Curtis 1212S User Manual
Manual
Model 1212S
Electronic Motor Controller
Read Instructions Carefully!
Specications are subject to change without notice.
© 2016 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. 53153 Rev B 10/2016
Curtis Instruments, Inc.
200 Kisco Avenue
Mt. Kisco, NY 10549
www.curtisinstruments.com
CONTENTS
1. OVERVIEW ............................................................................. 1
2. INSTALLATION AND WIRING ............................................ 4
Mounting the Controller ................................................... 4
Connections: High Current .............................................. 5
Connections: Low Current ................................................ 5
Controller Wiring .............................................................. 6
Throttle Wiring ................................................................. 7
Switches and Other Hardware ............................................ 8
3. PROGRAMMABLE PARAMETERS ..................................... 10
Program Menus ................................................................ 10
4. MONITOR MENU ............................................................... 22
5. INITIAL SETUP .................................................................... 24
6. VEHICLE PERFORMANCE ADJUSTMENT ..................... 27
7. DIAGNOSTICS AND TROUBLESHOOTING ................... 32
8. MAINTENANCE ................................................................... 35
appendix a Vehicle Design Considerations
appendix b EN 13849 Compliance, 1212S Controller
appendix c Battery Discharge Indicator (BDI) Setup
appendix d Programming Devices
appendix e 1212S Controller Specifications
ii
Curtis 1212S Manual, Rev. B
FIGURES
fig. 1: Curtis 1212S electronic motor controller ................................. 1
fig. 2: Mounting dimensions, Curtis 1212S controller ....................... 4
fig. 3: Standard wiring configuration, 1212S controller ...................... 6
fig. 4: Wiring for 5kΩ, 3-wire potentiometer ..................................... 7
fig. 5: Wiring for voltage throttle ....................................................... 7
fig. 6: Effect of adjusting the Throttle Map parameter ..................... 15
fig. 7: Wiring for Pump SRO ........................................................... 21
fig. B-1: Safety channel block diagram ................................................. 38
TABLES
table 1: Programmable parameter menus ....................................... 10
table 2: Troubleshooting chart ....................................................... 33
table E-1: Specifications, 1212S controllers ....................................... 44
iii
Curtis 1212S Manual, Rev. B
1
Fig. 1 Curtis 1212S
electronic motor controller.
1 — OVERVIEW
OVERVIEW
The Curtis 1212S motor speed controller provides precise and smooth control
of permanent magnet drive motors for battery powered vehicles. This controller
is designed for use in pallet truck applications.
The 1212S controller is fully programmable by means of a Curtis programming device. Use of the programmer offers diagnostic and test capability
as well as configuration flexibility.
Curtis 1212S Manual, Rev. B
Like all Curtis motor controllers, the 1212S offers superior operator control
of the vehicle’s motor drive speed. Key features include:
Smooth and Secure Control
✓ Advanced speed regulation maintains precise speed over varied terrain,
obstacles, curbs, and ramps
✓ Linear cutback of current ensures smooth control, with no sudden loss
of power during undervoltage or overtemperature
✓ Proprietary algorithms help prevent gearbox wear while providing
smooth starts and reversals
✓ The vehicle is brought to a complete stop before the electromagnetic
brake is applied, ensuring safe and secure stops under all conditions
✓ Charger inhibit input prevents driving while charger is attached
✓ Key Off Decel function ensures a smooth “brake to stop” when the
key is turned off while driving or when a fault occurs that requires the
vehicle to stop
More Features
☞
1
1 — OVERVIEW
✓ Anti-Rollback/Roll-forward function provides smooth and safe vehicle
control on hills and ramps
✓ Internal main relay provides secure power-off
✓ Boost current gives a brief boost of current greatly improving
transient loads such as starting on a hill, crossing thresholds, etc.
