Manual - Curtis Instruments

ManualModel 1212CCANopen Permanent MagnetController for Class III VehiclesCurtis Instruments, Inc.200 Kisco AveMt. Kisco, NY 10549www.curtisinstruments.comRead Instructions Carefully!Specifications are subject to change without notice. 2020 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.53233, RevA July 2020

TABLE OF CONTENTS1: OVERVIEW. 1FEATURES. 1SMOOTH AND SECURE CONTROL. 1EASY INSTALLATION AND SETUP. 2SAFETY AND RELIABILITY. 2CAN FEATURES. 2ADDITIONAL FEATURES. 2CONVENTIONS. 3NUMERAL SYSTEM NOTATION. 3MISCELLANEOUS CONVENTIONS. 3GETTING THE MOST OUT OF YOUR CURTIS CONTROLLER. 32: INSTALLATION AND WIRING. 4MOUNTING THE CONTROLLER. 4CONNECTIONS: HIGH CURRENT. 5BATTERY VOLTAGE AND CUTBACKS. 5CONNECTIONS: LOW CURRENT. 5LOGIC CONNECTOR (J1). 6COMMUNICATION CONNECTOR (J2). 7EM BRAKE CONNECTOR (J3). 7WIRING DIAGRAM. 8THROTTLE WIRING. 93-WIRE 5KΩ POTENTIOMETER THROTTLE. 9VOLTAGE THROTTLE. 10CAN THROTTLE. 10INPUTS AND OUTPUTS (I/OS). 10DIGITAL INPUT SPECIFICATIONS. 10ANALOG INPUT SPECIFICATIONS. 11DRIVER OUTPUT SPECIFICATIONS. 11KEYSWITCH (KSI). 11INTERLOCK INPUT. 11MOTOR TEMPERATURE SENSOR. 12EMERGENCY REVERSE INPUT (BELLY BUTTON SWITCH). 12pg. iiCurtis Model 1212C – July 2020

TABLE OF CONTENTS cont’dMODE INPUT. 12FORWARD AND REVERSE SWITCHES. 12EMERGENCY STOP SWITCH. 12BATTERY DISCHARGE INDICATOR (BDI). 13CHARGER INHIBIT. 13CIRCUITRY PROTECTION DEVICES. 13I/O GROUND. 13EXTERNAL STATUS LED. 13LIFT DRIVER. 14LIFT LOCKOUT DRIVER. 14LOWER VALVE DRIVER. 15AUX SWITCH INPUT. 15HORN DRIVER. 16EM BRAKE. 16CAN CONNECTIONS. 163: PROGRAMMABLE PARAMETERS. 17DRIVE MENU. 17SPEED AND MODE MENUS. 19THROTTLE MENU. 20THROTTLE RESPONSE PARAMETERS. 21MAIN RELAY MENU. 22INTERLOCK BRAKING MENU. 23CURRENT MENU. 23INPUTS MENU. 24DRIVERS MENU. 25EM BRAKE MENU. 25MOTOR MENU. 26BDI MENU. 27COMPENSATION MENU. 28EMERGENCY REVERSE MENU. 29CANOPEN MENU. 303140 MENU. 31MISCELLANEOUS MENU. 31Curtis Model 1212C – July 2020pg. iii

TABLE OF CONTENTS cont’d4 : MONITOR MENU. 32VOLTAGE MENU. 32CONTROLLER MENU. 33SWITCHES MENU. 33INPUTS AND OUTPUTS MENU. 34CAN STATUS MENU. 345: FUNCTIONS MENU. 356: CANOPEN COMMUNICATIONS. 36BYTE AND BIT SEQUENCE ORDER. 36NMT STATE CONFIGURATION. 36MESSAGE CAN-IDS. 36EMERGENCY MESSAGES AND FAULTS. 36EXPEDITED SDOs. 38PDOs. 39PDO TIMING. 39PDO1 — COMMUNICATING WITH A CAN TILLER. 40RPDO2 — RECEIVING DATA FROM A BATTERY MONITORING SYSTEM. 41CANOPEN OBJECT DICTIONARY. 427: DIAGNOSTICS AND TROUBLESHOOTING. 43CURTIS PROGRAMMER DIAGNOSTICS. 43LED DIAGNOSTICS. 43CANOPEN DIAGNOSTICS. 43FAULT HANDLING AND FAULT CODES. 438: INITIAL SETUP. 48STEP 1 BEGIN THE SETUP PROCEDURES. 48STEP 2 CONFIGURE THROTTLE. 48STEP 3 BASIC VEHICLE CHECKOUT. 49STEP 4 SET THE SYSTEM RESISTANCE. 509: TUNING VEHICLE PERFORMANCE. 51STEP 1 SET FORWARD AND REVERSE MAXIMUM SPEEDS. 51STEP 2 SET THE ACCELERATION AND DECELERATION RATES. 51STEP 3 ADJUST ANTI-ROLLBACK COMPENSATION. 53STEP 4 FINE-TUNING THE VEHICLE’S RESPONSE SMOOTHNESS. 54pg. ivCurtis Model 1212C – July 2020

