Curtis 1212S Bedienungsanleitung

Manual

Model 1212S

Electronic Motor Controller

Read Instructions Carefully!

Specications are subject to change without notice.

Curtis Instruments, Inc.

200 Kisco Avenue

Mt. Kisco, NY 10549

www.curtisinstruments.com

ii Curtis 1212S Manual, R e v. B

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 aVehicle Design Considerations

appendix bEN 13849 Compliance, 1212S Controller

appendix cBattery Discharge Indicator (BDI) Setup

appendix dProgramming Devices

appendix e1212S Controller Speciﬁcations

iii Curtis 1212S Manual, R e v. 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

Curtis 1212S Manual, R e v. B 1

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 pro-

gramming device. Use of the programmer offers diagnostic and test capability

as well as conﬁguration ﬂexibility.

Fig. 1 Curtis 1212S

electronic motor controller.

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 ☞

2Curtis 1212S Manual, R e v. B

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

✓Adjustable brake hold voltage reduces heating of the brake coil

✓Reverse polarity protection

Curtis 1212S Manual, R e v. B 3

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 EN12895:2000, EN13849-1(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.

1 — OVERVIEW

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.

4Curtis 1212S Manual, R e v. B

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.

2 — INSTALLATION & WIRING

Fig. 2 Mounting

dimensions, Curtis 1212S

controller.

Dimensions in millimeters.

✭

You will need to take steps during the design and development of your

end product to ensure that its EMC performance complies with applicable

regulations; suggestions are presented in Appendix A.

Curtis 1212S Manual, R e v. B 5

2 — INSTALLATION & WIRING

J1 Pin 1 Pot Wiper

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

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.

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 Pin 1 Rx

J2 Pin 2 I/O GND

J2 Pin 3 Tx/charge inhibit

J2 Pin 4 +15V

J3 Pin 1 Brake +

J3 Pin 2 Brake -

1234567

8910 11 12 13 14

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.

6Curtis 1212S Manual, R e v. B

Fig. 3 Standard wiring conﬁguration, Curtis 1212S controller.

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.

2 — INSTALLATION & WIRING

☞

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 M1

and M2 connections must be conﬁgured so that the vehicle drives away from

the operator when the emergency reverse button is pressed.

B+

B-

BRAKE +

BRAKE -

CHARGE INHIBIT

EM BRAKE

CHARGER

SOCKET

CURTIS 906

J3-1

J3-2

J1-9 Pin 3

EMERGENCY

STOP

POWER

FUSE

J2-4

J2-3

J2-2

J2-1

+15V

I/O GND

PROGRAMMER

B-

B+

J2-3

CONTROL

FUSE

KEYSWITCH

LIFT SW

PUMP CONTACTOR

COIL

INTERLOCK SW

MODE SW

EMR REV SW

POT LOW

POT HIGH

FORWARD

POT WIPER

REVERSE

FWD

0-5V

REV

GND

KSI CURTIS

ET-

1XXMCU

J1-7 B+

KSI

LIFT LOCKOUT

OUTPUT

EMERGENCY REVERSE

MODE (M1, M2)

INTERLOCK

J1-5

J1-3

J1-6

J1-4

J1-14

J1-8

J1-2

J1-10

J1-1

J1-12

J1-11

J1-13

MOTOR

1212S CONTROLLER

BDI (0–5V)

I/O GND

BATTERY

HORN

BDI

LIFT LOCKOUT

INPUT

HORN SW

Curtis 1212S Manual, R e v. B 7

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 con-

troller can be programmed for a Throttle Type 0 or 1 input signal; see page 14.

Fig. 5 Wiring for 5k

3-wire potentiometer

throttle.

1234567

8910 11 12 13 14

Fig. 4 Wiring for voltage

throttle.

1234567

8910 11 12 13 14

VOLTAGE

THROTTLE

Pot Wiper input (Pin 1)

B-

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.

The controller provides full pot fault protection against open or shorted

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

issued and driving is disabled until throttle is reduced to neutral.

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