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APPENDIX C

pg. 45

1212 & 1212P Manual - Sep 2019

APPENDIX C

BATTERY DISCHARGE INDICATOR (BDI) SETUP

The Battery Discharge Indicator used with the 1212/1212P is quite flexible and, once set up, will

provide the user with reliable information on the status of the battery system.
The BDI parameters (Program » BDI menu) must be set up specifically for the type and size of the

charger, the battery size, and the vehicle’s expected drive cycle.
When setting up the BDI parameters, use the same vehicle and set of batteries for the entire

procedure. Do not drive the vehicle or charge the batteries except when requested to do so in the

procedure.
Follow the steps in the order they are presented.
Before beginning the procedure, set the following initial values:

Full Voltage

= 24.4

Empty Voltage

= 20.8

Full Charge Voltage

= 28.2

Start Charge Voltage

= 25.2

Reset Voltage

= 25.0

Discharge Factor =

2.0

Charge Factor

=

2.0

Low BDI Level = 0

Low BDI Max Speed

=

50.

Step 1 — Setting the Reset Voltage

a. Plug in the charger, and fully charge the batteries. With the charger still attached and running,

measure the final battery voltage with a Digital Volt Meter (DVM).

b. Set the Full Charge Voltage 0.2 V lower than the measured value.
c. Turn off or disconnect the charger and let the batteries sit for 1 hour. Measure the battery voltage

again.

d. Set the Reset Voltage 0.2 V lower than the new measured value.

Step 2 — Setting the Full Voltage

a. Select a medium speed mode and drive the vehicle for 10–15 minutes.
b. After this time and while driving straight on a level surface, record the battery voltage displayed

in the 1311’s Monitor menu.

c. Set the Full Voltage parameter to this value.

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Summary of Contents for 1212

Page 1: ...ce 2019 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 53112 Rev F Sep 2019 Curtis Instruments Inc 200 Kisco Avenue Mt Kisco NY 10549 www curtisinstruments com Models 1212 1212P ...

Page 2: ...ARD INSTALLATION 1212P 7 THROTTLE WIRING 8 SWITCHES AND OTHER HARDWARE 10 3 PROGRAMMABLE PARAMETERS 13 DRIVE PARAMETERS 15 SPEED PARAMETERS 17 THROTTLE PARAMETERS 18 CURRENT PARAMETERS 21 INHIBIT PARAMETERS 21 BRAKE PARAMETERS 22 HORN PARAMETERS 22 MOTOR PARAMETERS 23 STALL PARAMETERS 23 BDI PARAMETERS 24 COMPENSATION PARAMETERS 25 EMERGENCY REVERSE PARAMETES 25 MISCELLANEOUS PARAMETERS 26 4 MONIT...

Page 3: ...12P CONTROLLER SPECIFICATIONS 48 FIGURES FIGURE 1 CURTIS 1212 1212P ELECTRONIC MOTOR CONTROLLER 1 FIGURE 2 MOUNTING DIMENSIONS CURTIS 1212 1212P CONTROLLERS 4 FIGURE 3A STANDARD WIRING CONFIGURATION CURTIS 1212 CONTROLLER 6 FIGURE 3B STANDARD WIRING CONFIGURATION CURTIS 1212P CONTROLLER 7 FIGURE 4 WIRING FOR 3 WIRE 5KΩ POTENTIOMETER THROTTLE 8 FIGURE 5 WIRING FOR VOLTAGE THROTTLE 9 FIGURE 6 WIRING...

Page 4: ...ABLE OF CONTENTS CONT D 1212 1212P Manual Sep 2019 TABLES TABLE 1 PROGRAMMABLE PARAMETER MENUS 13 TABLE 2 STATUS LED FAULT CODES 38 TABLE 3 TROUBLESHOOTING CHART 39 TABLE E 1 SPECIFICATIONS 1212 CONTROLLER 48 ...

Page 5: ...12 1212P controllers are fully programmable by means of a Curtis programming device Use of the programmer offers diagnostic and test capability as well as conﬁguration flexibility Figure 1 Curtis 1212 1212P Electronic Motor Controller Like all Curtis motor controllers the 1212 and 1212P offer superior operator control of the vehicle s motor drive speed Key features include Smooth and Secure Contro...