TABLE OF CONTENTS cont’d10: MAINTENANCE. 55DIAGNOSTIC HISTORY. 55APPENDIX A. 56EMISSIONS. 56IMMUNITY. 56APPENDIX B: EN 13849 COMPLIANCE, CURTIS 1212C CONTROLLER. 58APPENDIX C: BATTERY DISCHARGE INDICATOR (BDI) SETUP. 60STEP 1 SET PARAMETERS TO INITIAL VALUES. 60STEP 2 SET RESET VOLTAGE AND FULL CHARGE VOLTAGE. 60STEP 3 SET FULL VOLTAGE. 61STEP 4 SET EMPTY VOLTAGE. 61STEP 5 SET DISCHARGE TIME. 61STEP 6 SET CHARGE TIME AND START CHARGE VOLTAGE. 61STEP 7 RERUN AND VERIFY. 62APPENDIX D: CURTIS PROGRAMMING DEVICES. 63PC PROGRAMMING STATION (1314). 63HANDHELD PROGRAMMER (1313). 63PROGRAMMER FUNCTIONS. 63APPENDIX E: SPECIFICATIONS. 64Curtis Model 1212C – July 2020pg. v

TABLE OF CONTENTS cont’dFIGURESFIGURE 1 CURTIS 1212C MOTOR CONTROLLER. 1FIGURE 2 MOUNTING DIMENSIONS. 4FIGURE 3 WIRING DIAGRAM. 8FIGURE 4 WIRING FOR A 3-WIRE 5KΩ POT THROTTLE. 9FIGURE 5 WIRING FOR A VOLTAGE THROTTLE. 10FIGURE 6 MINIMUM AND MAXIMUM ACCELERATION RATES. 18FIGURE 7 MINIMUM AND MAXIMUM DECELERATION RATES. 19TABLESTABLE 1 LOGIC CONNECTOR PINS (J1). 6TABLE 2 FAULT CATEGORIES AND BITS. 37TABLE 3 TROUBLESHOOTING CHART. 44TABLE 4 SAFETY-RELATED PERFORMANCE. 58TABLE 5 MODEL CHART. 64pg. viCurtis Model 1212C – July 2020

Curtis Model 1212C – July 2020Return to TOC1 — OVERVIEWThe Curtis 1212C motor speed controller provides efficient control of permanent magnet drivemotors for battery-powered industrial vehicles. The 1212C is optimized for use on light-duty ClassIII pallet trucks, floor care machines such as sweepers and scrubbers, and similar industrial vehicles.However, the controller’s flexible programmability means the 1212C can be configured for any lowpower permanent magnet motor application. You can use a Curtis programming device to configurethe 1212C. Curtis programming devices also provide monitoring and diagnostic capabilities.The 1212C complies with CANopen DS 301. The controller’s object dictionary includes all parameters.In addition, the 1212C provides preconfigured PDOs for CAN bus communications with a CANtiller and a battery monitoring system (BMS).Figure 1Curtis 1212C Motor ControllerFEATURESThe following sections describe the 1212C controller’s features.Smooth and Secure Control Maintains precise speed over varied terrain, obstacles, curbs, and ramps. Linear cutback of current ensures smooth control, with no sudden loss of power duringundervoltage or overtemperature.1 — OVERVIEWpg. 1

Curtis Model 1212C – July 2020Return to TOC Proprietary algorithms help prevent gearbox wear while providing smooth startsand reversals. 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 whiledriving or when a fault occurs that requires the vehicle to stop. Anti-Rollback and Anti-Roll Forward functions provide safe vehicle control on hillsand ramps. Boost Current function provides superior performance with transient loads such as startingon a hill, crossing thresholds, climbing obstacles, etc.Easy Installation and Setup Industry standard footprint, mounting centers, and wiring allows drop-in replacement ofother controllers. Industry standard Mini-Fit Molex Jr. and FASTON terminals. The controller is programmable with a Curtis programming device or can be suppliedpre-programmed. Supports voltage, 3-wire resistance, CAN, single ended, and wigwag throttles.Safety and Reliability High RF immunity prevents speed variation and shutdowns in noisy RF environments. Controller power circuits and microprocessor software are continuously monitored forproper operation. On power-up, the system automatically checks the throttle, brake, and associated wiring, anddisables driving if a fault is found. Emergency reverse with belly

The following topics describes terms and notations used in this manual. Numeral System Notation The following table describes how this manual denotes decimal, binary, and hexadecimal numbers. Note: The letter n in the format column represents a digit. Numeral System Format Exampl