose
gear box
standard type - nylon
0,5 mm
polyester net
Electronic float with stop vacuum
motor
956 W
2 stage
electro-mechanical actuator
two easily adjustable indipendent
electro deposition coating painted
without the use of tools
automatic - without the use of
Ø 38 mm Hose
225 litres
high density polythene
removable stainless steel cartridge
Manual or automatic adjustment +
solenoid valve
Technical Specifications
electro-mechanical actuator
electro-mechanical actuator
36 V
320 Ah 6V (C5 - 5h) x 6
Voltage level on the LCD dispay
brush stop
2 ( disk )
automatic - without the use of
205 litres
Parabolic type
5h
gr/cm² 4,50
page 1 of 2 CT230 tech ENG 5.1®.xls

CT230 Technical Specifications
Version BT 85 BT 105
Traction Traction system
Operated
Forward speed
Reverse gear speed
Speed adjustment
Maximum speed
Maximum climbing angle
Motor power
Wheels Front
Type
Diameter
Material
Rear
Type
Diameter
Material
Parking brake with signal
Steering External radius
(Wall to Wall) 3000 mm 3100 mm
Chassis Material
Thickness
Paint treatment
Dimensions Length
Width (without squeegee) 935 mm 1155 mm
Heigth
Battery box dim. Length
Width
Heigth
Weigth Without battery
(empty tanks)
350 Kg
377,5 Kg
With battery (empty tanks)
750 Kg (320 Ah) 777,5 Kg (320 Ah)
From operator ear (Brush-
Pad)
From operator ear
(Microfiber)
Hand
Body
Safety systems
Certification European
1100 W
1
yes
traction motor wheel
1466 mm
300 mm
accelerator pedal
6,5 km/h
2
emergency switch ▲
fixed on the chassis
300 mm
non markingrubber
electro deposition coating and
galvanised parts
440 mm
530 mm
CE
auto power off system ( operator
accelerator pedal
1950 mm
all moving parts fully protected
yes
620 mm
Vibration 1 m/sec²
0,4 m/sec²
75 LpA (Db)
Noise level
16%
non marking / non skid rubber
rollers bumpers on squeegee and
brush head
front traction motor wheel +
electronic card
yes
Protection against impact
Steel
3 mm
page 2 of 2 CT230 tech ENG 5.1®.xls

PLDC01956
CT230 Quick Guide
This Guide is intended for quick consultation only and does not replace the Use and Maintenance Manual.
Before using the machine, read the Use and Maintenance Manual contained in the machine packaging thoroughly and rigorously respect all the
instructions.
PREPARATION/
OPERATION
1. Fill the detergent tank.
2. Fill the Chem Dose tank
(OPTIONAL)
3. Raise the side flaps and
insert the brushes under
the head, making sure they
rest against the aligners.
4. Turn the ignition key to
switch the machine on.
5. To attach the brushes
automatically, proceed as
follows:
Press the "Click-Off-On"
button. The machine first
performs a release
operation, then immediately
afterwards enables the
attachment operation.
Press the "Click-Off-On"
button again to
automatically attach the
brushes.
6. Select the most suitable
cleaning programme
according to the surface
and dirt to be removed:
P1: light cleaning
programme
P2: medium cleaning
programme
P3: heavy cleaning
programme.
After the cleaning
programme has been
selected, the machine
chooses the advance
speed and quantity of
detergent, then turns the
suction and brush motors
on.
7. The machine can be
operated without using the
3 cleaning programmes
provided by the
manufacturer. In this case,
the brush and suction
motors must be turned on
and the quantity of
detergent regulated
manually by pressing the
buttons shown.
8. Choose the direction of
movement by moving the
direction selector. Select
maximum speed by turning
the potentiometer.
9. Press the Chem Dose
system button (OPTIONAL)
10. Adjust the pump to the
required flow 0.5-3%, the
regulator is under the bung
shown.
11. Operate the machine
movement pedal.
12. If necessary, release the
service or parking brake.
13. Begin working.
14. When you have finished
cleaning, proceed as
follows:
•Turn the brush/suction
motor off.
•Turn the ignition key.
•If necessary, charge the
batteries.