Easy Installation and Setup
✓ Industry standard footprint, mounting centers, and wiring allows
drop-in replacement of other controllers
✓ 1212S controller is easily programmed with a Curtis
programming device, or can be supplied pre-programmed
✓ Accepts standard single-ended voltage/resistance throttles
✓ Throttle sense can be inverted for all throttle types
✓ Simplified troubleshooting and diagnostics
✓ Standard Molex Mini-Fit-Jr. terminals provide proven connections
for the control wiring
✓ Bolt-on terminals provide robust connections for the high current
wiring
Valuable Additional Features
✓ Automatic compensation for changes in motor condition to ensure
optimum drive performance at all times
✓ Multi-mode provides for two distinct and programmable control
modes (indoor/outdoor)
✓ Emergency reverse with belly button switch input
✓ Emergency stop provides immediate EM braking when throttle
transitioned through neutral to >80% reverse request
✓ Lift Lockout input from Curtis 906 battery discharge indicator meter
✓ Output Lift Lockout signal, which can drive a pump contactor
✓ Pump SRO can be enabled to prevent pump startup when KSI
first turned on
✓ Sleep function prevents the controller draining the battery
when the vehicle is inactive
✓ Battery Discharge Indicator output
2
✓ Adjustable brake hold voltage reduces heating of the brake coil
✓ Reverse polarity protection
Curtis 1212S Manual, Rev. B
1 — OVERVIEW
Robust Safety and Reliability
✓ High RF immunity prevents speed variation and shutdowns in noisy
RF environments
✓ Controller power circuits and microprocessor software are
continuously monitored for proper operation
✓ On power-up, system automatically checks the throttle, brake,
and associated wiring, and disables drive if a fault is found
✓ Whenever the 1212S senses a loss of KSI or any fault that requires a
stop, it smoothly decelerates the vehicle to a stop
Meets or Complies with Relevant US and International regulations
✓ Electronics sealed to IPX5
✓ Designed to meet EN 12895:2000, EN 13849-1(PL=B, Cat 2),
and UL583.
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.
Working on electric vehicles is potentially dangerous. You should protect
yourself against runaways and high current arcs:
RUNAWAYS — Some conditions could cause the vehicle to run out of control.
Disconnect the motor or jack up the vehicle and get the drive wheels off
the ground before attempting any work on the motor control circuitry.
HIGH CURRENT ARCS — Always open the battery circuit before working on
the motor control circuit. Wear safety glasses, and use properly insulated
tools to prevent shorts.
Curtis 1212S Manual, Rev. B
3
2 — INSTALLATION & WIRING
2
Fig. 2 Mounting
dimensions, Curtis 1212S
controller.
INSTALLATION AND WIRING
MOUNTING THE CONTROLLER
The 1212S 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.
The outline and mounting hole dimensions are shown in Figure 2. The
controller should be mounted by means of the mounting holes at the opposing
corners of the base, using two M4 screws.
Dimensions in millimeters.
end product to ensure that its EMC performance complies with applicable
regulations; suggestions are presented in Appendix A.
✭
4
You will need to take steps during the design and development of your
Curtis 1212S Manual, Rev. B
2 — INSTALLATION & WIRING
12
34
CONNECTIONS: High Current
Four M4 bolt-on power terminals are provided for the high current connections:
two for the motor
(M1, M2) and two for the battery (B-, B+). The recommended
assembly torque for the M4 bolts is 1.6±0.2 N.m.
CONNECTIONS: Low Current
The low current logic control connections are provided by a 14-pin connector.
J1
1234567
8910 11 12 13 14
J1 Pin 1
J1 Pin 2 Pot High
J1 Pin 3 Lift Lockout Output
J1 Pin 4 Mode Switch (open=M1, closed=M2)
J1 Pin 5 Keyswitch Input (KSI)
J1 Pin 6 Interlock Input
J1 Pin 7 B+
J1 Pin 8 Pot Low
J1 Pin 9 Lift Lockout Input / Pump SRO input
J1 Pin 10 Forward Input
J1 Pin 11 BDI Output (0–5V)
J1 Pin 12 Reverse Input
J1 Pin 13 I/O GND
J1 Pin 14 Emergency Reverse
Pot Wiper
A 4-pin low power connector is provided for the programmer and the charge
inhibit input, and a 2-pin low power connector for the electromagnetic brake.
J2
J2 Pin 1 Rx
J2 Pin 2 I/O GND
J2 Pin 3 Tx/charge inhibit
J2 Pin 4 +15V
J3
1
2
J3 Pin 1 Brake +
J3 Pin 2 Brake -
The mating connectors are:
J1 Molex Mini-Fit-Jr. receptacle p/n 39-01-2140
J2 Molex Mini-Fit-Jr. receptacle p/n 39-01-2040
J3 Molex Mini-Fit-Jr. receptacle p/n 39-01-2020,
all with appropriate 45750-series crimp terminals.
Curtis 1212S Manual, Rev. B
5
2 — INSTALLATION & WIRING
WIRING: STANDARD INSTALLATION, 1212S
The wiring diagram presented in Figure 3 shows a typical installation for a
pallet truck application. This installation is shown with a Curtis ET-1XX MCU
electronic throttle.
The J2 connector can be used interchangeably for the programmer or
for the charge inhibit input.