Page 6: ...device or can be supplied pre programmed Accepts all standard throttle types including single ended wigwag and unipolar Simpliﬁed troubleshooting and diagnostics Standard Mini Fit Molex Jr and Faston terminals provide proven robust wiring connections Valuable Additional Features Optional Push Switch input releases the brake and allows the motor to free wheel 1212 models only Push Too Fast feature ...

Page 7: ...put from Curtis 906 battery discharge indicator meter Output Lift Lockout signal which can drive a relay Neutral input that can be used to shut off output regardlessof throttle input Note Push feature is not available with the 1212P 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 conta...

Page 8: ...o 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 two mounting holes at the opposing corners of the heatsink using M4 8 screws Figure 2 Mounting Dimensions Curtis 1212 and 1212P Controllers Dimensions in millimeters and inches You will need to take steps during the design and developme...

Page 9: ...J1 Pin 7 B J1 Pin 8 pot low J1 Pin 9 speed pot pump SRO input lift lockout input J1 Pin 10 status LED J1 Pin 11 BDI J1 Pin 12 reverse switch neutral input J1 Pin 13 I O GND J1 Pin 14 push switch emergency reverse Lift lockout emergency reverse pump SRO and neutral input available only on 1212P A 4 pin low power connector is provided for the programmer and the battery charger The mating connector i...

Page 10: ... active Inhibit Type parameter set to 0 The J2 connector can be used interchangeably for the programmer or for the battery charger Figure 3a Standard Wiring Conﬁguration Curtis 1212 Controller SPEED INHIBIT KEYSWITCH CONTROL FUSE M2 M1 J1 8 J3 1 B B POWER FUSE BATTERY Programmer 1212 Controller MODE M1 M2 J1 4 J1 2 J1 1 J1 6 J2 4 J2 3 J2 2 J2 1 B I O GND Tx Rx MOTOR J1 5 KSI MODE SW STATUS LED REV...

Page 11: ...nd 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 CAUTION Figure 3b Standard Wiring Conﬁguration Curtis 1212P Controller INTERLOCK KEYSWITCH CONTROL FUSE M2 M1 INTERLOCK SW Inhibit Type 4 J1 8 J3 1 B B POWER FUSE BATTERY Programmer 1212P Controller MODE M1 M2 J1 4 J1 2 J1 13 J1 1 J1 6 ...

Page 12: ...ontroller can be programmed for a Throttle Type 0 4 input signal see page 18 1 2 3 4 5 6 7 8 9 10 11 12 13 14 Figure 4 Wiring for 3 Wire 5KW Potentiometer Throttle For wigwag inverted wigwag and unipolar applications the pot can be correctly centered within the controller s neutral band by using the throttle autocalibration feature see page 20 The controller provides full pot fault protection agai...

Page 13: ...hat it does not affect throttle input resistance and thus the throttle response a 100kΩ pot is recommended The speed limit pot is at its maximum speed setting when its wiper is shorted to the throttle s pot high connection Pin 2 When the speed limit pot is in its maximum speed position the vehicle s speed at full throttle corresponds to the programmed maximum speed setting The speed limit pot is a...

Page 14: ... Release Switch Brake Coil Disable Switch If a brake release lever is used to release the electromagnetic brake mechanically a brake coil disable switch is recommended This switch opens the electromagnetic brake coil circuit when the mechanical brake release lever releases the brake from the motor shaft The open brake coil circuit will register as a fault inhibiting controller operation if an oper...

Page 15: ... used to avoid draining the battery If your battery charger does not have a dedicated inhibit terminal you must wire B to J2 Pin 3 as shown in Figure 6 For pallet truck applications the charger B and B should not connect to J2 due to its low current rating as shown in Figure 3b 1 2 3 4 Figure 6 Wiring to Inhibit Operation During Battery Charging For Battery Chargers Without a Dedicated Inhibit Ter...

Page 16: ... and when the throttle autocalibration feature is being used The horn driver sinks a maximum current of 15mA Using a horn with a higher current requirement will damage and disable the driver The horn driver can be used to drive a brake light instead of a horn see Brake menu In 1212P models only Pin 3 can be used to drive a relay to control the pump contactor Setting the parameter Lift Lockout Enab...

Page 17: ...1311 Programmer DRIVE MENU p 15 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 Push Max Speed Soft Stop Speed Speed p 17 Mode 1 Max Speed Min Speed Rev Max Speed Rev Min Speed Mode 2 Max Speed Min Speed Rev Max Speed Rev Min S...

