Curtis Multimode 1214-8 User manual

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

Curtis 1214-/15-/19-8 Manual ii

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CONTENTS

1. OVERVIEW ..................................................................... 1

2. INSTALLATION AND WIRING ................................... 3

Mounting the Controller............................................ 3

Connections: Low Current......................................... 4

Connections: High Current ....................................... 5

Wiring: Standard Conﬁguration ................................ 6

Wiring: Throttle ........................................................ 8

Wiring: Emergency Reverse Check .......................... 12

Contactors, Switches, and Other Hardware ............. 13

Installation Checkout ............................................... 14

3. PROGRAMMING AND ADJUSTMENT .................... 16

4. MAINTENANCE .......................................................... 17

Cleaning ................................................................... 17

Diagnostic History ................................................... 17

Testing the Fault Detection Circuitry ...................... 18

5. DIAGNOSTICS AND TROUBLESHOOTING .......... 19

Programmer Diagnostics .......................................... 19

LED Diagnostics ...................................................... 21

6. PROGRAMMER MENUS............................................. 22

APPENDIX AGlossary of Features and Functions.......... A-1

APPENDIX BSpeciﬁcations ........................................... B-1

CONTENTS

Curtis 1214-/15-/19-8 Manual iii

FIGURES

FIG. 1: Curtis 1215-8 motor controller ....................................1

FIG. 2: Mounting dimensions,

Curtis 1214-/15-/19-8 controller ................................. 3

FIG. 3: Standard wiring diagram ..............................................6

FIG. 4: Wiring for 5kΩ–0 throttle (“Type 1”) ......................... 8

FIG. 5: Wiring for 20kΩpot used as a wigwag-style

throttle (“Type 1”) .......................................................9

FIG. 6: Wiring for 0–5kΩthrottle (“Type 3”) ......................... 9

FIG. 7: Wiring 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 controller with

maximum speed 60% and creep speed 10%............. A-9

TABLES

TABLE 1: Troubleshooting chart ................................................ 20

TABLE 2: LED codes ................................................................. 21

FIGURES / TABLES

Curtis 1214-/15-/19-8 Manual 1

1 — OVERVIEW

OVERVIEW

Curtis 1214-8, 1215-8, and 1219-8 programmable motor speed controllers

provide efﬁcient, cost-effective, and simple-to-install control for a variety of large

industrial vehicles. Typical applications include walkie/rider pallet trucks, fork

lifts, stackers, reach trucks, and other industrial trucks.

The 1207-based microprocessor logic section combined with a Curtis

MOSFET power section gives the 1214-/15-/19-8 controller high power and

advanced features in a rugged, compact package. The optional handheld pro-

grammer enables the user to set parameters, conduct tests, 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 programmer

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 superior

operator control of the vehicle’s motor drive speed. Features include:

✓Power MOSFET design, providing

•inﬁnitely variable drive and plug brake control

•silent high-frequency operation

•high efﬁciency (for reduced motor and battery losses)

✓Overvoltage and undervoltage protection

✓Thermal protection/compensation circuitry that provides

undertemperature cutback, constant current limit over operating range,

Curtis 1214-/15-/19-8 Manual 2

and linear rollback in overtemperature—thus preventing sudden power

loss regardless of thermal conditions

✓Intelligent handheld 13XX programmer provides a full set of parameter

and function settings

✓Diagnostic and test information for the controller—and other system

components—readily available through both an on-board LED and the

optional handheld programmer

✓Meets or exceeds EEC fault detect requirements, with circuitry and

software to detect faults in the throttle circuit, MOSFET drive circuits,

MOSFET output, contactor drivers, and contactors

✓Programmable input sequencing options include several combinations

of neutral start and static return to off (SRO)

✓Arcless contactor switching with microprocessor-controlled contactor

sequencing

✓Smooth, controlled plug braking—with either variable (throttle-

dependent) or ﬁxed plug current limit

✓Neutral 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, with coil drivers monitored

for shorts and open circuits—thus ensuring fail-safe operation

✓Flexible throttle circuitry accommodates a variety of throttle types:

5kΩ–0, 0–5kΩ, 0–5V, 0–10V, inductive, Hall, etc.

✓Programmable “ramp shape”(static throttle map) provides flexibility

in selecting throttle response feel

✓Sealed package, providing environmental protection

✓Power connections made by tin-plated solid copper busses,

with a polarized Molex connector for control signals

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

Curtis 1214-/15-/19-8 Manual 3

INSTALLATION AND WIRING

MOUNTING THE CONTROLLER

The controller can be oriented in any position, but the location should be

carefully chosen to keep the controller as clean and dry as possible. If a clean,

dry mounting location cannot be found, a cover must be used to shield the

controller from water and contaminants.

To ensure full rated output power, the controller should be fastened to a

clean, flat metal surface with four screws. The case 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 — INSTALLATION & WIRING

Fig. 2 Mounting

dimensions,

Curtis 1214-/15-/19-8

controllers.

169

(6.66)

.22

)

180

(7.1)

(0.893)

81.3

(3.2)

3.18 (0.125)

26.4

20.6

2.3 (1.04

0.81

0.09);

8.4 (0.33) dia. hole thru

7.1 (0.28) dia., 4 plcs

[6 plcs in 1219]

Dimensions in millimeters and (inches)

“B”

“A”

1214 1215 1219

“A”

210 (8.275) 253 (9.975) 309 (12.180)

“B”

165 (6.490) 208 (8.190) 264 (10.394)

[1219 MODELS ONLY]

Curtis 1214-/15-/19-8 Manual 4

CONNECTIONS: Low Current

A 24-pin low current connector in the front of the controller provides the low

current logic control connections (see pin list below). The mating connector is

Molex Mini-Fit Jr., part number 39-01-2245. Contact Molex regarding compat-

ible pins: 39-00-0078 for #16 AWG, 39-00-0039 for #18–24 AWG.

