Curtis 1207B User Manual

Manual

Model 1207B

MultiMode™ Electronic Motor Controller

Read Instructions Carefully!

Specifications are subject to change without notice.
© 2012 Curtis Instruments, Inc. ® Curtis is a registered trademark of Curtis Instruments, Inc.
© The design and appearance of the products depicted herein are the copyright of Curtis Instruments, Inc. 53118 Rev A 6/12

Curtis Instruments, Inc.

200 Kisco Avenue

Mt. Kisco, NY 10549

www.curtisinstruments.com

CONTENTS

1. OVERVIEW ..............................................................................1

CONTENTS

2. INSTALLATION AND WIRING .............................................

Mounting .............................................................................3

Connections: Low Current ..................................................

Connections: High Current .................................................

Wiring: Standard Configuration (Series Motor) ...................

Wiring: Compound Motor Configuration ...........................

Wiring: Throttle ................................................................

5k
0–5V, 3-wire potentiometer, and

Ω–0 throttle (“Type 1”) ...........................................10

electronic throttles (“Type 2”) .................................

0–5k

Ω throttle (“Type 3”) ...........................................13

Wiring: Emergency Reverse Check ....................................

Switches and Other Hardware ...........................................

Keyswitch ....................................................................

Main contactor ............................................................

Forward/reverse contactors ..........................................

F/R and emergency reverse switches ............................

Circuitry protection devices .........................................

Installation Checkout .........................................................

10

11

13
14
14
14
14
14
14
15

3

4
5
6
8

3. ADJUSTMENT OF PARAMETERS ......................................

Changing Parameter Values ................................................

Cloning Controllers ...........................................................

4. MAINTENANCE ...................................................................

C

leaning ............................................................................18

Fault History ......................................................................

Testing the Fault Detection Circuitry .................................

5. DIAGNOSTICS AND TROUBLESHOOTING ....................

LED D

iagnostics ................................................................20

Programmer Diagnostics ....................................................

6. HANDHELD PROGRAMMER .............................................

Programmer Operation

.....................................................24

Progammer Menus .............................................................

Program Menu ............................................................

Monitor Menu ............................................................

Fault Menu ..................................................................

APPENDIX A Glossary of Features and Functions
APPENDIX B Specifications

17
17
17

18

18
19

20

21

23

26
26
27
27

Curtis 1207B Manual

iii

FIGURES / TABLES

FIGURES

fig. 1: Curtis 1207B motor controller

and 1311 handheld programmer ................................1

fig. 2: Mounting dimensions, Curtis 1207B controller ........ 3

fig. 3: Standard wiring diagram (series motors) ....................6

fig. 4: Compound motor wiring diagram .............................8

fig. 5: Wiring for 5kΩ–0 throttle ......................................10

fig. 6: Wiring for 20kΩ potentiometer

used as a wigwag-style throttle ................................ 10

fig. 7: Wiring for 0–5V throttle ........................................11

fig. 8: Wiring for 3-wire pot throttle .................................. 12

fig. 9: Wiring for Curtis ET-XXX electronic throttle ......... 12

fig. 10: Wiring for 0–5kΩ throttle ...................................... 13

fig. 11: Alternative wiring for emergency reverse check .......13

fig. A-1: Ramp shape, with max speed = 100%

and creep speed = 0% ........................................... A-7

fig. A-2: Ramp shape, with max speed = 100%

and creep speed = 10% .......................................... A-7

fig. A-3: Ramp shape, with max speed = 60%

and creep speed = 10% .......................................... A-8

TABLES

table 1: LED codes ..............................................................20

table 2: Troubleshooting chart ............................................

22

iv

Curtis 1207B Manual

1

Fig. 1 Curtis 1207B

electronic motor
controller and 1311
handheld programmer.

1 — OVERVIEW

OVERVIEW

The Curtis 1207B programmable motor speed controller provides efficient,
cost-effective, and simple-to-install control for a variety of small electric ve
hicles. 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 1207B controller high power and
advanced features in a simple, compact package. The optional programmers
(Curtis 1311 and 1314) enable the user to set parameters, conduct tests, and
obtain diagnostic information quickly and easily.

-

Like all Curtis motor controllers, the 1207B models offer superior operator
control of the vehicle’s motor drive speed. Features

✓ Power MOSFET design, providing

• infinitely variable drive and plug brake control

• silent high-frequency operation

• high efficiency (for reduced motor and battery losses)

✓ Compact size

✓ Overvoltage and undervoltage protection

✓ 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

✓ Curtis 1311 handheld programmer (optional) provides a full set

of parameter and function settings, as does the Curtis 1314 PC
Programming Station (optional)

✓ Diagnostic and test information for the controller—and other system

components—readily available both on-board and through the
programmer

include:

More Features

☞

Curtis 1207B Manual

1

1 — OVERVIEW

✓ 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

✓ Input sequencing options include neutral start and static return to off

(SRO)