HORN
KEYSWITCH
PUMP CONTACTOR
COIL
INTERLOCK SW
MODE SW
EMR REV SW
CURTIS
KSI
ET-
1XXMCU
GND
HORN SW
CONTROL
LIFT SW
FWD
0-5V
REV
BDI
FUSE
J1-7
B+
J1-5
KSI
LIFT LOCKOUT
J1-3
OUTPUT
J1-6
INTERLOCK
J1-4
MODE (M1, M2)
J1-14
EMERGENCY REVERSE
J1-8
POT LOW
J1-2
POT HIGH
J1-10
FORWARD
J1-1
POT WIPER
J1-12
REVERSE
J1-11
BDI (0–5V)
J1-13
I/O GND
B+
B-
M1
M2
BRAKE +
BRAKE -
LIFT LOCKOUT
INPUT
CHARGE INHIBIT
+15V
I/O GND
Rx
POWER
FUSE
MOTOR
J3-1
J3-2
J1-9
J2-3
J2-4
J2-3
Tx
J2-2
J2-1
EMERGENCY
STOP
M
EM BRAKE
B+
BATTERY
CURTIS 906
Pin 3
CHARGER
SOCKET
B-
PROGRAMMER
Fig. 3 Standard wiring configuration, Curtis 1212S controller.
CAUTION
☞
The polarity of the motor M1 and M2 connections will affect the operation of
the emergency reverse feature. The forward and reverse switches and the
and
the operator when the emergency reverse button is pressed.
6
1212S CONTROLLER
M1
M2 connections must be configured so that the vehicle drives away from
Curtis 1212S Manual, Rev. B
1234567
8910 11 12 13 14
Fig. 4 Wiring for voltage
1234567
8910 11 12 13 14
+
-
VOLTAGE
THROTTLE
Pot Wiper input (Pin 1)
B-
throttle.
2 — INSTALLATION & WIRING: Throttle
THROTTLE WIRING
Either a resistance throttle or a voltage throttle can be used with the 1212S
controller. The controller can accept a single-ended or inverse single-ended
input signal from the throttle, depending on how the Throttle Type parameter
is programmed; see page 14.
Voltage Throttle
Wiring for a voltage throttle is shown in the wiring diagram (Figure 3) for a
Curtis ET-1XX MCU, and here in Figure 4 for a simple voltage throttle that
would require forward and reverse switches. With a voltage throttle, the controller can be programmed for a Throttle Type 0 or 1 input signal; see page 14.
Fig. 5 Wiring for 5k
3-wire potentiometer
throttle.
Ω
The PotHigh and PotLow parameters are used to set the voltage range of
these throttles. If the pot wiper voltage is higher than the programmed PotHigh
value or lower than the programmed PotLow value, the controller will issue
an out-of-range throttle fault. In order for the controller to be able to detect
out-of-range throttle faults, the throttle must have a range within the limits
of 0.4–4.6 V.
Note: If a 0–5V throttle is used, it is the responsibility of the OEM
to provide appropriate throttle fault detection.
5kΩ, 3-Wire Potentiometer
A resistance throttle is shown in Figure 5. With this throttle, the controller can
be programmed for a Throttle Type 2 or 3 input signal; see page 14.
,
wires anywhere in the throttle assembly. The overall pot resistance should be
4.3 to 7.0 kΩ. Values outside this range will trigger a fault condition. If a pot
fault occurs while the vehicle is moving, the controller will decelerate the vehicle
to a smooth stop using the decel rate set by the Key Off Decel parameter. If
the fault is corrected while the throttle is still applied, an HPD fault will be
Curtis 1212S Manual, Rev. B
issued and driving is disabled until throttle is reduced to neutral.
The controller provides full pot fault protection against open or shorted
7
2 — INSTALLATION & WIRING: Switches, etc.
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 controller and for the
other control input switches. It must be sized to carry the 150 mA quiescent
logic current plus the current necessary to drive the precharge function (1.5
A for 0.5 seconds) and the horn and any other accessories powered from the
keyswitch circuit.
Emergency Reverse Switch
When the vehicle moves forward or stops, if the emergency reverse switch
is pressed the vehicle will decelerate to a stop (if it was moving) and then be
driven in the reverse direction. The active input level depends on the setting
of the Switch Normally Closed parameter; see page 20.
Emergency Stop Switch
When the emergency stop button is pressed, the 1212S controller shuts off
the EM brake output regardless of vehicle speed, thus engaging the brake
immediately.