DAILY MAINTENANCE
Empty the dirty water drum
through the drain hose.
Clean the dirty water tank with
water or water and detergent.
Check the suction filter is
undamaged and clean.
Check the detergent output filter
is undamaged and clean.
Clean the brushes.
Check the detergent tank fill filter
is undamaged and clean.
Make sure the dirty water tank
filter is clean.
Check the squeegee is clean and
the blades are not damaged.
Check the battery charge shown
on the display.
To charge, insert the battery
charger connector in the
connector under the seat.
REPLACING THE SQUEEGEE BLADES
Front:
•unscrew the screws fixing the blade retainer;
•remove the blade retainer;
•remove the blade;
•put the same blade back, reversing the edge in contact with the floor, or replace with a new one;
•reposition the blade retainer and fix with the screws;
Back:
•unscrew the screws fixing the blade retainer;
•remove the blade retainer
•remove the blade;
•put the same blade back, reversing the edge in contact with the floor until all four edges are worn, or replace with a new one;
•reposition the blade retainer and fix with the screws;
BRUSH ATTACHMENT/RELEASE
Attaching:
Press the "Click-Off-On" button. The machine first performs a release operation, then immediately afterwards enables the attachment operation. Press
the "Click-Off-On" button again to automatically attach the brushes.
Releasing:
Press the "Click-Off-On" button, the machine releases the brushes.
TROUBLESHOOTING
CHECK THE EMERGENCY BUTTON IS NOT PRESSED
THE MACHINE DOES NOT COME ON/START UP
CHECK THE BATTERY CHARGE
CHECK THE DIRTY WATER DRUM IS NOT FULL
THE SUCTION MOTOR DOES NOT WORK
CHECK THE DIRTY WATER DRUM LEVEL SENSOR IS NOT BLOCKED/MALFUNCTIONING
CHECK THE SQUEEGEE BLADES ARE NOT WORN
CHECK THERE IS NO DEBRIS BETWEEN THE TWO SQUEEGEE BLADES
CHECK THERE IS NO DEBRIS IN THE SUCTION HOSE
CHECK THE SUCTION FILTER IS UNDAMAGED AND CLEAN
CHECK THE DIRTY WATER DRUM LID SEAL IS UNDAMAGED.
THE MACHINE LEAVES THE FLOOR WET
CHECK THE SUCTION HOSE IS CORRECTLY ATTACHED TO THE SQUEEGEE
THE MACHINE LEAVES THE FLOOR DIRTY
CHECK THE TYPE OF BRUSH/PAD IN USE IS SUITABLE FOR THE TYPE OF DIRT AND FLOOR.
CHECK THE FLOOR HAS BEEN BRUSHED BEFORE USING THE MACHINE
CHECK THERE IS NO DEBRIS BETWEEN THE TWO SQUEEGEE BLADES
CHECK THE SQUEEGEE BLADES ARE NOT WORN
THE MACHINE LEAVES STRIPES OF WET FLOOR
CHECK THE SQUEEGEE IS CORRECTLY ADJUSTED

n°00/0023
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IP Cleaning SpA div. Floor care - via Cartesio 39 42040 Villa Bagno RE
Tel. [phone] - Fax [phone] - [e-mail]
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Operative instruction
Istruzioni operative
PLDC01971
Model / Modello
CT 230 Release SoftWare 2.00.9
SUBJECT / OGGETTO ELECTRONIC PCB PROGRAMMING / PROGRAMMAZIONE SCHEDA ELETTRONICA
default values
version
DISC BRUSH
version
ROLLER BRUSH
UP 1.0 UP 1.0
UP 2.2 UP 2.0
UP 3.9 UP 3.0
Battery type
ACID
Battery type
ACID
UP.B 0 UP.B 0
t0.5 t0.0
t1.5 t1.0
t2.3 t2.0
t3.4 t3.0
Potentiometer
alignment Potentiometer alignment
HEAD OF BRUSHES
DISC *HEAD OF BRUSHES ROLLER 750mm
24 H BUZZER OFF ** 24 H BUZZER OFF **
Version 160 / 230 Version 160
PARAMETER MODIFICATION OUT OF THE DEFAULT VALUE, COULD CAUSE AN INCORRECT
WORKING OF THE MACHINE: CONTACT IPC TECHNICAL DPT, BEFORE ANY MODIFICATION.
To enter in the technical programming,
keep pushed the button P1 and P3 ( ref. 4 ) and turn to1 the key
( ref. 1 ). Display shows the first parameter ( UP 1.0 ).To pass from a paramater to another one, use the
ref.2 button.
To modify the default value use the the water buttons ( ref.3 ):
push - to encrease the value / push + to decrease the value
To hold the modification and exit, keep pushed the ref. 2 button until display shows the voltage.
To erase the modification done and exit, turn to 0 the key ( ref. 1 )
* THE VALUE MUST BE RELATED TO TH
E BRUSH HEAD IN
USE [ 700 , 850 (CT230) , 950, 1050 (CT230) mm ].
** THIS IS USED TO SET THE BUZZER .
BUZZER ON MEANS THE BUZZER IS ALWAYS PLAY WHILE
USING THE MACHINE
BUZZER OFF MEANS THE BUZZER PLAY ONLY
IN REVERSE
DIRECTION .
1
2 3
4