✓ Microprocessor-controlled contactor sequencing provides true arcless

contactor switching

✓ Smooth, controlled plug braking—with either variable (throttle-

dependent) or fixed plug current limit

✓ Neutral braking option provides automatic plug braking in neutral

✓ MultiMode™ input selects between two different operating modes,

thus allowing optimization of vehicle characteristics for different driving
conditions

✓ Emergency reverse (belly-button switch) with a single input

✓ Ramp-start feature provides full power for starting on ramps

✓ Simple contactor and switch wiring, with coil drivers monitored for

faults—thus ensuring fail-safe operation

✓ Flexible throttle circuitry accommodates a variety of throttle types

✓ Programmable “ramp shape” (static throttle map) provides flexibility in

selecting throttle response feel

✓ Connections made by solid copper power busses with a polarized Molex

connector for control signals

✓ Solid, well-protected construction—with an aluminum mounting plate

and injection-molded cover.

Familiarity with your Curtis 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.

2

Curtis 1207B Manual

2

66 (2.6)

28 (1.1)

122

(4.80)

152 (6.00)

6.3 (0.25)

22 (0.85)

66

(2.60)

4.8 (0.19)

21 × 16 × 1.5

(0.83

×

0.63 × 0.06);

8.4 (0.33) dia. hole thru

6.7 (0.265) dia.,
3 plcs

Dimensions in millimeters and (inches)

Status LED

C

L

165 (6.50)

127 (5.00)

Fig. 2 Mounting

dimensions,
Curtis 1207B controller.

2 — INSTALLATION & WIRING

INSTALLATION AND WIRING

MOUNTING

The 1207B 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.

Although not usually necessary, a thermal joint compound can be used
to improve heat conduction from the case to the mounting surface.

Curtis 1207B Manual

3

2 — INSTALLATION & WIRING

16 15 14 13 12 11 10 9

8 7 6 5 4 3 2 1

CONNECTIONS: Low Current

An integrated 16-pin low power connector molded into the front of the con­troller 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.

Pin 1 shunt field driver output; n/c 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 0–5V

Pin 7 throttle: pot low

Pin 8 throttle: 2-wire 5kΩ–0 or 0–5kΩ input

Pin 9 n/c

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)

4

Curtis 1207B Manual

2 — INSTALLATION & WIRING

M-

A2

B+B-

Programmer Connector

A 4-pin Molex connector is provided for the 1311 handheld programmer or
the 1314 PC Programming Station. A mating cable is supplied with the 1311
handheld 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

B- negative connection to battery

B+ positive connection to battery/field

A2 plug diode to motor armature

Cables are fastened to the bus bars by M8 (5⁄16") 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 1207B Manual

5

2 — INSTALLATION & WIRING

MULTI
MOD

E

EMERGENCY

REVERSE

A2

A1

REVERSE

CONT

ACTOR

PRECHARGE RESISTOR

(250

Ω, 5 W)

BRAKE

FORWARD

CONTACTORS

MAINREVERSE

SWITCHES

CONTROL

FUSE

M- A2

B+B-

FORWARD

CONTACTOR

POWER

FUSE

KEYSWITCH

POLARITY

PROTECTION

DIODE

S1

S2

MAIN

CONTACTOR

B-

B+

FORWARD

REVERSE

THROTTLE

5kΩ–0 (TYPICAL)

A

Fig. 3 Standard

wiring diagram
(series motor),
Curtis 1207B controller.

WIRING: Standard Configuration (Series Motor)

The basic wiring for series motors with field reversing is shown in Figure 3.

The configuration shown in Figure 3 is a typical arrangement for a series mo­tor. Curtis 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.

6

Curtis 1207B Manual

2 — INSTALLATION & WIRING

16-pin detail (see Fig. 3):

BRAKE

MULTI
MODE

EMERGENCY

REVERSE

FORWARD

REVERSE

KEYSWITCH

EMERGENCY

REVERSE

CHECK

OUTPUT

MAIN

CONTACTOR

FORWARD

CONTACTOR

REVERSE

CONTACTOR

2-WIRE POT

(5 kΩ)

POT

LOW

8 7 6 5 4 3 2 1

16 15 14 13 12 11 10

9

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 1207B 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):

The throttle shown in Figure 3 is a 5k

Curtis 1207B Manual

also be accommodated, and are discussed in the throttle wiring section.

Ω–0 type. Various other throttles can

7

2 — INSTALLATION & WIRING

MULTI
MODE

EMERGENCY

REVERSE

A2

A1

REVERSE

CONTACTOR

PRECHARGE RESISTOR

(250

Ω, 5 W)

BRAKE

FWD

CONTACTORS

MAINREV

SWITCHES

CONTROL

FUSE

M-

A2

B+B-

FORWARD

CONTACTOR

POWER

FUSE

KEYSWITCH

POLARITY

PROTECTION

DIODE

S1

S2

MAIN

CONTACTOR

B-

B+

FORWARD

REVERSE

SHUNT

THROTTLE

5kΩ–0 (TYPICAL)

A

B-

Fig. 4 Compound

motor wiring diagram,
Curtis 1207B 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 is shown
in Figure 4.