Page 18: ...ge 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 EMERGENCY REVERSE MENU p 25 Speed Time Limit Decel Rate Accel Rate Max Braking Current Switch Normally Closed EMR Interlock MISCELLANEOUS MENU p 26 Sleep Reset Drive Time Emergency Stop Pump SRO COMPENSATION MENU p 25 IR Comp Anti...

Page 19: ...ote 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 throttle is applied while the speed limit pot is in its minimum speed position 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 Hig...

Page 20: ...est exceeds the throttle deadband threshold Push Max Speed 25 50 Available only with 1212 Sets the maximum speed at which the vehicle can be pushed When the vehicle is powered on and in neutral it enters the push mode when the push button is activated The electromagnetic brake is released driving is inhibited and speed is limited to Push Max Speed When the vehicle is not powered on and the brake i...

Page 21: ... During forward operation defines the requested speed at full throttle when the speed limit pot is in its maximum speed position Note Allowable range is restricted by the M1 M2 Min Speed setting M1 M2 Min Speed 0 100 During forward operation defines the requested speed command at full throttle when the speed limit pot is in its minimum speed position Min Speed cannot be set higher than the program...

Page 22: ...for voltage throttles Types 5 9 For 5kΩ 3 wire pot throttles PotLow is determined by the throttle itself Neutral Deadband 5 30 Sets the throttle range the controller interprets as neutral Increasing the parameter setting increases the neutral range This parameter allows the neutral deadband to be defined wide enough to ensure the controller goes into neutral when the throttle is released Guideline...

Page 23: ...sitions providing enhanced slow speed maneuverability Values above 50 give the vehicle a faster more responsive feel at low throttle positions Tremor Suppression 0 100 This parameter can be used to limit the controller s response to sharp throttle movements such as movements resulting from hand tremors Larger values will provide a steadier ride but they also result in more sluggish response to thr...

Page 24: ...turn the keyswitch on 4 Select the program mode and scroll down to the throttle auto calibration parameter 5 Set the Calibration parameter On Program Throttle Calibration At this point the horn will probably sound indicating that the throttle pot is out of adjustment If the horn does not sound the pot is already centered and no further adjustment is necessary 6 With the throttle lever at the neutr...

Page 25: ...f current that greatly improves performance with transient loads such as starting on a hill crossing a threshold climbing obstacles etc When the controller recognizes that the motor needs more current to respond to a drive request it provides a cur rent boost of a set amount for a set time The Boost Current parameter defines the motor current limit during the boost period For 1212 22xx controllers...

Page 26: ...d to neutral and will remain on for about 2 seconds after the EM brake is engaged When the horn output is used as a brake light driver Fault Beep see Horn menu should be programmed Off When Brake Light is set to Off the horn output acts as a horn driver 1 2 3 4 5 6 7 8 9 10 11 12 13 14 Figure 8 Wiring for brake light HORN MENU PARAMETER ALLOWABLE RANGE DESCRIPTION Fault Beep On Off When programmed...

Page 27: ...he maximum vehicle speed will be the same whether the actual battery voltage is 27 volts or 23 volts or any value in between Current Rating model dependent This parameter should be set to the current rating provided by the motor manufacturer For 1212 22xx controllers it is adjustable from 0 to 45 amperes For 1212 24xx controllers it is adjustable from 0 to 70 amperes For 1212P 25xx controllers it ...

Page 28: ...attery from deep discharge Setting Low BDI Level to zero disables this function and allows the battery to discharge completely Low BDI Max Speed 10 100 Sets the maximum allowed vehicle speed when the battery charge falls below the programmed Low BDI Level External Lift Lockout On Off Available only with 1212P When programmed On the lift lockout input pin 9 activates the lift lockout feature When p...

Page 29: ...is moving in reverse direction Setting this parameter to zero means there is no time limit Decel Rate 0 2 4 0 s Sets the rate at which the vehicle brakes to a stop when emergency reverse is activated and the vehicle is moving forward If the vehicle is already moving in the reverse direction above the programmed EMR speed it will be brought down to the EMR speed Accel Rate 0 2 8 0 s Sets the rate a...