n°00/0024
23/05/2011
IP Cleaning SpA div. Floor care - via Cartesio 39 42040 Villa Bagno RE
Tel. [phone] - Fax [phone] - [e-mail]
1/2
Operative instruction
Istruzioni operative
PLDC01972
Model / Modello
CT 230 Release SoftWare 2.00.9
SUBJECT / SOGGETTO USER PROGRAMMING / PROGRAMMAZIONE UTENTE
default values
version
DISC BRUSH version ROLLER BRUSH
ENGLISH ENGLISH
Program 1
Pressure 020 Program 1 Pressure 020
Program 1
Brushes ON Program 1 Brushes ON
Program 1
Suction ON Program 1 Suction ON
Program 1
Water 2 Program 1 Water 2
Program 1
AutoPowerOFF ON Program 1 AutoPowerOFF ON
Program 2
Pressure 040 Program 2 Pressure 030
Program 2
Brushes ON Program 2 Brushes ON
Program 2
Suction ON Program 2 Suction ON
Program 2
Water 3 Program 2 Water 4
Program 2
AutoPowerOFF ON Program 2 AutoPowerOFF ON
Program 3
Pressure 060 Program 3 Pressure 040
Program 3
Brushes ON Program 3 Brushes ON
Program 3
Suction ON Program 3 Suction ON
Program 3
AUTO Program 3 Water 3
Program 3
AutoPowerOFF ON Program 3 AutoPowerOFF ON
PARAMETER MODIFICATION OUT OF THE
DEFAULT VALUE, COULD CAUSE AN
INCORRECT WORKING OF THE MACHINE:
CONTACT IPC TECHNICAL DPT, BEFORE ANY
MODIFICATION.
To enter in the user programming, turn to 1 the key
( ref. 1 ) and after 5 seconds, keep pushed the
button ref. 2 for 10 seconds. Display shows the first
parameter ( ITALIANO ), the language. To pass
from a parameter to another one, use the ref. 2
button.
To modify the default value use the water buttons
( ref. 3 ):
push “ – “ to increase or push “ + “ to decrease the
value.
To read the default values table, change to
ENGLISH the language.
To hold the modification and exit, keep pushed the
ref.2 button until display shows the voltage.
Turning to 0 the key ( ref. 1 ) doesn’t erase the
modification and doesn’t turn OFF the machine.
To exit without modification, set with the follow
default list and hold the data.
1
2 3

A
B
C
D
E
C1
Drive circuit board
B4
Checking and replacing the float switches
D4
Wiring diagram
C2
Drive motor wheel
Error codes
Troubleshooting
E2
Troubleshooting
E1
Error codes
Circuit boards
Electrical system
D2
Functions circuit board
D1
Control panel board
Tanks/suction
assembly
B2
B3
Checking actuator draw and replacing
the squeegee assembly
Checking and replacing the detergent pump
Checking and replacing the solenoid valve
Cleaning the filters
B1
A4
Replacing the head flaps
Cleaning and replacing the solenoid valve
Checking and/or replacing the compensator
Checking the draw of the suction motor
Replacing the suction motor
A2
A1
Checking the current draw of the brush motors
Checking and replacing the brush motor carbon brushes
Checking head actuator current draw
Checking actuator operation manually
Replacing the head actuator
Checking operation of the internal actuator micro switches
Brush head
A3
A5
Disassembling the brush head
Replacing the brush motors and carbon brushes
Drive assembly
C3
Accelerator pedal
Slow steering sensor
C5
D3
Important electrical components
C4
Brake pedal

Indicates particularly important instructions.
In line with the company's policy of constant product development and updating,
! DANGER
Indicates the need for attention in order to avoid a series of consequences which
could cause death or damage to the health of the operator.