The configuration shown in Figure 4 requires the use of a compound wound
motor. Pure shunt motors cannot be used with 1207B 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.

8

Curtis 1207B Manual

Power Wiring for Compound Motor

16-pin detail (see Fig. 4):

BRAKE

MULTI
MODE

EMERGENCY

REVERSE

FORWARD

REVERSE

KEYSWITCH

EMERGENCY

REVERSE

CHECK

OUTPUT

FORWARD

CONTACTOR

REVERSE

CONTACTOR

2-WIRE POT

(5 kΩ)

POT

LOW

8 7 6 5 4 3 2 1

16 15 14 13 12 11 10

9

SHUNT

2 — INSTALLATION & WIRING

The field must be wired between

B+ and A2 and the armature between M- and

A2. The internal plug diode in the 1207B 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 B-.

16-pin detail (see Fig. 4):

The throttle shown in Figure 4 is a 5k

Curtis 1207B Manual

also be accommodated, and are discussed in the throttle wiring section.

to handle the increased current from the shunt field.

Ω–0 type. Various other throttles can

Polarity protection diodes and control fuses must be sized appropriately

9

2 — INSTALLATION & WIRING

8 7 6 5 4 3 2 1

FASTER

16 15 14 13 12 11 10 9

5kΩ POT

Pin 8
Pin 7

5kΩ–0
Pot Low

PIN KEY

8 7 6 5 4 3 2 1

FASTERFASTER

16 15 14 13 12 11 10 9

20kΩ POT

Pin

8

Pin

7

5kΩ–0
Pot Low

PIN KEY

Fig. 5 Wiring for

5kΩ–0 throttle
(“Type 1”).

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 pro
grammer. 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.

5kΩ–0 Throttle (“Type 1”)

The 5kΩ–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 5k

Ω–0/0–5kΩ 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 5kΩ and full speed corresponds to 0Ω.

-

Fig. 6 Wiring for 20k

potentiometer used as a
wigwag-style throttle
(“Type 1”).

In addition to accommodating the basic 5kΩ–0 throttle, the Type 1

throttle is the easiest with which to implement a wigwag-style throttle. Using

Ω potentiometer wired as shown in Figure 6, the pot wiper can be set

a 20k
such that the controller has 5k
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 between Pins 7 and 8, which increases the controller output. The

Ω

Ω between Pins 7 and 8 when the throttle is

10

Curtis 1207B Manual

Fig. 7 Wiring for 0–5V

8 7 6 5 4 3 2 1

8 7 6 5 4 3 2 1

16 15 14 13 12 11 10 9

+

-

+

B-

16 15 14 13 12 11 10 9

4.7 kΩ

(Shunt impedance 150 kΩ to ground)

Pin 7
Pin 6
Pin 5

Pot Low
0–5V Input
Pot High

PIN KEY

Pin 7
Pin 6

Pot Low
0–5V Input

PIN KEY

SENSOR GROUND

SENSOR OUTPU

T

0–5V

SENSOR

throttle (“Type 2”).

2 — INSTALLATION & WIRING

throttle 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.

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 0V and full speed corresponds to 5V. Pot Low is the cur
rent 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.

(a) 0–5V throttle sensor

-

Curtis 1207B Manual

(b) Ground-referenced

0–5V throttle

11

2 — INSTALLATION & WIRING

8 7 6 5 4 3 2 1

16 15 14 13 12 11 10 9

OFFON

3-WIRE POT

Pin 7
Pin 6
Pin 5

Pot Low
0–5V Input
Pot High

PIN KEY

8 7 6 5 4 3 2 1

16 15 14 13 12 11 10 9

ET-XXX

B-

B+

B-

GREEN

ORANGE

BLACK

BLACK/WHITE

WHITE

WHT/BRN

Pin 16
Pin 12
Pin 11

Pin

6

KSI Input
Forward
Reverse

0–5V Input

PIN KEY

KEYSWITCH

WHT/
GR

N

Fig. 8 Wiring for 3-wire

potentiometer throttle
(“Type 2”).

Fig. 9 Wiring for

Curtis ET-XXX electronic
throttle (“Type 2”).

3-Wire Potentiometer (500Ω–10kΩ) Throttle

The 3-wire potentiometer is used in its voltage divider mode—with the voltage
source and return being provided by the 1207B controller. Pot High provides
a current-limited 5V source to the potentiometer, and Pot Low provides the
return path. Wiring is shown in Figure 8.

Curtis ET-XXX Electronic Throttle

The Curtis ET-XXX provides throttle and forward/reverse inputs to the 1207B
controller. Wiring for the Curtis ET-XXX is shown in Figure 9.

12

Curtis 1207B Manual

Fig. 10 Wiring for

8 7 6 5 4 3 2 1

FASTER

16 15 14 13 12 11 10 9

5kΩ POT

Pin 8
Pin 7

5kΩ–0
Pot Low

PIN KEY

MULTI
MOD

E

EMERGENCY

REVERSE

For rest of wiring diagram, see Fig. 3 (series motors) or Fig. 4 (compound motors).

