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  12 1 2 MOTOR CONTROLLER © 2009 CURTIS INSTRUMENTS, INC. DESIGN OF CURTIS PMC 1200 SERIES CONTROLLERS PROTECTED BY U.S. PATENT NO. 4626750. 1212 Manual, p/n 53112 Rev. A: July 2009 URTIS NSTRUMENTS, 200 Kisco Avenue Mt. Kisco, New York 10549 USA Tel.

• Page 3: Table Of Contents

  4. MONITOR MENU…………..23 5. INITIAL SETUP…………..24 6. VEHICLE PERFORMANCE ADJUSTMENT…….27 7. DIAGNOSTICS AND TROUBLESHOOTING ….33 8. MAINTENANCE …………..38 Vehicle Design Considerations APPENDIX A Battery Discharge Indicator (BDI) Setup APPENDIX B Programmer Operation APPENDIX C 1212 Controller Specifications APPENDIX D Curtis 1212 Manual…

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  FIGURES / TABLES FIGURES . 1: Curtis 1212 electronic motor controller ……..1 . 2: Mounting dimensions, Curtis 1212 controller ……4 . 3: Standard wiring configuration ………..6 . 4: Wiring for 5kΩ, 3-wire potentiometer ……..7 . 5: Wiring for voltage throttle…………7 .

• Page 5: Overview

  The 1212 controller is fully programmable by means of the Curtis 1311 handheld programmer. Use of the programmer offers diagnostic and test ca- pability as well as configuration flexibility.

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  Easy Installation and Setup ✓ Industry standard footprint, mounting centers, and wiring allows drop-in replacement of other controllers ✓ Model 1212 controllers are easily programmed with Model 1311 handheld or Model 1314 PC programmers, or can be supplied pre-programmed ✓ Accepts all standard throttle types, including single-ended, wigwag, and unipolar ✓…
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  ✓ FDA documentation filed ✓ TÜV certification pending. Familiarity with your Curtis controller will help you install and operate it properly. We encourage you to read this manual carefully. If you have ques- tions, please contact the Curtis office nearest you.

• Page 8: Installation And Wiring

  INSTALLATION AND WIRING MOUNTING THE CONTROLLER The 1212 controller can be oriented in any position, but the location should be carefully chosen to keep the controller clean and dry. If a clean, dry mounting location cannot be found, a cover must be used to shield the controller from water and contaminants.

• Page 9: Connections: High Current

  A 2-pin low power connector is provided for the electromagnetic brake. J3 Pin 1 Brake + J3 Pin 2 Brake — The mating connector is a Molex Mini-Fit-Jr. receptacle p/n 39-01-2020 with appropriate 45750-series crimp terminals. Curtis 1212 Manual…

• Page 10: Controller Wiring: Standard Installation

  B- active (Speed Inhibit parameter set to 0). The J2 connector can be used interchangeably for the programmer or for the battery charger. Fig. 3 Standard wiring configuration, Curtis 1212 controller. Curtis 1212 Manual…

• Page 11: Throttle Wiring

  Throttle Type parameter is programmed; see page 15. Throttle wiring is described in the following text. If the throttle you are planning to use is not covered, contact the Curtis office nearest you. 5kΩ, 3-Wire Potentiometer A 5kΩ, 3-wire potentiometer is shown in the wiring diagram (Figure 3) as well as in Figure 4.

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  If a speed limit pot is not used, the Speed Limit Pot parameter should be programmed Off to disable the fault check at the speed limit pot. Curtis 1212 Manual…

• Page 13: Switches And Other Hardware

  Off (pulling it to B-) puts the controller in Mode 1. Battery Discharge Indicator (BDI) The 1212 controller can drive a BDI panel meter to show the battery pack’s state of charge as a percentage of the amp-hour capacity of the batteries. The batteries must be put through a full charge cycle with the controller installed before the BDI will begin operation.

• Page 14: Fig . 6: Wiring To Inhibit Operation During Battery Charging

  Status LED The 1212 controller has the capability to drive a panel indicator LED, which can be used to tell the operator, at a glance, the controller’s status. This LED always indicates whether the controller is powered on or off. It will also provide diagnostics information via flash codes (see Section 7).

• Page 15: Programmable Parameters

  3 — PROGRAMMABLE PARAMETERS PROGRAMMABLE PARAMETERS The 1212 controller has a number of parameters that can be programmed using a Curtis 1311 handheld programmer or Curtis 1314 PC Programming Station. These programmable parameters allow the vehicle’s performance to be customized to best fit the needs of individual vehicle operators.

• Page 16: Drive Parameters

  Note: Allowable range is restricted by Rev Decel High Speed setting. Key Off Decel 0.2–4.0 sec Sets the rate (in seconds) that is used to slow down the vehicle at key-off or in the event of a major fault. Curtis 1212 Manual…

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  Soft Stop Speed 0–30 % Sets the speed at which a gentler deceleration is initiated when the throttle is released to neutral; larger values start the soft stop deceleration sooner. Curtis 1212 Manual…

• Page 18: Speed Parameters

  M1/M2 Speed Parameters SPEED MODES The 1212 controller’s Multi-Mode™ feature allows operation in two distinct modes: Mode 1 and Mode 2. These modes can be programmed to provide two different sets of operating characteristics, which can be useful for operation in different conditions.