Page 30: ... will stop abruptly The emergency stop switch with dual contacts is strongly recommended otherwise the function could be ineffective for some downhill applications and this MUST be evaluated by the OEM Off When the emergency stop button is pressed the battery is disconnected and the vehicle will decelerate for a short distance before it fully stops Pump SRO On Off Available only with 1212P Pin J1 ...

Page 31: ...easured motor armature current Current Limit 0 90 A Ultimate current limit of the controller taking into account boost mode thermal protection etc Resistance 0 854 mW Measured system resistance when the motor is stalled Throttle 0 100 Available throttle input Speed Limit Pot 0 100 Available speed limit pot input Mode Input On Off Status of the mode switch at J1 4 Reverse Input On Off Status of the...

Page 32: ...ond to the absolute full range of your particular throttle mechanism It is advisable to include some buffer around the absolute full range of the throttle mechanism to allow for throttle resistance variations over time and temperature as well as variations in the tolerance of potentiometer values between individual throttle mechanisms Tuning the Neutral Deadband Starting with the Neutral Deadband ...

Page 33: ... that the throttle operates correctly in both forward and reverse Conﬁrming proper throttle operation Select a direction and operate the throttle The motor should begin to turn in the selected direction If it does not verify the wiring to the throttle and motor The motor should run proportionally faster with increasing throttle If not refer to Section 7 1212P models The polarity of the motor s M1 ...

Page 34: ... amps 1212 24xx and 1212P models d Set the Boost Current Limit parameter Program Current Boost Current Limit to the same value as the Main Current Limit 25 amps for 1212 22xx models and 35 amps for 1212 24xx and 1212P models e In the Monitor menu scroll down to the Resistance ﬁeld f With the speed limit pot set at maximum apply the throttle full forward driving the vehicle against the immovable ob...

Page 35: ...antage of the controller s features Please refer to the descriptions of the applicable parameters in Section 3 if there is any question about what any of them do Instructions are provided for the following four tuning steps Step 5 Setting the maximum speeds Step 6 Setting the acceleration and deceleration rates Step 7 Adjusting load compensation Step 8 Fine tuning the vehicle s response smoothness...

Page 36: ...ggest that you drive in a conﬁned area such as an ofﬁce where low speed maneuverability is crucial Depending on how you liked the forward acceleration you experienced increase or decrease the Accel Min Speed value Continue testing and adjusting this value until you are satisﬁed with the vehicle s low speed forward acceleration b Now adjust Decel Low Speed Driving at full throttle with the speed li...

Page 37: ... stops typically as fast as possible without making the vehicle unstable n Note that Key Off Decel should always be set faster than or equal to the fastest forward deceleration rate Decel High Speed E Stop deceleration rate The E Stop Decel parameter sets the decel rate that will be used when the vehicle is moving forward and the throttle makes a fast transition through neutral to a 80 reverse thr...

Page 38: ... numbers provide stiffer stronger response If the value needs to be much larger or smaller than this range to achieve acceptable performance the System Resistance has probably not been set up correctly and should be checked Note Largely different settings for IR Comp will affect the maximum speeds that were set in Step 5 Therefore if you make large changes to IR Comp you should repeat Step 5 Just ...

Page 39: ... how the slop transition is softened at the expense of a small bit of nonlinearity in the acceleration rate d Adjust Gear Soften until you ﬁnd a setting you like noting that you probably won t notice much of a difference if you re using a brand new tight transaxle Some users prefer a softened feel while others prefer this parameter set to zero because they want complete linearity in response In se...

Page 40: ...sition i e a torque direction reversal Generally we recommend that you do your tuning with Tremor Suppression set to the default value 50 and then adjust it if necessary as the ﬁnal piece of tuning higher values for more suppression lower values for less Tremor compensation is most noticeable when the throttle is moved quickly from full to low but non neutral values The function is bypassed in the...

Page 41: ...e is recommended each time the vehicle is brought in for maintenance Refer to the troubleshooting chart Table 3 for suggestions about possible causes of the various faults For information on programming devices see Appendix D LED DIAGNOSTICS During normal operation with no faults present the status LED is steadily on If the controller detects a fault the status LED flashes a 2 digit fault identiﬁc...