BRAKE

FORWARD

CONT

ACTORS

MAIN

REVERSE

SWITCHES

FORWARD

REVERSE

9.1 kΩ

0–5Ω throttle (“Type 3”).

2 — INSTALLATION & WIRING

0–5kΩ Throttle (“Type 3”)

The 0–5kΩ throttle (“Type 3” in the programming menu) is a 2-wire resistive
throttle that connects between the 5k

Ω–0/0–5kΩ pin (Pin 8) and the Pot Low
pin (Pin 7), as shown in Figure 10. It doesn’t matter which wire goes on which
pin. Zero speed corresponds to 0

Ω and full speed corresponds to 5kΩ.

Fig. 11 Alternative

wiring for 1207B
emergency reverse check.

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.

This feature must be enabled at Curtis. 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).

Alternatively, a 9.1 k

Ω resistor can be wired directly across the emer­gency reverse switch to provide the dc bias, as shown by the dashed line in
Figure 11.

Curtis 1207B Manual

13

2 — INSTALLATION & WIRING

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 1207B controller, coil cur
rent 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 1207B 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

.

After initial closing of the contacts, inrush currents flow as the controller’s

internal filter capacitors are charged. A 250

Ω, 5W resistor (such as Curtis 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 con
nected directly to B- in this configuration.

-

-

Forward/Reverse Contactors

For forward/reverse, a paired single-pole, double-throw (2×SPDT) contactor
is recommended, such as an Albright DC88 or DC182

. With 4-terminal split

field motors, two single-pole, single-throw (SPST) contactors 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

These 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.

14

Curtis 1207B Manual

2 — INSTALLATION & WIRING

INSTALLATION CHECKOUT

Before operating the vehicle, carefully complete the following checkout proce­dure. 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.

C AU T I O N

☞

Put the vehicle up on blocks to get the drive wheel(s) off
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.

1. 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 you are using a programmer, put it into the fault mode by entering
the System Faults menu (Fault » System Faults). The display should
indicate “Currently no faults.”

Release the brake (close the brake switch). To do this on a walkie,

pull the tiller down to the operating position. The LED should continue
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.

4. With the brake released, select a direction and operate the throttle. The

Curtis 1207B Manual

motor should begin to turn in the selected direction. If it does not, verify
the wiring to the forward/reverse switches, forward/reverse contactors,
and motor. The motor should run proportionally faster with increasing
throttle. If not, refer to Section 5.

15

2 — INSTALLATION & WIRING

5. If you are using a programmer, put it into monitor mode by entering
the Monitor menu. Scroll down the Monitor menu 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 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 wir
ing, verify that the circuit is operational by momentarily disconnecting
one of the emergency reverse wires. The vehicle should be disabled and
a fault indicated.

-

16

Curtis 1207B Manual

3

3 — ADJUSTMENT OF PARAMETERS

ADJUSTMENT OF PARAMETERS

A number of controller parameters can be adjusted electronically via the op­tional programmers: either the 1311 handheld programmer or the 1314 PC
Programming Station.

For a complete list of the adjustments that can be made, see Section 6:

Handheld Programmer.

CHANGING PARAMETER VALUES

To change a parameter using the programmer, enter the Program menu and scroll
through the Program menu to select the desired parameter. Press the appropri
ate Data Inc/Dec key (“up” or “down”) until the desired value 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 programmer is
being used to adjust a parameter and a limit is reached, the display will stop
changing.

Use of the programmer is described more fully in Section 6.

*

-

CONTROLLER CLONING

The optional handheld programmer also allows you to “clone” controllers,
via options in its Functions menu. You 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 creating a family of controllers
with identical settings.

Instructions for using the 1314 PC Programming Station

*

are included in that programmer’s software. In this 1207B
controller manual, only the 1311 handheld programmer is
described. However, the 1314 has all the capabilities and
features of the 1311.

Curtis 1207B Manual

17

4 — MAINTENANCE

4

MAINTENANCE

There are no user-serviceable parts inside the Curtis 1207B controller. 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 peri
odically, and—if a handheld programmer is available—this periodic cleaning
provides a good opportunity to check the controller’s fault history file. It is
also recommended that the controller’s fault detection circuitry be checked
whenever the vehicle is serviced.

-

C AU T I O N

☞

The 1207B 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 lim

ited to: proper training, wearing eye protection, avoiding loose
clothing and jewelry, and using insulated wrenches.

CLEANING

Although the 1207B controller requires virtually no maintenance if properly
installed, the following minor maintenance is recommended in certain ap
plications.

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 controller’s 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.

-

-

-

FAULT HISTORY

The handheld programmer can be used to access the controller’s fault history
file. Connect the programmer, and select the Fault History menu (Fault »
Fault History). The programmer will read out all the faults the controller has
experienced since the last time the fault 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.

18

4. Make sure the connections to the bus bars are tight. Use two well insu
lated wrenches for this task in order to avoid stressing the bus bars.

Curtis 1207B Manual

-

4 — MAINTENANCE

After a problem has been diagnosed and corrected, clearing the fault
history file is advisable. This allows the controller to accumulate a new file of
faults. By checking the new fault history file at a later date, you can readily
determine whether the problem was indeed completely fixed.