• Page 19: Throttle Parameters

  RANGE DESCRIPTION Type 0–9 The 1212 controller can accept inputs from both 5kΩ, 3-wire pot throttles and voltage throttles. Set the throttle type parameter to match the throttle used in your application. 5k Ω , 3-wire pot throttles 0 = wigwag 1 = inverted wigwag 2 = single-ended;…

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  (high settings). Fig. 7 Effect of throttle adjustment parameters. These four parameters determine the controller’s response to throttle position, in forward and reverse. Here, Deadband = 10% Throttle Max = 90% Creep = 0%. Curtis 1212 Manual…
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  8. Set the calibration parameter Off, or cycle the keyswitch to reset it to Off. (If you are performing the reset by cycling the keyswitch, note that KSI must remain off for at least 4 seconds.) The vehicle will not drive if the throttle autocalibration parameter is left On. Curtis 1212 Manual…

• Page 22: Current Parameters

  For 1212-22xx controllers, it is adjustable from 10 to 45 amperes. For 1212-24xx controllers, it is adjustable from 15 to 70 amperes.

• Page 23: Brake Parameters

  On vehicles with reverse switches, the horn will sound when the reverse switch is activated. Beep Constant On/Off Sets the reverse beep to be a constant tone (when programmed On) or a 1Hz pulse (when programmed Off). Curtis 1212 Manual…

• Page 24: Motor Parameters

  This parameter should be set to the current rating provided by the motor 0–70 A manufacturer. For 1212-22xx controllers, it is adjustable from 0 to 45 amperes. For 1212-24xx controllers, it is adjustable from 0 to 70 amperes. Max Current Time 0–120 sec…

• Page 25: Bdi Parameters

  Setting Low BDI Level to zero disables this function and allows the battery to discharge completely. Low BDI Max Speed 10–100 % Sets the maximum allowed vehicle speed when the battery charge falls below the programmed Low BDI Level. Curtis 1212 Manual…

• Page 26: Compensation Parameters

  “clone” controllers with identical settings. Note: Cloning only works between controllers with the same model number and software version. For example, the programmer can read all the information from a 1212-2201 controller and write it to other 1212-2201 controllers; however, it cannot write that same information to 1212-2202 controllers.

• Page 27: Monitor Menu

  Status of the main contactor driver. Brake On/Off Status of the EM brake driver. 0–100 % Status of battery capacity. Drive Time 0–65535 hours Hours of operation since the hourmeter was last reset (Reset Drive Time = On). Curtis 1212 Manual…

• Page 28: Initial Setup

  If you are using a wigwag or unipolar throttle, you should center it before proceeding with the throttle tuning procedures. Instructions for centering, using the Throttle Calibration parameter, are presented on page 17. Curtis 1212 Manual…

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  Conducting the procedure with a warm motor will lead to erroneous settings. The correct System Resistance value is determined as follows. 4-a. Position the vehicle up against a wall, high curb, or some other immovable object. Curtis 1212 Manual…
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  4-b. Plug in the programmer and turn the keyswitch on. 4-c. Set the Main Current Limit parameter (Program » Current » Main Current Limit) to 25 amps (1212-22xx models) or to 35 amps (1212-24xx models). 4-d. Set the Boost Current Limit parameter (Program » Current » Boost Current Limit) to the same value as the Main Current Limit: 25 amps for 1212-22xx models, and 35 amps for 1212-24xx models.

• Page 31: Vehicle Performance Adjustment

  It is important that the effect of these programmable parameters be understood in order to take full advantage of the 1212 controller’s features. Please refer to the descriptions of the applicable parameters in Section 3 if there is any question about what any of them do.

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  Forward parameters. Fine tuning the acceleration and deceleration rates 6-i. Drive around in both Mode 1 and Mode 2, while varying the posi- tion of the throttle and the speed limit pot. In most cases, setting the Curtis 1212 Manual…
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  Adjust the E Stop Pause value to provide the ap- propriate pause. A longer pause might be preferred for a vehicle that will be mainly used indoors, whereas for a vehicle that will be used outdoors a faster initiation of reverse travel might be desirable. Curtis 1212 Manual…
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  7-d. If the vehicle is still moving on a modest ramp when the brake gets set, Anti-Rollback Comp is set too low. 7-e. If the vehicle seems to decelerate to a stop in a nonlinear fashion, Anti-Rollback Comp could be set too high. Curtis 1212 Manual…
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  Having separate parameters for the soft start and gear soften functions allows you to set the Soft Start parameter lower than the Gear Soften parameter. Setting the two parameters the same in effect collapses them into a single parameter. Curtis 1212 Manual…
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  These setup and tuning procedures cover the most critical aspects of vehicle performance. Additional parameters can be used to make further adjustments, if necessary. However, in most cases, the default values of the other parameters prove satisfactory. Curtis 1212 Manual…

• Page 37: Diagnostics And Troubleshooting

  7 — DIAGNOSTICS & TROUBLESHOOTING DIAGNOSTICS AND TROUBLESHOOTING The 1212 controller provides diagnostics information to assist technicians in troubleshooting drive system problems. The diagnostics information can be obtained in two ways: by reading the appropriate display on the handheld programmer or by observing the fault codes issued by the status LED.

