Curtis 1214-8, 1215-8, 1219-8 User Manual

MANUAL

1214-8 1215-8 1219-8

MultiMode™

MOTOR CONTROLLERS

DESIGN OF CURTIS PMC 1200 SERIES CONTROLLERS PROTECTED BY U.S. PATENT NO. 4626750.

CURTIS INSTRUMENTS, INC.

200 Kisco Avenue Mount Kisco, NY 10509 USA Tel: 914-666-2971 Fax: 914-666-2188 www.curtisinst.com

1214-8 / 1215-8 / 1219-8 Manual

p/n 16369, Rev. C: April 2003

1

CONTENTS

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

2. INSTALLATION AND WIRING ................................... 3

Mounting the Controller............................................ 3

Curtis 1214-/15-/19-8 Manual ii

3. PROGRAMMING AND ADJUSTMENT .................... 16

4. MAINTENANCE .......................................................... 17

5. DIAGNOSTICS AND TROUBLESHOOTING .......... 19

6. PROGRAMMER MENUS............................................. 22

APPENDIX A Glossary of Features and Functions.......... A-1

APPENDIX B Speciﬁcations ........................................... B-1

Connections: Low Current......................................... 4

Connections: High Current ....................................... 5

Wiring: Standard Conﬁguration ................................ 6

Wiring: Throttle ........................................................ 8

Wiring: Emergency Reverse Check .......................... 12

Contactors, Switches, and Other Hardware ............. 13

Installation Checkout ...............................................14

Cleaning ................................................................... 17

Diagnostic History ................................................... 17

Testing the Fault Detection Circuitry ...................... 18

Programmer Diagnostics .......................................... 19

LED Diagnostics ...................................................... 21

CONTENTS

234567890

FIGURES / TABLES

FIGURES

FIG. 1: Curtis 1215-8 motor controller .................................... 1

FIG. 2: Mounting dimensions,

Curtis 1214-/15-/19-8 controller ................................. 3

FIG. 3: Standard wiring diagram ..............................................6

FIG. 4: Wiring for 5kΩ–0 throttle (“Type 1”) ......................... 8

FIG. 5: Wiring for 20kΩ pot used as a wigwag-style

throttle (“Type 1”) .......................................................9

FIG. 6: Wiring for 0–5kΩ throttle (“Type 3”) ......................... 9

FIG. 7: Wiring for 0–5V throttle (“Type 2”)..........................10

FIG. 8: Wiring for 0–10V throttle (“Type 2”)........................11

FIG. 9: Wiring for 3-wire pot throttle (“Type 2”) ..................11

FIG. 10: Wiring for Curtis ET-XXX electronic throttle

(“Type 2”) ................................................................. 12

FIG. A-1: Ramp shape (throttle map) for controller with

maximum speed 100% and creep speed 0 ................A-8

FIG. A-2: Ramp shape (throttle map) for controller with

maximum speed 100% and creep speed 10%........... A-9

FIG. A-3: Ramp shape (throttle map) for controller with

maximum speed 60% and creep speed 10%............. A-9

TABLES

TABLE 1: Troubleshooting chart ................................................ 20

TABLE 2: LED codes ................................................................. 21

Curtis 1214-/15-/19-8 Manual iii

OVERVIEW

1 — OVERVIEW

1

Fig. 1 Curtis 1215-8

motor controller. The 1214-8 and 1219-8 controllers are similar, but differ in overall length.

Curtis 1214-8, 1215-8, and 1219-8 programmable motor speed controllers provide efﬁcient, cost-effective, and simple-to-install control for a variety of large industrial vehicles. Typical applications include walkie/rider pallet trucks, fork lifts, stackers, reach trucks, and other industrial trucks.

The 1207-based microprocessor logic section combined with a Curtis MOSFET power section gives the 1214-/15-/19-8 controller high power and advanced features in a rugged, compact package. The optional handheld programmer enables the user to set parameters, conduct tests, and obtain diagnostic information quickly and easily.