To clear the fault history file, select the Clear Fault History menu (Fault
» Clear Fault History). The programmer will prompt you to acknowledge or
cancel. See Section 6 for more detail on programmer 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 A 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 on 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 1207B Manual

19

5

5 — DIAGNOSTICS & TROUBLESHOOTING

DIAGNOSTICS AND TROUBLESHOOTING

The 1207B controller provides diagnostics information to assist technicians
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 Status LED is located
on top of the controller.

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:

              

( 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  controller operational; no faults

1,2   hardware fail-safe error
1,3   M- fault or motor output short
1,4   sequencing fault (SRO)

2,1   5kΩ–0 or throttle wiper input fault
2,2
2,3
2,4

3,1
3,2
3,3
3,4

  emerg. rev. circuit check fault (BB wiring)
  high-pedal-disable fault (HPD)
  Throttle Type setting changed

  contactor or shunt driver overcurrent
  welded direction contactor
  incorrect main driver feedback signal
  missing contactor or shunt

4,1
4,2
4,3
4,4

Note: Only one fault is indicated at a time, and faults are not queued up.

20

  low battery voltage
  overvoltage
  thermal cutback
  [reserved for future use]

Curtis 1207B Manual

5 — DIAGNOSTICS & TROUBLESHOOTING

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 Fault menu,
and the status of the controller inputs/outputs is displayed in the Monitor
menu.

The following 4-step process is generally used for diagnosing and troubleshoot
ing 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, enter System Faults menu
(Fault » System Faults), and read the displayed fault information.
In this example, the display shows “Currently no faults,” indicat

-

ing the controller has not detected anything out of the norm.

step 3: Enter the Monitor menu, 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.

step 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 1207B Manual

21

5 — DIAGNOSTICS & TROUBLESHOOTING

Table 2 TROUBLESHOOTING CHART

LED PROGRAMMER
CODE LCD DISPLAY

EXPLANATION POSSIBLE CAUSE

1,2 H W F ai ls a fe hardware fail-safe error 1. Controller defective.

1,3 M - S ho r t ed

M- output shorted 1. M- output shorted to ground.

2. Direction contactor not closing.

3. Direction contactor not closing fast enough.

4. Internal motor short to ground.

1,4 S RO

SRO fault 1. Improper sequence of KSI, brake, and

direction inputs.

2. Wrong SRO type selected.

3. Brake or direction switch circuit open.

4. Sequencing delay too short.

2,1 T hro tt le Fau lt 1

5kΩ–0 or wiper fault 1. Throttle input wire open.

2. Throttle input wire shorted to ground or B+.

3. Throttle pot defective.

4. Wrong throttle type selected.

2,2 B B W iri ng C h eck

emerg. reverse wiring fault 1. BB wire open.

2. BB check wire open.

2,3 H PD

HPD sequencing fault 1. Improper seq. of KSI, brake, throttle inputs.

2. Wrong HPD type selected.

3. Misadjusted throttle pot.

2,4 T hro tt le Fau lt 2 Throttle Type setting changed 1. Throttle Type setting was changed without
cycling KSI.

3,1 C ONT D RV R OC driver output overcurrent 1. Direction contactor coil shorted.

2. Shunt field shorted.

3,2 D IR CO NT We l ded welded direction contactor 1. Direction contactor stuck closed.

3,3 Contactor Driver Fault incorrect main driver feedback 1. Main contactor driver circuit failed.
signal (when shunt driver
function is disabled)

3,4 M iss in g C ont act or missing contactor or shunt 1. Direction contactor coil open.

2. Direction contactor missing.

3. Shunt field open.

4. Wire to shunt or direction contactor open.

4,1 L ow Ba tt e ry Vo lta g e low battery voltage 1. Battery voltage <16 volts.

2. Corroded battery terminal.

3. Loose battery or controller terminal.

4,2 O ver Vo lt age overvoltage 1. Battery voltage >33V.

2. Vehicle operating with charger attached.

4,3 T her ma l C utb ack over-/under-temp. cutback 1. Temperature >85°C or <-25°C.

2. Excessive load on vehicle.

3. Improper mounting of controller.

4. Operation in extreme environments.

22

Curtis 1207B Manual

6

6 — HANDHELD PROGRAMMER

HANDHELD PROGRAMMER

The universal Curtis 1311 handheld programmer (optional) allows you to
program, test, and diagnose Curtis programmable controllers. The program
mer is powered by the host 1207B controller, via a 4-pin Molex connector on
the front panel.

-

The Menu Navigation Key is used to scroll up and down, and move right and
left, within menus.

or monitor variables. To set a bookmark, select the item and press one of the book
mark keys for more than 2 seconds. To jump to the bookmarked location, press
the appropriate bookmark key quickly (for less than 2 seconds). The bookmark
keys also have another function: when adjusting the value of a parameter, you
can use these keys to increase the increments by which the value changes; with
Bookmark 1 pressed, for example, values change in 10-digit increments.

