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Curtis 1212S Manual, 

Rev. B

7 — DIAGNOSTICS & TROUBLESHOOTING

7

 

DIAGNOSTICS AND TROUBLESHOOTING

The 1212S controller provides diagnostics information to assist technicians in 
troubleshooting drive system problems. The diagnostics information can be 
obtained in two ways:  by reading the appropriate display on the 1313 handheld 
programmer or the 1314 PC Programming Station, or by observing the fault 
codes displayed by the Status LED.

PROGRAMMER DIAGNOSTICS

The programming devices present complete diagnostic information in plain 
language. Faults are displayed in the Faults/Diagnostics menu, and the status 
of the controller inputs/outputs is displayed in the Monitor menu. 

Additionally, the fault history file in the Faults/Diagnostics menu provides 

a list of the faults that have occurred since the file was last cleared. Checking 
(and clearing) the fault history file is recommended each time the vehicle is 
brought in for maintenance.

Refer to the troubleshooting chart (Table 2) 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 iden-
tification code continuously until the fault is corrected. 

For example, code “1,4”—undervoltage—appears as:

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( 1 , 4 ) 

( 1 , 4 ) 

( 1 , 4 )

Refer to the troubleshooting chart (Table 2) for the fault codes, and for 

suggestions about possible causes of the various faults. 

Note:  The Status LED can only indicate one fault at a time. If multiple 

faults are detected, the highest priority fault code flashes until it is cleared. 

 

FAULT HANDLING

When a fault is detected, the controller operates in a manner that is safe in the 
presence of that fault. Depending on the severity of the fault, the response can 
range from reduction of current to complete shutdown of drive. 

Содержание 1212S

Страница 1: ...e 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 Instrument...

Страница 2: ...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 appen...

Страница 3: ...con guration 1212S controller 6 fig 4 Wiring for 5k 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...

Страница 4: ...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 curr...

Страница 5: ...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...

Страница 6: ...5 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 y...

Страница 7: ...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...

Страница 8: ...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...

Страница 9: ...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 M1 M2 B B BRAKE BRAKE CHAR...

Страница 10: ...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...

Страница 11: ...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 i...

Страница 12: ...n 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 whi...

Страница 13: ...rlock MISCELLANEOUS MENU p 21 Sequencing Delay Sleep Reset Drive Time Emergency Stop Pump SRO Reset Parameter DRIVE MENU p 11 Accel Max Speed Accel Min Speed Decel High Speed Decel Low Speed Rev Accel...

Страница 14: ...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 rat...

Страница 15: ...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...

Страница 16: ...different sets of operating characteristics which can be useful for operation in different conditions For example Mode 1 could be programmed such that the vehicle moves slowly for precise indoor mane...

Страница 17: ...Neutral Deadband 5 30 Sets how far from neutral the throttle must move to begin vehicle movement and release the brakes This parameter allows the neutral deadband to be defined wide enough to ensure...

Страница 18: ...ttle command at half throttle as shown in Figure 6 A setting of 50 provides linear response Values below 50 reduce the throttle command at low throttle positions providing enhanced slow speed maneuver...

Страница 19: ...E PARAMETER RANGE DESCRIPTION Main Current Limit 15 90 A Sets the maximum current the controller will supply to the motor during normal driving By limiting the current supplied this parameter can be u...

Страница 20: ...automatically measured under a preset low current before the brake is released The measured motor resistance plays an important role in IR compensation The Resistance Auto Comp parameter enables disab...

Страница 21: ...d to start charging Note Allowable range is restricted by the Full Voltage and Full Charge Voltage settings Allowable Start Charge Voltage range 1212S 2xxx 21 0 29 0 V 1212S 3xxx 31 5 43 5 V Reset Vol...

Страница 22: ...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 Defines how the lift lockout feature will be a...