M- (motor armature)

4-pin connector for handheld programmer

LED

24-pin low-power connector

B- (negative battery)

B+ (positive battery)

Like all Curtis motor controllers, the 1214-/15-/19-8 controller offers superior operator control of the vehicle’s motor drive speed. Features include:

✓ Power MOSFET design, providing

• inﬁnitely variable drive and plug brake control

• silent high-frequency operation

• high efﬁciency (for reduced motor and battery losses)

✓ Overvoltage and undervoltage protection ✓ Thermal protection/compensation circuitry that provides

undertemperature cutback, constant current limit over operating range,

Curtis 1214-/15-/19-8 Manual 1

A2 (plug diode to

motor armature)

1 — OVERVIEW

and linear rollback in overtemperature—thus preventing sudden power

loss regardless of thermal conditions ✓ Intelligent handheld 13XX programmer provides a full set of parameter

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

components—readily available through both an on-board LED and the

optional handheld programmer ✓ Meets or exceeds EEC fault detect requirements, with circuitry and

software to detect faults in the throttle circuit, MOSFET drive circuits,

MOSFET output, contactor drivers, and contactors ✓ Programmable input sequencing options include several combinations

of neutral start and static return to off (SRO) ✓ Arcless contactor switching with microprocessor-controlled contactor

sequencing ✓ 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) provides full function

with a single input

✓ Anti-rollback (ramp start) provides full power for starting on ramps ✓ Simple contactor and switch wiring, with coil drivers monitored

for shorts and open circuits—thus ensuring fail-safe operation ✓ Flexible throttle circuitry accommodates a variety of throttle types:

5kΩ–0, 0–5kΩ, 0–5V, 0–10V, inductive, Hall, etc. ✓ Programmable “ramp shape” (static throttle map) provides flexibility

in selecting throttle response feel

✓ Sealed package, providing environmental protection ✓ Power connections made by tin-plated solid copper busses,

with a polarized Molex connector for control signals

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.

Curtis 1214-/15-/19-8 Manual 2

2 — INSTALLATION & WIRING

INSTALLATION AND WIRING

2

Fig. 2 Mounting

dimensions, Curtis 1214-/15-/19-8 controllers.

MOUNTING THE CONTROLLER

The 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, dry 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 four screws. The case outline and mounting hole dimensions are shown in Figure 2. Access is needed at the front of the controller to plug the programmer into its connector, and to view the LED.

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

180

(7.1)

169

(6.66)

“A” “B”

[1219 MODELS ONLY]

1214 1215 1219

“A”

210 (8.275) 253 (9.975) 309 (12.180)

“B”

165 (6.490) 208 (8.190) 264 (10.394)

23

(0.893)

5.5 (0

.22

)

81.3

(3.2)

Dimensions in millimeters and (inches)

Curtis 1214-/15-/19-8 Manual 3

7.1 (0.28) dia., 4 plcs [6 plcs in 1219]

26.4×20.6×2.3 (1.04×0.81×0.09);

8.4 (0.33) dia. hole thru

3.18 (0.125)

2 — INSTALLATION & WIRING

CONNECTIONS: Low Current

A 24-pin low current connector in the front of the controller provides the low current logic control connections (see pin list below). The mating connector is Molex Mini-Fit Jr., part number 39-01-2245. Contact Molex regarding compatible pins: 39-00-0078 for #16 AWG, 39-00-0039 for #18–24 AWG.

24 23 22 21 20 19 18 17 16 15 14 13

121110987654321

Pin 1 keyswitch input (KSI) Pin 2 brake input Pin 3 mode selection input Pin 4 n/c Pin 5 throttle: 0–10V Pin 6 emergency reverse input Pin 7 n/c Pin 8 n/c Pin 9 n/c Pin 10 forward input Pin 11 reverse input Pin 12 n/c

Pin 13 throttle: 3-wire pot high Pin 14 throttle: pot low Pin 15 throttle: 0–5V (3-wire pot wiper) Pin 16 throttle: 2-wire 5kΩ–0 or 0–5kΩ input Pin 17 main contactor driver output Pin 18 forward contactor driver output Pin 19 reverse contactor driver output Pin 20 n/c Pin 21 n/c Pin 22 n/c Pin 23 n/c Pin 24 emergency reverse (BB) check output [optional]

A 4-pin low power connector, also located on the front of the controller, is provided for the handheld programmer.