Curtis 1207B Manual

The Data Inc/Dec Key is used to increase (+) and decrease (-) values.
The three Bookmark Keys allow you to jump to frequently used parameters

-

23

6 — HANDHELD PROGRAMMER

PROGRAMMER OPERATION

Menu structure

When the programmer is first plugged into the controller, it uploads informa­tion from the controller and then displays the Main Menu:

Pr o g ram
Mo n i tor
Fa u l t
Fu n c tio n s
In f o rma t io n
Sy s t em Se t ti ng s

You scroll up and down the Main Menu by using the up and down arrows on
the Navigation Key. A blinking square (shown here as solid black) indicates
the selected item.

You can go deeper into the Main Menu by using the right arrow of the

Navigation Key; you return to the Main Menu by using the left arrow.

Pressing the right arrow when the Program menu is selected will bring you
to the list of programmable parameters, displayed in a second column to the
right. The LCD on the programmer can show seven lines of text at a time.

Pr o g ram
EM R R e v C/L 2 50A
Th ro ttl e Typ e 2
Ra mp S hap e 30
Cr ee p Spe e d 5%
EM R R e v Spe e d 9 0 %
Se qu enc i n g DLY 1. 0s

Selecting a parameter (in this example, Creep Speed) and then pressing the right
arrow of the Navigation Key will display a screen with additional information,
which in this example is a bar graph.

Pr o g ram

Cre ep Spe ed

5%

min

0

max

25

To return to the list of parameters, press the left arrow. To return to the Main
Menu, press the left arrow again.

24

Curtis 1207B Manual

6 — HANDHELD PROGRAMMER

Changing parameter values

When the programmer is first connected to a 1207B controller, that controller’s
parameter list is uploaded to the programmer along with the present settings. You
can scroll through this list and adjust parameter settings and test the results.

Select “Program” (the top item in the Main Menu), and then press the
right arrow on the Navigation Key to see the list of parameters. Use the down
arrow to scroll down to the parameter you wish to adjust. The present value of
the parameter, and its units, will be displayed. Use the Data Inc/Dec Key to
change the parameter’s value.

Alternatively, before adjusting the parameter value from this screen, you
can press the right arrow key. This will cause a bar graph of that parameter to
appear, showing its present value and also the minimum and maximum allowed
values. You can change the value of the parameter from this screen, as well,
using the Data Inc/Dec Key.

The programmer automatically sends the change to the controller. The
new value is set when the Data Inc/Dec Key is released.

Use the left arrow on the Navigation Key to return to the previous screen.

Real-time monitoring

The programmer can request and display real-time data from the 1207B con
troller. Select “Monitor” in the Main Menu, and use the right arrow on the
Navigation Key to display the list of Monitor variables. The values are periodi
cally updated in this list view.

To view a single variable at a faster rate, select that variable in the list
view and press the right arrow to show a detail screen. The update rate will be
faster on this screen, because only one variable is being updated.

Use the left arrow on the Navigation Key to return to the previous screen.

Faults and fault history

The programmer allows access to the present and past status of the 1207B con
troller. The controller runs continuous self-diagnostics and will record and log
each error event in non-volatile memory. When the programmer is connected
to the controller, this log file is automatically uploaded into the programmer.

To see the present status of the controller, use the Navigation Key to
select “Fault” and then “System Faults.” To see the log file, select “Fault” and
then “Fault History.”

It is useful to clear the fault history file after reading it. To do this, use the
Navigation Key to select “Fault” and then “Clear Fault History.” When asked
to confirm your action, use Data Inc/Dec Key. The “+” arrow means Yes and
the “-” arrow means No (that is, it cancels clearing the fault history).

-

-

-

Curtis 1207B Manual

25

6 — HANDHELD PROGRAMMER

PROGRAMMER MENUS

Items are listed for each menu in the order they appear in the actual menus
displayed by the handheld programmer.

Program Menu (not all items available on all controllers)

E MR Rev C/ L Emergency reverse current limit

T hro t tl e Ty pe Throttle type

R amp Sh a pe Throttle map

C ree p S p eed Creep speed, as percent PWM duty cycle

E MR R ev Spe ed Emerg. reverse speed, as % PWM duty cycle

S equ e nc i ng DLY Sequencing delay, in seconds

Var iab le P l ug Throttle-variable plug braking:

on (variable plug) or off (fixed plug)

H igh Pe d al Dis High pedal disable (HPD): type †
S RO Static return to off (SRO): type ‡

A nti - Ti ed own Anti-tiedown: on or off

B B C h ec k BB wiring check: on or off

Q uic k S t ar t Quick-start throttle factor

M1 Ma in C /L Mode 1 main current limit

M 1 P l ug C/L Mode 1 plug current limit

M 1 R a mp C/L Mode 1 ramp start current limit

M 1 A c ce l Ra te Mode 1 acceleration rate, in seconds

M 1 M a x S pee d Mode 1 maximum speed, as % PWM output

M2 Ma in C /L Mode 2 main current limit

M 2 P l ug C/L Mode 2 plug current limit

M 2 R a mp C/L Mode 2 ramp start current limit

M 2 A c ce l Ra te Mode 2 acceleration rate, in seconds

M 2 M a x S pee d Mode 2 maximum speed, as % PWM output

Ne ut Bra k e C /L Neutral brake current limit

N eut r al Bra ke Neutral brake: on or off

*

* Throttle types: Type 1 = 5kΩ–0

Type 2 = 0–5V, 3-wire pot, and electronic throttles
Type 3 = 0–5kΩ throttles

† HPD types: Type 0 = no HPD

Type 1 = HPD on brake input
Type 2 = HPD on KSI

‡ 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

(For more detail on these options, see Appendix A: Glossary of Features and Functions.)