IMPORTANT
Indicates the need for attention in order to avoid a series of consequences which
the Manufacturer reserves the right to make modifications without warning.
Although your machine may differ appreciably from the illustrations in this document,
safety and the information contained in this manual are guaranteed.
PLDC01938
REVISION 00
01/06/2011
TECHNICAL DEPT.
Stavale
could cause damage to the machine or work environment or financial loss.
i INFORMATION

Page
A
A1
2
A1.1
3
A1.2
8
A1.3
13
A2
21
A2.1
22
A2.2
28
A2.3
31
A2.4
35
A3
32
A3.1
45
A3.2
48
A3.3
55
A4
58
A4.1
59
A4.2
60
A4.3
61
A4.4
62
A5
63
A5.1
64
A5.2
66
A5.3
70
B
B1
74
B1.1
75
B1.2
79
B2
83
B2.1
84
B2.2
87
B2.3
91
B2.4
94
B2.5
103
B2.6
106
B3
108
B3.1
109
B3.2
114
B4
122
B4.1
124
B4.2
128
B4.3
129
B4.4
133
C
C1
136
C1.1
137
C1.2
139
C1.3
142
C2
143
C2.1
144
C2.2
151
C2.3
154
C2.4
160
C3
162
C3.1
163
C3.2
164
Replacing the complete drive motor wheel
ACCELERATOR PEDAL
Replacing the accelerator pedal
Replacing the accelerator potentiometer and/or micro switch
DRIVE MOTOR WHEEL
Checking and replacing the motor wheel carbon brushes
Checking and replacing the thermal cutout
Replacing the rubber tyred motor wheel ring
Checking electrical connections and the presence of voltage (V)
POWER BOARD
Checking the input signals on the drive logic board
Replacing the drive circuit board
CHECKING OPERATION OF AND/OR REPLACING THE FLOAT SWITCH
Checking operation of the detergent tank float switch
DRIVE ASSEMBLY
Replacing the detergent tank float switch
Checking operation of the dirty water tank float switch
Replacing the dirty water tank float switch
Regulating the squeegee
CLEANING THE FILTERS/DETERGENT PUMP
Cleaning the filters
Checking operation of the detergent pump + solenoid valve
Checking squeegee actuator operation manually
Replacing the squeegee actuator
Checking head actuator operation manually on the bench
Replacing the squeegee flaps
Checking the draw of the suction motor
Replacing the suction motor
SQUEEGEE AND ACTUATOR ASSEMBLY
Checking electromechanical actuator draw
TANKS/SUCTION ASSEMBLY
Checking and/or replacing the solenoid valve
Controlling and/or replacing the compensator
CHECKING SUCTION MOTOR CURRENT DRAW
Replacing the front and back flaps
Replacing the side flaps
CLEANING, CHECKING AND REPLACING THE SOLENOID VALVE
Cleaning the solenoid valve
REPLACING THE BRUSH HEAD FLAPS
Checking and replacing the brush motor carbon brushes on the bench
Replacing the brush centring flaps
Replacing the brush centring bearing and roller
PLDC01938
REVISION 00
01/06/2011
TECHNICAL DEPT.
Stavale
INDEX
Subject
BRUSH HEAD
CHECKING THE CURRENT DRAW OF THE BRUSH MOTORS
Checking brush motor draw with a clamp meter
Checking head actuator operation manually
Replacing the brush head actuator
Checking brush motor draw from the control panel
Checking and replacing the brush motor carbon brushes
HEAD ACTUATOR CURRENT DRAW - REPLACEMENT
Checking brush head actuator draw
DISASSEMBLING THE BRUSH HEAD - BRUSH MOTORS - CARBON BRUSHES
Checking head actuator operation manually on the bench
Disassembling the brush head
Disassembling and replacing the brush motors