Страница 23: ...the reverse direction above the programmed EMR speed the vehicle will be brought down to the EMR speed Accel Rate 0 2 8 0 s Sets the rate at which the vehicle sccelerates in the reverse direction whe...

Страница 24: ...battery is disconnected and the vehicle will stop abruptly Off When the emergency stop button is pressed the battery is disconnected and the vehicle will decelerate for a short distance before it ful...

Страница 25: ...k 0 100 Current cutback during motor overtemperature as a percentage of max current 100 no cutback Armature Current 100 100 A Measured motor armature current Current Limit 0 100 A Ultimate current lim...

Страница 26: ...DESCRIPTION Main Relay On Off Status of the main relay driver Brake On Off Status of the EM brake driver BDI 0 100 Status of battery capacity as a percentage Drive Time 0 65535 hours Hours of operatio...

Страница 27: ...pond 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 v...

Страница 28: ...s and the M1 and M2 connections must be configured so that the vehicle drives away from the operator when the emergency reverse button the belly button switch is pressed 3 Basic vehicle checkout Using...

Страница 29: ...oll down to the Resistance eld 4 f Apply the throttle full forward driving the vehicle against the immovable object 4 g Observe the Resistance value displayed in the Monitor menu 4 h Repeat steps 4 f...

Страница 30: ...e smoothness 5 Setting the maximum speeds The four maximum speeds with full throttle applied are set by the four Max Speed parameters M1 M2 Max Speed and M1 M2 Rev Max Speed Each of the maximum speeds...

Страница 31: ...icle s low speed forward deceleration 6 c Next adjust Accel Max Speed Select Mode 2 and apply full throttle Depending on how you liked the forward acceleration you experienced increase or decrease the...

Страница 32: ...ate 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 throttle request This p...

Страница 33: ...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 set...

Страница 34: ...erence 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 setting this par...

Страница 35: ...fault history le is recommended each time the vehicle is brought in for maintenance Refer to the troubleshooting chart Table 2 for suggestions about possible causes of the various faults For informati...

Страница 36: ...Off Fault 1 Main relay driver failed open Bridge is shorted and throttle Correct fault set to zero 2 2 EMR Sequencing 1 Emergency Reverse belly button Throttle output inhibited Correct fault by Fault...

Страница 37: ...ridge is shorted and throttle Must use programmer Fault set to zero to clear as follows select Program menu alter data value of any parameter cycle KSI 4 5 Battery Disconnect 1 Battery not connected W...

Страница 38: ...an be used to access the controller s fault his tory le The programmer will read out all the faults that the controller has experienced since the last time the history le was cleared The faults may be...

Страница 39: ...ires near each other bundle contactor wires with Coil Return bundle motor wires separately For applications requiring very low emissions the solution may involve enclosing the controller interconnect...

Страница 40: ...on is necessary in which case many small holes are preferable to a few larger ones Applying this same concept to seams or joints between adjacent pieces or segments of a shielded enclosure it is impor...

Страница 41: ...egulatory 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 1212S contro...

Страница 42: ...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 s...

Страница 43: ...r 2 0 Charge Factor 2 0 Low BDI Level 0 Low BDI Max Speed 50 Step 1 Setting the Reset Voltage 1 a Plug in the charger and fully charge the batteries With the charger still attached and running measure...

Страница 44: ...u want the BDI gauge to respond to partial charging The traditional method is to require a full recharge and not to reset the BDI gauge until the battery is full The 1212S can also be programmed to al...

Страница 45: ...under various conditions to verify that they provide an acceptable indication of the battery state of charge The settings can be fine tuned by repeating the entire procedure It is important to note t...

Страница 46: ...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 f...

Страница 47: ...40 C to 85 C Operating ambient temp range 25 C to 50 C Overvoltage cutoff 1212S 2xxx 34V 1212S 3xxx 51V Package environmental rating ISTA 2A electronics sealed to IPX5 Weight 0 45 kg Dimensions W L H...

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