26

Curtis 1207B Manual

6 — HANDHELD PROGRAMMER

Monitor Menu (not all items available on all controllers)

Th ro tt l e Throttle reading, as percent of full throttle

Ba t t Vol tag e Battery voltage

He a tsi nk Temp Heatsink temperature
Ma x Tem p Maximum temperature seen
Mi n Tem p Minimum temperature seen

Br a ke Inp ut Brake switch: on/off

Sp e ed Inp ut Mode switch: on (Mode 1) / off (Mode 2)

EM R Re v I npu t Emergency reverse switch: on/off

Fo r wa rd Inp u t Forward switch: on/off

Re v ers e I npu t Reverse switch: on/off

Fw d Co nt Forward contactor: on/off

Re v Co nt Reverse contactor: on/off

*

*

* Maximum/minimum temperatures recorded

since the Fault History was last cleared.

Fault List

This is not a menu as such, but simply a list of the possible messages you may
see displayed in the “Fault » System Faults” menu or the “Fault » Fault History”
menu. The messages are listed here in alphabetical order.

BB Wi r ing Ch eck BB wiring check failed

Co n tac tor Dr i ver Fa ult Incorrect main driver feedback signal

CO N T D RVR OC Contactor driver overcurrent

Cu r ren tly no fau lts No known faults

DI R CO NT Wel ded Direction contactor welded

HP D High-pedal-disable (HPD) activated

HW Fai lsa fe Hardware failsafe activated

Lo w Ba tte ry Vo l tag e Low battery voltage (<16V)

M- Sho rt ed M- output fault

Mi s sin g C ont a cto r Missing contactor

Ov e r Vol tag e Overvoltage (>33V)

SR O Static-return-to-off (SRO) activated

Th e rma l C utb a ck Cutback, due to over/under temp

Th r ott le Fau l t 1 Throttle input fault

Th r ott le Fau l t 2 Throttle Type changed without cycling KSI

(when shunt function is disabled)

Curtis 1207B Manual

27

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.

The acceleration rates in Mode 1 and in Mode 2 are independently adjust

able via the handheld programmer.

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 already 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 direc
tion is de-selected, so that the controller current will be reduced to zero before
the direction contactor drops out.

BB (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.

Contactor drivers and circuits

The1207B controller 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 con-

tactors operate correctly; see Fault detection.

-

Curtis 1207B Manual

A-1

APPENDIX A: GLOSSARY

The shunt winding of a compound motor can 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 throttle). Creep speed is adjustable from 0 to 25% of the controller
duty factor; the adjustment can be made via the handheld programmer.

Current limiting

Curtis 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).

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 pro
grammer, as is the emergency reverse current limit.

-

Current multiplication

During acceleration and during reduced speed operation, the Curtis 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
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 re
sponse, which is linear.

A-2

-

Curtis 1207B Manual

APPENDIX A: GLOSSARY

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
emergency 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.

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.

Fault » Fault History menu provides access to the controller’s diagnostic history
file—the entire fault event list created since the diagnostic history file was last
cleared. The Fault » System Faults menu, on the other hand, provides informa
tion about only the currently active faults.

Curtis 1207B Manual

The fault event list can be loaded into the programmer for readout. The

-

A-3

APPENDIX A: GLOSSARY

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
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 1 clears when condition gone
undervoltage when battery voltage rises above undervoltage

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 imme
diately 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
regained by reducing the throttle demand to less 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 (
starts diagnostics. In combination with the brake input, KSI enables all logic
functions.

the key permanently turned on.

A-4

Key Switch Input) provides power to the logic board, and initializes and

Some vehicles may have no keyswitch (KSI simply tied to B+) or may have

Curtis 1207B Manual

APPENDIX A: GLOSSARY

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.

MOSFET

A MOSFET (

Metal Oxide Semiconductor Field Effect Transistor) is a type of

transistor characterized by its fast 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
maneuvering in Mode 2 and faster, long distance travel in Mode 1. The fol
lowing 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 thermal conditions.)

Curtis 1207B Manual

A-5

APPENDIX A: GLOSSARY

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 contac
tors, thereby shutting down the controller. Overvoltage can result during bat
tery charging or from an improperly wired controller. Controller operation
resumes 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 1207B 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. Note: Plug current limit on
the 1207B 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.

The plug current limits in Mode 1 and in Mode 2 are independently ad
justable via the handheld programmer.

