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MANUAL

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

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

p/n 16369, Rev. C: April 2003

CURTIS INSTRUMENTS, INC.

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

MultiMode™

MOTOR CONTROLLERS

1214-8
1215-8
1219-8

Содержание MultiMode 1214-8

Страница 1: ... CONTROLLERS PROTECTED BY U S PATENT NO 4626750 1214 8 1215 8 1219 8 Manual p n 16369 Rev C April 2003 CURTIS INSTRUMENTS INC 200 Kisco Avenue Mount Kisco NY 10509 USA Tel 914 666 2971 Fax 914 666 2188 www curtisinst com MultiMode MOTOR CONTROLLERS 1214 8 1215 8 1219 8 ...

Страница 2: ...901 12345678901 12345678901 12345678901 12345678901 12345678901 12345678901 12345678901 12345678901 12345678901 12345678901 12345678901 12345678901 12345678901 12345678901 12345678901 12345678901 12345678901 12345678901 12345678901 12345678901 12345678901 12345678901 12345678901 12345678901 12345678901 12345678901 12345678901 12345678901 12345678901 12345678901 12345678901 12345678901 12345678901 ...

Страница 3: ... 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...

Страница 4: ...ests and obtain diagnostic information quickly and easily Fig 1 Curtis 1215 8 motor controller The 1214 8 and 1219 8 controllers are similar but differ in overall length M motor armature 24 pin low power connector 4 pin connector for handheld program m er LED B positive battery B negative battery A2 plug diode to motor armature Like all Curtis motor controllers the 1214 15 19 8 controller offers s...

Страница 5: ...eutral 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 wit...

Страница 6: ...e 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 2 2 INSTALLATION WIRING Fig 2 Mounting dimensions Curtis 1214 15 19 8 controllers 169 6 66 5 5 0...

Страница 7: ...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 ...

Страница 8: ...ould 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 c...

Страница 9: ...n 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 2 INSTALLATION WIRING Fig 3 Standard wiring diagram Curtis 1214 15 19 8 controller A BRAKE SEAT MODE SELECT EMERG REV FORWARD REVERSE REV CONTACTORS MAIN FWD B B POWER FUSE KEYSWITCH CONTROL FUSE POLARITY PROTECTION DIODE 5kΩ 0 THROTTLE TYPICAL ...

Страница 10: ...s 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 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 2 INSTALLATION WIRING 24 pi...

Страница 11: ...ON WIRING Fig 4 Wiring for 5kΩ 0 throttle Type 1 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 potenti ometer 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 design...

Страница 12: ...n For Type 3 throttles zero speed corresponds to 0Ω and full speed corresponds to 5kΩ 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 ...

Страница 13: ...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 F...

Страница 14: ...nimum 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 NOTE The Pot Low pin Pin 14 must not be tied to ground 14 13 15 16 17 18 19 20 21 22 23 24 12 11 10 9 8 7 6 5 4 3 2 1 OFF ON 500Ω 10kΩ Pin 15 Pin 14 Pin 13 Pot Wiper Pot Low Pot High PIN KEY Fig 8 Wiring for 0 10V throttle Type 2 b 0 10V throttle sensor a ...

Страница 15: ...e connected directly to the emergency reverse belly button switch provides for broken wire detection when that feature is enabled at the factory The emergency reverse check output wire periodically pulses the emer gency reverse circuit to check for continuity If there is no continuity the controller limits the vehicle to 15 speed and a fault code is indicated If the option is selected and the chec...

Страница 16: ...ngle pole single throw SPST contactors are typically used The coil voltage should match the vehicle voltage The maximum allowed coil current is 1 ampere A built in coil suppression diode is connected between each forward reverse contactor coil output and the brake seat switch input Forward Reverse Emergency Reverse and Mode Selection Switches These switches can be any type of single pole single th...

Страница 17: ...ed tools 1 If a programmer is available connect it to the programmer connector 2 Turn the keyswitch on The programmer should power up with an initial display and the controller s Status LED should begin steadily blinking a single flash If neither happens check for continuity in the keyswitch circuit and controller ground 3 If you are using a programmer put it into the diagnostic mode by pressing t...

Страница 18: ...ller s M and B terminals c Turn the keyswitch on release the brake and apply the throttle The motor should not operate and the direction contactors should not pull in d Leave the keyswitch on and remove the inline fuse wire The vehicle status should continue to remain off e Cycle the keyswitch off and on release the brake and apply the throttle The vehicle should now operate normally 7 Take the ve...