Page
PLDC01938
REVISION 00
01/06/2011
TECHNICAL DEPT.
Stavale
INDEX
Subject
C
C4
168
C4.1
169
C4.2
171
C5
173
C5.1
174
D
D1
176
D1.1
177
D2
178
D2.1
179
D3
180
D3.1
181
D3.2
182
D4
184
E
E1
186
E1.1
186
E1.2
188
E2
190
E2.1
190
195
OPTIONALS
ERROR CODES
Curtis drive board alarms
Functions board alarms and display
TROUBLESHOOTING
ERROR CODES - TROUBLESHOOTING
Contactor TL1 (functions) and TL2 (drive)
Disassembling and/or replacing the chem-dose pump
WIRING DIAGRAM
Connecting the chem-dose switch on the control panel (optional)
FUNCTIONS CIRCUIT BOARD
Removing the functions circuit board
IMPORTANT ELECTRICAL COMPONENTS
CONTROL PANEL BOARD - ELECTRICAL CIRCUIT
SLOW STEERING SENSOR
Replacing and/or regulating the steering sensor
CONTROL PANEL BOARD
DRIVE ASSEMBLY
BRAKE PEDAL
Replacing the brake pedal/Adjusting the brakes
Checking, adjusting and/or replacing the micro switch
Troubleshooting
REVISIONS - UPDATES

PLDC01938
REVISION 00
01/06/2011
TECHNICAL DEPT.
Stavale
- date 05/09/2011 1/195
A BRUSH HEAD

 
 IMPORTANT
Go to the designated draining area and empty the detergent
and dirty water tanks via the hoses provided.
Move the machine onto flat ground and apply the brake.
If necessary, place chocks under the wheels.
Switch the machine off by turning the ignition key to position "0".
Disconnect the electronic circuit from the batteries by
means of the Anderson connector with handle.
i INFORMATION
Particularly important instructions
In this Technical Service Manual, the terms RIGHT and LEFT
are used to indicate the sides of the machine.
They always refer to the direction of travel.
In this Technical Service Manual, you may find the version of
machine (BT 85, BT 105, BT 95 R) written in brackets “( )”.
This indicates that the instructions refer to the version
specified in brackets only.

PLDC01938
REVISION 00
01/06/2011
TECHNICAL DEPT.
Stavale
- date 05/09/2011 2/195
A1 CHECKING THE CURRENT DRAW OF THE BRUSH MOTORS
The CT 230 is available in two sizes with disk heads of different widths, the BT 85 with a
cleaning strip of 850 mm and the BT 105 with a cleaning strip of 1050 mm.
Apart from the size, the two heads also differ in the type of motor used.
The BT 85 version mounts a 400 W motor (the same motor as on the CT 160) with free cooling,
while the BT 105 version mounts a 500 W motor with forced cooling by means of a fan in the
top part of the motor itself protected by a casing which also serves as an air conveyor.
BT 85 BT 105
PHOTO 1
i

PLDC01938
REVISION 00
01/06/2011
TECHNICAL DEPT.
Stavale
- date 05/09/2011 3/195
A1.1 Checking the current draw of the brushes from the control
panel
1 Make sure the batteries are charged and the tank contains detergent.
2 Move the machine to a relatively smooth floor to obtain a mean current reading.
3 Enter the machine's technical programming function, following the procedure given in the "Programming the
circuit board" annex or as described below to activate the function to read current draw, actuator activation
tolerance and maximum brush pressure.
4 With the machine off and the key in position "0", press and hold the buttons A"P1" and "P3" and at the same
time turn the key Bto position "1". Keep the buttons pressed until "UP 1.0" is displayed.
5 Press the display button Cto scroll through the menu until you reach UP.B 0. Press the water regulation "+"
and "-" buttons Dto select 1 (only two values appear, 0 and 1). This setting enables the current draw of both
motors together during the washing phase to be displayed.
For disk brush versions only (BT 85 - BT 105), modify the activation tolerance setting
(T0.X) in the brush head actuator activation control section.
For roller brush versions (BT 95 R - BT 95 R Sweep) the default setting is "0".
6 Press the display button Cagain to move on to the next setting in the menu, parameter T0.5. Press the
water regulation "+" and "-" buttons Dto set a value of 0 (zero), 10%, the minimum tolerance possible, by
scrolling through the values of 0 - 9.
C
D
PHOTO 3
A
B
PHOTO 2
D
PHOTO 4
C
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