• Page 38: Table 2-0: Status Led Fault Codes, Type 0

  ¤¤¤¤ ¤¤¤ (not used) ¤¤¤¤ ¤¤¤¤ BATTERY DISCONNECT FAULT ❊ ¤¤¤¤ ¤¤¤¤¤ Must cycle keyswitch to clear. ❊ Must use programmer to clear, as follows: select Program menu, † alter data value of any parameter, cycle keyswitch. Curtis 1212 Manual…

• Page 39: Table 2-1: Status Led Fault Codes, Type 1

  MAIN ON FAULT PRECHARGE FAULT ❊ BRAKE ON FAULT ¤¤¤¤¤¤¤¤¤ OVERVOLTAGE FAULT ¤¤¤¤¤¤¤¤¤¤ Must cycle keyswitch to clear. ❊ Must use programmer to clear, as follows: select Program menu, † alter data value of any parameter, cycle keyswitch. Curtis 1212 Manual…

• Page 40: Table 2-2: Status Led Fault Codes, Type 2

  MAIN FAULT ❊ MAIN OFF FAULT MAIN ON FAULT PRECHARGE FAULT ❊ Must cycle keyswitch to clear. ❊ Must use programmer to clear, as follows: select Program menu, † alter data value of any parameter, cycle keyswitch. Curtis 1212 Manual…

• Page 41: Table 3 Troubleshooting Chart

  2. Bad connection at battery or controller. 3,1 7 6 WIRING FAULT HPD fault present >10 sec. 1. Misadjusted throttle. 2. Broken throttle pot or throttle mechanism. Jack up vehicle and retest to confirm diagnosis. Clean connections, inspect system wiring, and retest. ★ Curtis 1212 Manual…

• Page 42: Maintenance

  8 — MAINTENANCE MAINTENANCE There are no user serviceable parts in the Curtis 1212 controller. No attempt should be made to open, repair, or otherwise modify the controller. Do- ing so may damage the controller and will void the warranty. However, it is recommended that the controller’s fault history file be checked and cleared…

• Page 43: Appendix A Vehicle Design Considerations

  Emissions Signals with high frequency content can produce significant emissions if connected to a large enough radiating area (created by long wires spaced far apart). Contactor drivers and the motor drive output from Curtis controllers can contribute to RF emissions. Both types of output are pulse width modulated square waves with fast rise and fall times that are rich in harmonics.

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  field. This coupling can be reduced by placing the controller as far as possible from the noise source or by enclosing the controller in a metal box. Some Curtis controllers are enclosed by a heatsink that also provides shielding around the controller circuitry, while others are partially shielded or unshielded.
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  APPENDIX B: BDI SETUP APPENDIX B BATTERY DISCHARGE INDICATOR (BDI) SETUP The Battery Discharge Indicator used with the 1212 is quite flexible and, once set up, will provide the user with reliable information on the status of the bat- tery system.
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  BDI gauge until the battery is full. The 1212 controller can also be programmed to allow the user to stop the charge in mid-cycle and display a proportional amount of charge, or “partial charge”…
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  The settings can be fine tuned by repeating the entire procedure. It is important to note that battery age and driving conditions (hilliness, driving surface, weight of user) will all affect the accuracy of the BDI measure- ment. Curtis 1212 Manual…

• Page 48: Fig . C-1: Curtis 1311 Handheld Programmer

  PROGRAMMERS Curtis programmers provide programming, diagnostic, and test capabilities for 1212 controllers. The power for operating the programmer is supplied by the host controller via a 4-pin connector. Two programmers are available: the PC Programming Station (1314) and the handheld programmer (1311). The Programming Station has features not available on the handheld unit;…

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  — displays data about the host controller: model and serial numbers, date of manufacture, hardware and software revisions, and itemization of other devices that may be associated with the controller’s operation. Programmer Setup — displays data about the programmer: model and serial numbers, and date of manufacture. Curtis 1212 Manual…
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  APPENDIX D: SPECIFICATIONS APPENDIX D SPECIFICATIONS Table D-1 SPECIFICATIONS: 1212 CONTROLLER Nominal input voltage 24 V PWM operating frequency 15.6 kHz Electrical isolation to heatsink (min.) 500 V Minimum motor resistance 160 m Ω (45 amp models); 120 m Ω…

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