Страница 19: ...cally the brake seat switch must be cycled before the new options take effect CLONING One of the most powerful features of the programmer is its ability to clone controllers The programmer can read all the parameters and options from one controller and write them to other controllers Cloning only works between controllers with the same model number and software version For example the programmer c...

Страница 20: ...controller requires virtually no maintenance when properly installed the following minor maintenance is recommended in certain applications 1 Remove power by disconnecting the battery 2 Discharge the capacitors in the controller by connecting a load such as a contactor coil or a horn across the controller s B and B terminals 3 Remove any dirt or corrosion from the bus bar area The controller shoul...

Страница 21: ... History is the top line in the display and then press MORE INFO again The programmer will prompt you to acknowledge or cancel See Section 6 of this manual for more detail on program mer operation TESTING THE FAULT DETECTION CIRCUITRY Specific material handling directives such as prEN1175 require periodic testing of the controller s fault detection circuitry It is recommended that each time the ve...

Страница 22: ...ate in forward is brought in for repair STEP 1 Examine the vehicle and its wiring for any obvious problems such as broken wires or loose connections STEP 2 Connect the programmer put it in diagnostic mode and read the displayed fault information In this example the display shows No Faults Present indicating that the control ler has not detected anything out of the norm STEP 3 Put the programmer in...

Страница 23: ... inputs 2 Wrong HPD type selected 3 Misadjusted throttle pot 4 Sequencing delay too short 2 4 THROT T LE FAUL T 2 Pot Low broken or shorted 1 Pot Low wire open 2 Pot Low wire shorted 3 Wrong throttle type selected 3 1 CONT DRVR OC driver output overcurrent 1 Direction contactor coil shorted 3 2 D I R CONT WELDED welded direction contactor 1 Direction contactor stuck closed 3 4 M I SS I NG CONTACTO...

Страница 24: ...ults 1 2 hardware fail safe error 1 3 M fault or motor output short 1 4 sequencing fault SRO 2 1 5kΩ 0 or throttle wiper input fault 2 2 emerg rev circuit check fault BB wiring 2 3 high pedal disable fault HPD 2 4 throttle pot low open or shorted to B or B 3 1 contactor driver overcurrent 3 2 welded direction contactor 3 3 reserved for future use 3 4 missing contactor 4 1 low battery voltage 4 2 o...

Страница 25: ...S High pedal disable HPD type S R O Static return to off SRO type A N T I T I E D O W N Anti tiedown on or off Q U I C K S T A R T Quick start throttle factor M 1 M A I N C L Mode 1 main current limit M 1 P L U G C L Mode 1 plug current limit M 1 R A M P C L Mode 1 ramp start current limit M 1 A C C E L R A T E Mode 1 acceleration rate in seconds M 1 M A X S P E E D Mode 1 maximum speed as PWM out...

Страница 26: ... input before forward input Test Menu not all items available on all controllers F O R W A R D S W I T C H Forward switch on off R E V E R S E S W I T C H Reverse switch on off B R A K E S W I T C H Brake switch on off T H R O T T L E Throttle reading in percent of full S P E E D S W I T C H Speed switch on off E M R R E V S W I T C H Emergency reverse switch on off F W D C O N T A C T O R Forward...

Страница 27: ...e programmer is operating in either of the Diagnostics modes The messages are listed in alphabetical order for easy reference B B W I R I N G C H E C K BB wiring check failed C O N T D R V R O C Contactor driver overcurrent D I R C O N T W E L D E D Direction contactor welded H P D High pedal disable activated H W F A I L S A F E Hardware failsafe activated L O W B A T T E R Y V O L T A G E Batter...

Страница 28: ...ks that the mode selection switch has been released after the last cycling of the brake switch This feature discourages operators from taping or otherwise tying down the mode switch If Mode 1 is already selected before the brake is released the controller remains in Mode 2 until the mode switch is released and pressed again For information on how Mode 1 and Mode 2 are selected see MultiMode Arcles...

Страница 29: ...ed only by motor demand PWM output to the power section is reduced smoothly until the motor current falls below the set limit level In addition to protecting the controller the current limit feature also protects the rest of the system By eliminating high current surges during vehicle acceleration stress on the motor and batteries is reduced and their efficiency enhanced Similarly there is less we...