PLDC01938
REVISION 00
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TECHNICAL DEPT.
Stavale
- date 05/09/2011 4/195
7 To save the new settings, keep button Cpressed until the battery voltage is displayed.
8 Press the display button Cagain for at least 10 seconds until the first selectable parameter, the language, is
displayed.
9 Press the display button Cto scroll through the selectable parameters until you reach "Program 1 Pressure
0X0". The default setting is 020 = 20%.
10 Press the "+" and "-" buttons Dto set the pressure value to maximum: 100 = 100%.
11 Press the display button Cagain to continue scrolling through the menu until you come to: "Program 1
AutoPowerOFF ON".
12 Press the "+" and "-" buttons Dto change the setting from "ON" to "OFF"
13 Keep the display button Cpressed for a few seconds to save the new settings.
For practical reasons, AutoPowerOff is disabled to allow the brushes to be used independently
from the drive. With AutoPowerOff enabled (ON), the brushes are connected to the accelerator
pedal and each time the accelerator pedal is released, the brushes stop operating after a delay of
about 5 seconds.
It was decided to vary the Program 1 settings in order for these settings to be called up by the
manual operation buttons, the brush button Eand the suction motor button. In short, when the
brush button Eis pressed, all Program 1 settings are called up and the brushes operate with
these settings.
PHOTO 5
PHOTO 6
PHOTO 7
PHOTO 8
PHOTO 9
E
i
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PLDC01938
REVISION 00
01/06/2011
TECHNICAL DEPT.
Stavale
- date 05/09/2011 5/195
F
G
PHOTO 10
Make sure the detergent tank is not completely empty and that it contains sufficient
detergent for the tests.
Carry out the tests on an inconspicuous part of the floor, or where it is not important if you
leave marks (caused by the brushes rubbing).
14 Check the draw of the brush motors without load, with the brushes removed.
15 Press the button Fto release the brushes from the drive disks, the LED Gwill flash. At the end of the
operation, remove the brushes.
16 Press the button Fto perform a brush attachment operation without attaching the brushes LED Hwill flash.
17 After the attachment phase (without attaching the brushes), LED off, press the display button Cto scroll
through the menu. The display changes from the volts, to an indication of battery level, then finally the
current draw of the brushes (Isp - Tara).
18 Press the "+" and "-" buttons Dto set water delivery to zero (all LEDs off) as water is not necessary for the
test.