Mode Switch
A mode switch is used to select operation in Mode 1 or Mode 2. Typically,
Mode 1 is programmed for slower indoor driving and Mode 2 for faster outdoor
driving; see Speed menu. The controller is in Mode 2 when the mode switch is
in the On position (input connected to B+). Leaving the mode input floating
or actively switching it Off (pulling it to B-) puts the controller in Mode 1.
The two modes have independent programmable settings.
Interlock Switch
The interlock switch, typically implemented as a tiller switch, deadman
footswitch, or seat switch, provides a safety interlock for the system. The switch
is allowed to be cycled within a set time (the Sequencing Delay). This feature is
useful in applications where the switch may bounce or be momentarily cycled
during operation.
Forward/Reverse Switches
Direction switches connected to B+ are used to select the driving direction.
Battery Discharge Indicator (BDI)
The 1212S controller can drive a BDI panel meter to show the battery pack’s
state of charge as a percentage of the ampere-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.
8
Curtis 1212S Manual, Rev. B
2 — INSTALLATION & WIRING: Switches, etc.
Circuitry Protection Devices
To protect the control wiring from accidental shorts, a low current fuse (appropriately sized for the maximum control circuit current draw) should be
connected in series with the B+ logic supply. A fuse is also recommended in
the high power circuit from the battery to the controller’s B+ terminal. This
fuse will protect the power system from external shorts and should be sized
appropriately for the maximum rated current of the controller.
Charge Inhibit
Typically, battery chargers have a dedicated third terminal that automatically
provides inhibit. Inhibit is provided through J2 Pin 3; see wiring diagram, page 6.
When J2 Pin 3 (charge inhibit input) is pulled low, the controller disables the
drive functions and engages the EM brake while the charger is connected. The
charger inhibit automatically powers up the controller without the keyswitch
on so that BDI can be tracked during charge. After BDI is 100% reset, power
is totally shut off (no current used) to avoid draining the battery.
Status LED
The 1212S controller has an internal Status 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).
Lift Lockout / Pump SRO
When the External Lift Lockout parameter is programmed on (see page 19),
the 1212S will take the external lift lockout signal from a Curtis 906 meter
to control the lift lockout driver when lift lockout is triggered, and the driver
will be activated when the input signal is low. The maximum current for this
low-side driver is 1.5 A.
The Pump SRO safety feature can be used to check the status of the pump
switch wired to B+. When the Lift Lockout Enable parameter (see page 19) is
programmed on, if the switch is closed before KSI is turned on, the 1212S will
report a Pump SRO fault and will disable the Lift Lockout Output.
Curtis 1212S Manual, Rev. B
9
3 — PROGRAMMABLE PARAMETERS
The 1212S controller has a number of parameters that can be programmed
3
using a Curtis handheld programmer or Curtis PC Programming Station. These
programmable parameters allow the vehicle’s performance to be customized to
best fit the needs of individual vehicle operators.
see Section 6.
The programmable parameters are grouped hierarchically into menus, as shown
in Table 1. Not all of these parameters are displayed on all controllers; the list
for any given controller depends on its specifications.
Table 1 Programmable Parameter Menus: 1311 Programmer
PROGRAMMABLE PARAMETERS
For information on programmming devices, see Appendix D.
For information on how to use the parameters to optimize performance,
DRIVE MENU ............................ p. 11
—Accel Max Speed
—Accel Min Speed
—Decel High Speed
—Decel Low Speed
—Rev Accel Max Speed
—Rev Accel Min Speed
—Rev Decel High Speed
—Rev Decel Low Speed
—Key Off Decel
—E Stop Decel
—E Stop Pause
—Soft Start
—Gear Soften
—Creep Speed
—Soft Stop Speed
—Speed ........................... p. 13
—Mode 1
—Max Speed
—Rev Max Speed
—Mode 2 (same)
THROTTLE MENU ........................p. 14
—Type
—PotHigh
—PotLow
—Neutral Deadband
—Throttle Max
—HPD
—Throttle Map
CURRENT MENU ......................... p. 16
—Main Current Limit
—Braking Current Limit
—Boost Current
—Boost Time
BRAKE MENU ............................ p. 16
—Delay
—Fault Check
—Hold Voltage
—Interlock Decel
—Interlock Brake Timeout
MOTOR MENU ............................p. 17
—System Resistance
—Resistance Auto Comp
—Auto Comp Current Limit
—Speed Scaler
BDI MENU ..................................p. 18
—Full Voltage
—Empty Voltage
—Full Charge Voltage
—Start Charge Voltage
—Reset Voltage
—Discharge Factor
—Charge Factor
—Low BDI Level
—Low BDI Max Speed
—External Lift Lockout
—Lift Lockout Enable
—Lift Lockout Threshold
—Lift Lockout Output Type
COMPENSATION MENU ................ p. 19
—IR Comp
—Anti-Rollback Comp
EMERGENCY REVERSE MENU .......p. 20
—Speed
—Time Limit
—Decel Rate
—Accel Rate
—Max Braking Current
—Switch Normally Closed
—EMR Interlock
MISCELLANEOUS MENU ............... p. 21
—Sequencing Delay
—Sleep
—Reset Drive Time
—Emergency Stop
—Pump SRO
—Reset Parameter
10
Curtis 1212S Manual, Rev. B
3 — PROGRAMMABLE PARAMETERS:
Drive Parameters
DRIVE MENU
ALLOWABLE
PARAMETER RANGE DESCRIPTION
Accel Max Speed 0.2 – 8.0 s Sets the rate (in seconds) at which the speed command increases when
full throttle is applied and the vehicle is traveling forward. Larger values
represent slower response.