-

-

-

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 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 “quick­start” 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.

A-6

The quick-start throttle factor is adjustable via the handheld programmer.

Curtis 1207B Manual

Fig. A-1 Ramp shape

THROTTLE (percent)

PWM (percent)

70%

60%

50%

40%

30%

20%

RAMP SHAPE

100

90

80

70

60

50

40

30

20

10

0

100

908070605040302010 0

CREEP
SPEED

(0)

MAXIMUM SPEED (100%)

THROTTLE (percent)

PWM (percent)

70%

60%

50%

40%

30%

20%

RAMP SHAPE

100

90

80

70

60

50

40

30

20

10

0

100

908070605040302010 0

CREEP SPEED (10%)

MAXIMUM SPEED (100%)

(throttle map) for controller
with maximum speed set at
100% and creep speed set
at 0.

APPENDIX A: GLOSSARY

Ramp shape (throttle map)

“Ramp shape” is a programmable parameter that determines the static throttle
map of the 1207B controller. Eleven preprogrammed ramp shapes are available,
in 5% steps between 20% and 70% (20, 25, 30, 35, 40, 45, 50, 55, 60, 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 maximum 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.

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

(throttle map) for controller
with maximum speed set at
100% and creep speed set at
10%.

Curtis 1207B Manual

A-7

APPENDIX A: GLOSSARY

THROTTLE (percent)

PWM (percent)

70%

60%

50%

40%

30%

20%

RAMP SHAPE

100

90

80

70

60

50

40

30

20

10

0

100

908070605040302010 0

CREEP SPEED

(10%

)

MAXIMUM SPEED

(60%

)

Fig. A-3 Ramp shape

(throttle map) for controller
with maximum speed set
at 60% and creep speed
set at 10%.

In Figure A-3, the creep speed is kept at 10% and the maximum speed setting
dropped to 60%.

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 50% 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
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:

A-8

until the opposite direction is selected for more than one second.

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.

The Mode 1 and Mode 2 ramp start current limits can be set independently.

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 start mode, it will continue to do so

When the brake is first released, the ramp start current limit level will be

The ramp start current limit is adjustable via the handheld programmer.

Curtis 1207B Manual

for

APPENDIX A: GLOSSARY

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 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 1200 Series controllers, the 1207B allows 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 modulation (PWM)—per
mits silent, stepless operation.

Speed settings

The maximum speed setting defines the upper-limit speed as a percentage of
PWM output at full throttle. The maximum speed settings in Mode 1 and
in Mode 2 are independently adjustable via the handheld programmer; the
maximum creep speed and the maximum emergency reverse speed are similarly
adjustable.

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

-

Curtis 1207B Manual

A-9

APPENDIX A: GLOSSARY

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,

step 2. brake released (brake input “high”), and

step 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 required (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.

A-10

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
temperature sensor is also used to calculate and display the heatsink temperature
on the handheld programmer.

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 Monitor menu) are cleared
each time the controller’s diagnostic history file is cleared.

Curtis 1207B Manual

APPENDIX A: GLOSSARY

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 1207B controller. The throttle map parameter is called “ramp shape”; see
Ramp shape for more information.

Throttle response

The dynamic throttle response (duty factor as a 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 automati
cally accelerates (or decelerates) through a straight line until the new throttle
demand is obtained.

Throttle types

The 1207B controller accepts a variety of throttle inputs, through various
combinations of its four throttle input pins. The most commonly used throttles
can all be hooked up directly: 5k

Ω–0 and 0–5kΩ 2-wire rheostats, 3-wire pots,

0–5V throttles, and the Curtis ET-XXX 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 op
eration. Adjustments and settings are independent of throttle type. However,
throttle fault conditions will vary by throttle type.

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 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 bat
tery voltage is pulled below the undervoltage point by an external load. The
undervoltage cutback point is set in ROM, and is not adjustable.

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.

Curtis 1207B Manual

-

During normal operation, the controller duty factor will be reduced when

A-11

APPENDIX A: GLOSSARY

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 micropro­cessor, 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. 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 sequen
tial 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.

-

A-12

Curtis 1207B Manual

SPECIFICATIONS: 1207B CONTROLLERS

Nominal input voltage 24 V

Maximum operating voltage 30 V

Overvoltage point 33 V

Minimum operating voltage 16 V (= undervoltage point)

Electrical isolation to heatsink 500 V ac (minimum)

PWM operating frequency 15 kHz

APPENDIX B: SPECIFICATIONS

APPENDIX A: GLOSSARY

Output current

1207B-41XX 1207B-51XX

*

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 24 V

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 current (maximum) 2 amps

Shunt driver spike protection active clamp at 47 V

KSI input voltage 16 – 30 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 1.1 kg (2.5 lbs)

Dimensions 122

Output current rating test conditions:

*

1. Controller cover installed

2. Controller mounted to 230

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 1207B Manual

× 165 × 66 mm (4.8" × 6.5" × 2.6")

× 305 × 3.2 mm (9" × 12" × 0.125") aluminum plate heatsink

A-13

B-1