PHOTO 12
C
F
H
PHOTO 11



D
PHOTO 13

PLDC01938
REVISION 00
01/06/2011
TECHNICAL DEPT.
Stavale
- date 05/09/2011 6/195
19 Press the manual brush button Eto operate the brushes.
20 Read the draw value. The board provides two values, both very important. The first row (Isp) gives the draw
of the brush motors during the washing phase, in this case without the brushes. The second row (Tara)
gives the draw value of the brush motors without load (with or without the brushes).
When the brushes start rotating, the control unit reads the draw value at start-up and the value
an instant before the brush actuator lowering command is given. It then calculates the
mathematical mean of these two values, known as TARA.
Once the TARA value has been calculated, while the actuator is lowering the head, the control
unit also calculates the pressure to be exerted on the brushes as a function of the set value (in
this case in "Program 1").
The brushes are pushed towards the floor by the actuator commanded by the control unit until
the brush motor draw reaches the value calculated, considering the set tolerance (T0.Xin this
case in "Program 1").
During normal use, the control unit dedicates a maximum of 50 A to the brush motor and limits
output if the current draw exceeds 65 A for more than 10 (ten) seconds.
The control unit controls the head raising and lowering actuator in order to maintain the
set pressure. In output limitation situations, the control unit commands raising of the
head to the minimum acceptable height. If the draw does not drop within ten seconds, the
control unit turns off current to the brush motors and brings the head to the standby
position.
No error message is displayed.
If the brush lowering command is given while the output limitation situation is still present,
the head will remain in the standby position. The shutdown may be caused by the motor
seizing (bearings, rotor) or mechanical interference (brushes jammed).
In this case, in order to read the draw value calculated, the control unit commands descent of
the actuator to the maximum extent of its travel until it touches the limit micro switch which also
indicates the maximum limit of brush wear, providing the information on the display and via a
buzzer.
E
PHOTO 14
i
i
PHOTO 15
PHOTO 16
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PLDC01938
REVISION 00
01/06/2011
TECHNICAL DEPT.
Stavale
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21 The first row of the display (lsp) gives the draw of the brush motors. To obtain the correct draw value, wait a
few minutes with the motors turning until the value stabilises.
22 After a few minutes, the display shows the stabilised brush motor current draw value without load, without
the brushes (in this case lsp = 5.3 A) .
23 Now perform a wash cycle with the brushes mounted following the instructions above.
24 Remount the brushes on the head: place the brushes under the head, centring is automatic. Press the brush
attachment button F. The LED Gwill flash and the machine will form a release operation without the brushes
attached. At the end of this, press the button Fagain, LED Hflashes and the machine performs the brush
attachment operation.
25 Move the machine to a relatively smooth area of floor in order to obtain a constant reading.
26 To avoid wasting water, press the "+" and "-" buttons Dto set the quantity of water to minimum, one LED on
only (3.0 - 5.0 litres/minute). This is sufficient to wet the floor and avoid overheating the brush bristles.
27 Press the manual brush button Eto operate the brushes
28 Read both draw values, lsp (brush motor draw during the washing phase) and Tara (brush motor draw
without load, with the brushes mounted but before they touch the floor).
29 Compare the values against the table below.
30 Check brush motor draw with a clamp meter (following paragraph) or restore the modified values to the
previous default values.
Important: set maximum pressure during testing
Min Max Min Max
Draw A (amps) 850 1050
Without load, without brushes (Tara) 3.0 A 6.0 A 3.0 A 8.0 A
Without load, with brushes (Tara) 4.0 A 10.0 A 4.0 A 11.0 A
Without brushes during the washing phase "P1" (lsp) 3.0 A 6.0 A 3.0 A 8.0 A
With brushes during the washing phase "P1" (lsp) 10.0 A 28.0 A 10.0 A 35.0 A
PHOTO 17
PHOTO 18
D

PLDC01938
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A1.2 Checking the current draw of the brush motors
1 Make sure the batteries on the machine are charged.
2 Obtain a clamp meter able to read up to 200 A (amps), see photograph 19.
3 Move the machine to the tank draining area and completely empty the dirty water tank.
4 Empty the clean water tank, leaving a small amount to perform the tests.
5 Move the machine onto a flat, dry, smooth floor.
6 Make sure there is sufficient space around the machine to carry out the tests.
7 Identify and disconnect the "operator present" sensor connector Aand bridge it with a wire.
8 Turn the ignition key to position "1" and wait for the board to complete the check (about 3 seconds).
9 Press the button C"-" to set the quantity of water delivered during the washing phase to zero.
10 Press the button B nearest the left side of the display for at least 10 seconds.
11 The first parameter, the language, is displayed.
12 Press the same button B(on the left of the display) to scroll through the parameters.
13 Reach "Program 1 AutoPowerOff".
14 Press the water regulation "+" and "-" buttons Cto select "OFF".
15 More precise information on regulating "AutoPowerOff" can be found in the "User Programming"
sheet included as an annex to this manual.
16 Press the button Bfor at least ten seconds to save the selected settings.
17 Modify the electronic brush control (if not already done) as described from point 3 to point 13 of paragraph
A1.1.
18 Remove the brushes from the head as described from point 14 to point 16 of the previous paragraph.
PHOTO 19
A
C
B
PHOTO 20

PLDC01938
REVISION 00
01/06/2011
TECHNICAL DEPT.
Stavale
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19 Unscrew the knob D by turning it anticlockwise to release the tanks from the machine chassis.
20 Press the pedal E to put the parking brake on.
21 Lift the dirty water and detergent tanks to access the brush motors.
22 Identify the left F1 and right F2 brush motor power connectors and, without disconnecting them, connect the
clamp meter to first one, then (after performing the test) the other to read the current draw of both brush
motors separately.
23 The polarities of the left brush motor connector F1 are the opposite to those of the right brush motor
connector so that the motor rotates in the opposite direction (clockwise).
24 When correctly connected, the
electrical connection of the
brush motors F causes the two
motors to rotate in opposite
directions, with forwards
rotation towards the centre of
the machine.
F1
F2
F1
F2
D
E
PHOTO 21
PHOTO 22
FRONT
PHOTO 23