Note: Allowable range is restricted by the Accel Min Speed setting.
Accel Min Speed 0.2 – 8.0 s Sets the rate (in seconds) at which the speed command increases when
minimal throttle is applied and the vehicle is traveling forward. Larger
values represent slower response
Note: Allowable range is restricted by the Accel Max Speed setting.
Decel High Speed 0.2 – 8.0 s Sets the rate (in seconds) that is used to slow down the vehicle when it
is traveling forward at high speed and throttle is reduced. Larger values
represent slower response.
Note: Allowable range is restricted by the Decel Low Speed setting.
Decel Low Speed 0.2 – 8.0 s Sets the rate (in seconds) that is used to slow down the vehicle when it
is traveling forward at low speed and throttle is reduced. Larger values
represent slower response.
Note: Allowable range is restricted by the Decel High Speed setting.
Rev Accel Max Speed 0.2 – 8.0 s Sets the rate (in seconds) at which the speed command increases when
full throttle is applied and the vehicle is traveling in reverse. Larger values
represent slower response.
Note: Allowable range is restricted by Rev Accel Min Speed setting.
Rev Accel Min Speed 0.2 – 8.0 s Sets the rate (in seconds) at which the speed command increases when
minimal throttle is applied and the vehicle is traveling in reverse. Larger
values represent slower response.
Note: Allowable range is restricted by Rev Accel Max Speed setting.
Rev Decel High Speed 0.2 – 8.0 s Sets the rate (in seconds) that is used to slow down the vehicle when it is
traveling in reverse at high speed and throttle is reduced. Larger values
represent slower response.
Note: Allowable range is restricted by Rev Decel Low Speed setting.
Rev Decel Low Speed 0.2 – 8.0 s Sets the rate (in seconds) that is used to slow down the vehicle when it
is traveling in reverse at low speed and throttle is reduced. Larger values
represent slower response.
Note: Allowable range is restricted by Rev Decel High Speed setting.
Key Off Decel 0.2 – 4.0 s Sets the rate (in seconds) that is used to slow down the vehicle at key-off
or in the event of a major fault.
E Stop Decel 0.2 – 4.0 s Sets the rate (in seconds) that is used to slow down the vehicle during
emergency reverse, i.e., when a throttle command >80% in the reverse
direction is given while the vehicle is moving forward. This gives the
operator a way to stop more quickly when unexpected conditions arise.
Curtis 1212S Manual, Rev. B
11
3 — PROGRAMMABLE PARAMETERS:
Drive Parameters
DRIVE MENU, cont’d
ALLOWABLE
PARAMETER RANGE DESCRIPTION
E Stop Pause 0.0 – 1.0 s Sets a pause before reversing direction after an emergency reverse stop.
This gives the operator time to return the throttle to neutral without moving
backwards.
Soft Start 0 – 100 % This parameter can be used to soften the bump associated with gear
slack in the transaxle when throttle is applied from the neutral state.
Larger values provide a softer slack take-up.
Gear Soften 0 – 100 % This parameter is intended to soften the bump associated with gear slack
in the transaxle when throttle is released and then reapplied while the
vehicle is still moving. Larger values provide a softer slack take-up.
Creep Speed 0 – 10 % Creep Speed helps to prevent vehicle rollback on inclines when the brake
is released with very little throttle applied. It is activated when the throttle
request exceeds the throttle deadband threshold.
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.
12
Curtis 1212S Manual, Rev. B
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