Curtis 1214-/15-/19-8 Manual 4

M-

2 — INSTALLATION & WIRING

CONNECTIONS: High Current

Four tin-plated solid 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

A2

B-

CAUTION

☞

B+

Working on electric vehicles is potentially dangerous. You should protect yourself against runaways, high current arcs, and outgassing from lead acid batteries:

RUNAWAYS — Some fault conditions could cause the vehicle to run

out of control. Jack up the vehicle and get the drive wheels off the ground before attempting these procedures or any other work on the motor control circuitry.

HIGH CURRENT ARCS — Electric vehicle batteries can supply very high

power, and arcs can occur if they are short circuited. Always open the battery circuit before working on the motor control circuit. Wear safety glasses, and use properly insulated tools to prevent shorts.

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.

LEAD ACID BATTERIES — Charging or discharging generates hydrogen

gas, which can build up in and around the batteries. Follow the battery manufacturer’s safety recommendations. Wear safety glasses.

Curtis 1214-/15-/19-8 Manual 5

2 — INSTALLATION & WIRING

WIRING: Standard Configuration

The conﬁguration shown in Figure 3 is a typical arrangement for most applications. For walkie applications, the brake switch is typically activated by the tiller, and a belly button switch provides emergency reverse. The emergency reverse check feature (wiring shown by dotted line) is a factory option.

For rider applications, the brake switch is typically a seat switch or a foot switch, and there is no emergency reverse.

Fig. 3 Standard

wiring diagram, Curtis 1214-/15-/19-8 controller.

KEYSWITCH

FUSE

CONTROL

B+

B-

SWITCHES

BRAKE/

SEAT

POLARITY

PROTECTION

DIODE

POWER

FUSE

CONTACTOR

PRECHARGE RESISTOR

(250 Ω, 5 W)

MAIN

FORWARD

REVERSE

M-

B-

B-B-

CONTACTORS

REV

FORWARD

CONTACTOR

A1

FWD

A

MAIN

S1S2

A2

B+

5kΩ–0

THROTTLE

(TYPICAL)

A2

REVERSE

CONTACTOR

SWITCHES

MODE

SELECT

EMERG.

REV

Curtis 1214-/15-/19-8 Manual 6

2 — INSTALLATION & WIRING

Standard Power Wiring

In every wiring conﬁguration, it is imperative that the ﬁeld be wired between B+ and A2 and that the armature be wired between M- and the A2 terminal. The internal plug diode used in the 1214-/15-/19-8 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.

Standard Control Wiring

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 17 unconnected.

24-pin detail (see Fig. 3):

EMERGENCY

REVERSE

CHECK

OUTPUT

(factory option)

FORWARD

CONTACTOR

REVERSE

CONTACTOR

2-WIRE POT

MAIN

CONTACTOR

(5 k

Ω

)

POT

LOW

24 23 22 21 20 19 18 17 16 15 14 13

121110987654321

FORWARD

REVERSE

EMERGENCY

REVERSE

(walkies only)

MODE

SELECT

SEAT SWITC H

KEYSWITCH

BRAKE

or

The throttle shown in Figure 3 is a 5kΩ–0 type. Various other throttles can also be accommodated, and are discussed in the throttle wiring section.

Curtis 1214-/15-/19-8 Manual 7

2 — INSTALLATION & WIRING

WIRING: Throttle

Wiring for various throttles is described below. These include 5kΩ–0 and 0–5kΩ throttles, 0–5V and 0–10V throttles, 3-wire potentiometer throttles, and electronic throttles. If the throttle you are planning to use is not covered, 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 2-Wire Pot pin (Pin 16) and the Pot Low pin (Pin 14), as shown in Figure 4. It doesn’t matter which wire goes on which pin. For Type 1 throttles, zero speed corresponds to 5kΩ and full speed corresponds to 0Ω.

Fig. 4 Wiring for 5k

throttle (“Type 1”).