Page 42: ...2 1 MAIN OFF FAULT 2 2 EMR SEQUENCING FAULT MOTOR STALLED 2 3 MAIN FAULT 2 4 MAIN ON FAULT 2 5 PUMP SRO FAULT 3 1 WIRING FAULT 3 2 BRAKE ON FAULT 3 3 PRECHARGE FAULT 3 4 BRAKE OFF FAULT 3 5 HPD FAULT 4 1 CURRENT SENSE FAULT 4 2 HARDWARE FAILSAFE 4 3 EE CHECKSUM FAULT 4 4 MOTOR OPEN 4 5 BATTERY DISCONNECT FAULT Must cycle keyswitch to clear Must use programmer to clear as follows select Program men...

Page 43: ...ded or stuck open 2 Main contactor driver fault 2 4 MAIN ON FAULT main contactor driver On fault 1 Main contactor driver failed closed 2 5 PUMP SRO FAULT 1212P improper sequencing 1 Pump switches pressed before KSI on 3 1 WIRING FAULT HPD fault present 10 sec 1 Misadjusted throttle 2 Broken throttle pot or throttle mechanism 3 2 BRAKE ON FAULT brake On fault 1 Electromagnetic brake driver shorted ...

Page 44: ...programmer can be used to access the controller s fault history ﬁle The programmer will read out all the faults that the controller has experienced since the last time the history ﬁle was cleared The faults may be intermittent faults faults caused by loose wires or faults caused by operator errors Faults such as HPD or overtemperature may be caused by operator habits or by overloading After a prob...

Page 45: ...ve enclosing the controller interconnect wires contactors and motor together in one shielded box Emissions can also couple to battery supply leads and throttle circuit wires outside the box so ferrite beads near the controller may also be required on these unshielded wires in some applications It is best to keep the noisy signals as far as possible from sensitive wires Immunity Immunity to radiate...

Page 46: ... of a shielded enclosure it is important to minimize the open length of these seams Seam length is the distance between points where good ohmic contact is made This contact can be provided by solder welds or pressure contact If pressure contact is used attention must be paid to the corrosion characteristics of the shield material and any corrosion resistant processes applied to the base material I...

Page 47: ...guidelines that must be followed in order to achieve compliance Some industries have developed further standards called type C standards that refer to EN13849 and specifically outline the path to regulatory compliance EN1175 1 is a type C standard for battery powered industrial trucks Following a type C standard provides a presumption of conformity to the Machinery Directive Curtis 1212P controlle...

Page 48: ...ety performance up to PL d Mean Time To Dangerous Failure MTTFd is related to the expected reliability of the safety related parts used in the controller Only failures that can result in a dangerous situation are included in the calculation Diagnostic Coverage DC is a measure of the effectiveness of the control system s self test and monitoring measures to detect failures and provide a safe shutdo...

Page 49: ...t the following initial values Full Voltage 24 4 Empty Voltage 20 8 Full Charge Voltage 28 2 Start Charge Voltage 25 2 Reset Voltage 25 0 Discharge Factor 2 0 Charge Factor 2 0 Low BDI Level 0 Low BDI Max Speed 50 Step 1 Setting the Reset Voltage a Plug in the charger and fully charge the batteries With the charger still attached and running measure the final battery voltage with a Digital Volt Me...

Page 50: ...full recharge and not to reset the BDI gauge until the battery is full The 1212 1212P can also be programmed to allow the user to stop the charge in mid cycle and display a proportional amount of charge or partial charge reading If you want to require a full charge to reset the BDI gauge a Set the Charge Factor to 10 0 b Set the Start Charge Voltage equal to the Full Charge Voltage With these sett...

Page 51: ...t only the User level whereas an OEM programmer has full access PC PROGRAMMING STATION 1314 The Programming Station is an MS Windows 32 bit application that runs on a standard Windows PC Instructions for using the Programming Station are included with the software HANDHELD PROGRAMMER 1313 The 1313 handheld programmer is functionally equivalent to the PC Programming Station operating instructions a...

Page 52: ... at 80 C 176 F complete cutoff at 105 C 221 F Heatsink undertemperature cutback starts at 10 C 14 F and is reduced linearly to 50 at 25 13 F Undervoltage cutoff 14 V Overvoltage cutoff 34 V Package environmental rating electronics sealed to IP54 per IEC60529 Weight 0 3 kg 0 7 lbs Dimensions W L H 72 131 39 mm 2 8 5 2 1 5 Regulatory compliance 1212 Designed to meet EN 12184 EN 55022 IEC 61000 6 2 4...

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