Страница 30: ...al no direction is selected or until the brake is cycled brake then brake release However repeatedly pressing the BB switch will reactivate the emergency reverse function each time Because emergency reverse immediately powers the reverse contactor some arcing may occur Fault detection An internal microcontroller automatically maintains surveillance over the func tioning of the controller When a fa...

Страница 31: ...e was last cleared The Diagnostics mode on the other hand provides information about only the currently active faults Fault recovery including recovery from disable Almost all faults require a cycling of the KSI or brake seat switch input to reset the controller and enable operation The only exceptions are these FAULT RECOVERY anti tiedown release and re select Mode 1 contactor overcurrent when co...

Страница 32: ...e the throttle is above the HPD threshold 25 HPD is not activated if the brake seat switch is then closed before the delay time elapses KSI type HPD The HPD feature can be activated by KSI input instead of brake seat switch input if preferred To start a vehicle with this type of HPD the controller must receive a KSI input before receiving a throttle input KSI KSI Key Switch Input provides power to...

Страница 33: ...e mode selection switch Pin 3 is pulled high Otherwise the controller operates by default in Mode 2 When the controller transitions between modes it automatically changes the main current limit the plug current limit the ramp start current limit the acceleration rate and the maximum speed to their individual mode specific settings If the anti tiedown feature is active Mode 1 must be re selected ea...

Страница 34: ...urrent the armature current in plug mode will be higher than the field current There are two types of plug braking control fixed and variable The fixed plug current limit is set to a fixed level The variable plug current limit varies the current limit to correspond to the throttle position The Mode 1 and Mode 2 plug current limits are independently adjustable via the handheld programmer PWM Pulse ...

Страница 35: ...0 ramp shape corresponds to a linear response The six even number ramp shapes for maximum and creep speeds set at 100 and 0 are shown in Figure A 1 Changing either the maximum speed setting or the creep speed setting changes the output range of the controller Ramp shape output is always a percentage of that range Ramp shapes with the creep speed setting raised to 10 are shown in Figure A 2 In Figu...

Страница 36: ... 40 30 20 RAMP SHAPE 100 90 80 70 60 50 40 30 20 10 0 100 90 80 70 60 50 40 30 20 10 0 CREEP SPEED 10 MAXIMUM SPEED 60 Fig A 3 Ramp shape throttle map for control ler with maximum speed set at 60 and creep speed set at 10 In all cases the ramp shape number is the PWM output at half throttle as a percentage of its full range So for example in Figure A 3 a 50 ramp shape gives 35 PWM output at half t...

Страница 37: ...mp start current limit when the brake is first released depends on throttle position and increases to the maximum pro grammed value as the throttle is increased Reset Almost all faults require a cycling of the KSI or brake seat switch input to reset the controller and enable operation see Fault recovery for exceptions Sequencing delay Sequencing delay allows the brake seat switch to be momentarily...

Страница 38: ...steps 1 and 2 is the same as between steps 2 and 3 that is KSI input must precede brake seat switch input by at least 50 msec Once the controller is operational turning off either KSI or the brake seat switch input causes the controller to turn off re enabling the controller requires the 3 step sequence Similarly if your controller is wired so that KSI brake seat switch and forward inputs are all ...

Страница 39: ...time is shaped by the acceleration rate setting Dynamic throttle response is linear The newest throttle input is mapped to the throttle map and the controller then automatically accelerates or decelerates through a straight line until the new throttle demand is obtained Throttle types The 1214 15 19 8 controller accepts a variety of throttle inputs through various combinations of its four throttle...

Страница 40: ...oltage continues to drop below the undervoltage level to a severe undervoltage condition due to battery drain or external load the controller continues to behave in a predictable fashion with its output disabled Watchdog external internal The external watchdog timer guards against a complete failure of the micropro cessor which would incapacitate the internal watchdog timer This independent system...

Страница 41: ...ent operating temperature range 40 C to 50 C Heatsink overtemperature cutback 85 C Heatsink undertemperature cutback 25 C 1214 8 1215 8 1219 8 Dimensions L W H 210 180 82 mm 254 180 82 mm 309 180 82 mm 8 3 7 1 3 2 10 0 7 1 3 2 12 2 7 1 3 2 30 second rating NOMINAL VOLTAGE UNDER BATTERY CURRENT 1 MIN 2 MIN DROP VOLTAGE MODEL VOLTAGE LIMIT RATING RATING 100 AMPS CUTBACK NUMBER volts amps amps amps v...

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