Fig. 5 Wiring for 20k

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

Ω

–0

Pin 16 Pin 14

5kΩ–0

PIN KEY

2-Wire Pot Pot Low

FASTER

14 1315161718192021222324

121110987654321

In addition to accommodating the basic 5kΩ–0 throttle, the Type 1 throttle input can be used to implement a wigwag-style throttle. Using a 20kΩ potentiometer wired as shown in Figure 5, the pot wiper can be set such that the controller has 5kΩ between Pins 14 and 16 when the throttle is in the neutral position. The throttle mechanism can then be designed such that rotating it either forward or back decreases the resistance between Pins 14 and 16, which increases the controller output. The throttle mechanism must provide signals to

Ω

Pin 16 Pin 14

20 kΩ

PIN KEY

2-Wire Pot Pot Low

FASTERFASTER

14 1315161718192021222324

121110987654321

Curtis 1214-/15-/19-8 Manual 8

2 — INSTALLATION & WIRING

the controller’s forward and reverse inputs independent of the throttle pot resistance. The controller will not sense direction from the pot resistance.

With Type 1 throttles, broken wire protection is provided by the controller sensing the current flow from the 2-Wire Pot pin through the pot and into the Pot Low pin. If the Pot Low input current falls below 0.1 mA, a throttle fault is generated and the controller is disabled. NOTE: The Pot Low pin (Pin 14) must not be tied to ground.

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 2-Wire Pot pin (Pin 16) and Pot Low (Pin 14). It doesn’t matter which wire goes on which pin. For Type 3 throttles, zero speed corresponds to 0Ω and full speed corresponds to 5kΩ.

Fig. 6 Wiring for 0–5k

throttle (“Type 3”).

Ω

Pin 16 Pin 14

FASTER

0–5kΩ

PIN KEY

2-Wire Pot Pot Low

121110987654321

With Type 3 throttles, broken wire protection is provided by the controller sensing the current flow from the 2-Wire Pot pin through the pot and into the Pot Low pin. If the Pot Low input current falls below 0.1 mA, a throttle fault is generated and the controller is disabled. NOTE: The Pot Low pin (Pin 14) must not be tied to ground.

0–5V, 0–10V, 3-Wire Potentiometer, or Electronic Throttle (“Type 2”)

With these throttles (“Type 2” in the programming menu), the controller looks for a voltage signal at either the pot wiper/0–5V input (Pin 15) or the 0–10V input (Pin 5). Zero speed corresponds to 0V and full speed corresponds to either 5V or 10V. Pot Low (Pin 14) is the current return path for all Type 2 throttles. It is 200 mV above B- and must have at least 0.1 mA ﬂowing into it to prevent pot faults.

14 1315161718192021222324

Curtis 1214-/15-/19-8 Manual 9

2 — INSTALLATION & WIRING

0–5V Throttle

Two ways of wiring the 0–5V throttle are shown in Figure 7. Broken wire protection is provided by the controller looking for a minimum current into the Pot Low pin. If the Pot Low input current falls below 0.1 mA, a throttle fault is generated and the controller is disabled. 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

15) exceeds 8 volts, the controller output will be disabled. NOTE: In Figure 7(a), the throttle’s voltage input signal is in reference to Pot Low.

Fig. 7 Wiring for 0–5V

throttle (“Type 2”).

(a) Ground-referenced 0–5V throttle

(Shunt impedance 150 kΩ to ground)

+

-

B-

(b) 0–5V throttle sensor

+

0–5V

SENSOR

SENSOR GROUND

0–10V Throttle

121110987654321

Pin 15 Pin 14 Pin 13

121110987654321

SENSOR OUTPUT

Pin 15 Pin 14

4.7 kΩ

14 1315161718192021222324

PIN KEY

0–5V Input Pot Low Pot High

14 1315161718192021222324

PIN KEY

0–5V Input Pot Low

Two ways of wiring the 0–10V throttle are shown in Figure 8. Broken wire protection is provided by the controller looking for a minimum current into the Pot Low pin. If the Pot Low input current falls below 0.1 mA, a throttle fault is generated and the controller is disabled. If a throttle sensor is used, the sensor’s ground return current must be less than 10 mA. If the 0–10V throttle input (Pin

5) exceeds 16 volts, the controller output will be disabled. NOTE: In Figure 8(a), the throttle’s voltage input signal is in reference to Pot Low.

Curtis 1214-/15-/19-8 Manual 10

Curtis 1214-8, 1215-8, 1219-8 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

OVERVIEW

MOUNTING THE CONTROLLER

CONNECTIONS: Low Current

CONNECTIONS: High Current

WIRING: Standard Configuration

WIRING: Throttle