2 — INSTALLATION & WIRING

Pin 1 keyswitch input (KSI)

Pin 2 brake input

Pin 3 mode selection input

Pin 4 n/c

Pin 5 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 0–5kΩinput

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/c

Pin 22 n/c

Pin 23 n/c

Pin 24 emergency reverse (BB) check output [optional]

A 4-pin low power connector, also located on the front of the controller, is

provided for the handheld programmer.

24 23 22 21 20 19 18 17 16 15 14 13

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Curtis 1214-/15-/19-8 Manual 5

CONNECTIONS: High Current

Four tin-plated solid copper bus bars are provided for the high current connec-

tions to the battery and motor:

M- output to motor armature

B- negative connection to battery

B+ positive connection to battery/ﬁeld

A2 plug diode to motor armature

Cables are fastened to the bus bars by M8 (5⁄16")

bolts. When tightening the bolts, two opposing

wrenches should be used to prevent bending the bus

bars and putting undue strain on the internal con-

nections.

2 — INSTALLATION & WIRING

M-

B- B+

Working on electric vehicles is potentially dangerous. Youshould

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 can occur if they are short circuited. Always open

the battery circuit before working on the motor control circuit.

Wear safety glasses, and use properly insulated tools to prevent

shorts.

LEAD ACID BATTERIES —Charging or discharging generates hydrogen

gas, which can build up in and around the batteries. Follow the

battery manufacturer’s safety recommendations. Wear safety glasses.

☞

CAUTION

Curtis 1214-/15-/19-8 Manual 6

WIRING: Standard Configuration

The conﬁguration shown in Figure 3 is a typical arrangement for most applica-

tions. For walkie applications, the brake switch is typically activated by the tiller,

and a belly button switch provides emergency reverse. The emergency reverse

check feature (wiring shown 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.

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)

MAIN

CONTACTOR

REVERSE

CONTACTOR

FORWARD

CONTACTOR

A1 A2

M- A2

B- B+

SWITCHES SWITCHES

S1S2

PRECHARGE RESISTOR

(250 Ω, 5 W)

B-B-

Curtis 1214-/15-/19-8 Manual 7

Standard Power Wiring

In every wiring conﬁguration, it is imperative that the ﬁeld be wired between B+

and A2 and that the armature be wired between M- and the A2 terminal. The

internal plug diode used in the 1214-/15-/19-8 is connected between M- and A2.

Therefore, the armature and ﬁeld positions cannot be interchanged. Reversing

contactors can be used to switch either the armature or the ﬁeld.

Standard Control Wiring

Wiring for the input switches and contactors is 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-pin detail (see Fig. 3):

MODE

SELECT

FORWARD KEYSWITCH

EMERGENCY

REVERSE

CHECK

OUTPUT

(factory option)

BRAKE

SEAT SWITCH

EMERGENCY

REVERSE

(walkies only)

REVERSE

MAIN

CONTACTOR

REVERSE

CONTACTOR

2-WIRE POT

(5 k

Ω

)

FORWARD

CONTACTOR

POT

LOW

24 23 22 21 20 19 18 17 16 15 14 13

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Curtis 1214-/15-/19-8 Manual 8

WIRING: Throttle

Wiring for various throttles is described below. These include 5kΩ–0 and 0–5kΩ

throttles, 0–5V and 0–10V throttles, 3-wire potentiometer throttles, and elec-

tronic throttles. If the throttle you are planning to use is not covered, contact the

Curtis ofﬁce nearest you.

5kΩ–0 Throttle (“Type 1”)

The 5kΩ–0 throttle (called a “Type 1”throttle in the programming menu of the

handheld programmer) is a 2-wire resistive throttle that connects between the

2-Wire Pot pin (Pin 16) and the Pot Low pin (Pin 14), as shown in Figure 4. It

doesn’t matter which wire goes on which pin. For Type 1 throttles, zero speed

corresponds to 5kΩand full speed corresponds to 0Ω.

2 — INSTALLATION & WIRING

Fig. 4 Wiring for 5k

Ω

–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 20kΩpotenti-

ometer wired as shown in Figure 5, the pot wiper can be set such that the

controller has 5kΩbetween Pins 14 and 16 when the throttle is in the neutral

position. The throttle mechanism can then be designed such that rotating it

either forward or back decreases the resistance between Pins 14 and 16, which

increases the controller output. The throttle mechanism must provide signals to

Fig. 5 Wiring for 20k

Ω

potentiometer used as a

wigwag-style throttle

(“Type 1”).

14 1315161718192021222324

121110987654321

Pin 16

Pin 14 2-Wire Pot

Pot Low

PIN KEY

20 kΩ

FASTERFASTER

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121110987654321

Pin 16

Pin 14

2-Wire Pot

Pot Low

PIN KEY

5kΩ–0

FASTER

Curtis 1214-/15-/19-8 Manual 9

2 — INSTALLATION & WIRING

Fig. 6 Wiring for 0–5k

Ω

throttle (“Type 3”).

the controller’s forward and reverse inputs independent of the throttle pot

resistance. The controller will not sense direction from the pot resistance.

With Type 1 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 tied to ground.

0–5kΩThrottle (“Type 3”)

The 0–5kΩthrottle (“Type 3”in the programming menu) is a 2-wire resistive

throttle that connects between the 2-Wire Pot pin (Pin 16) and Pot Low (Pin 14).

It doesn’t matter which wire goes on which pin. For Type 3 throttles, zero speed

corresponds to 0Ωand 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 tied to ground.

0–5V, 0–10V, 3-Wire Potentiometer, or Electronic Throttle (“Type 2”)

With these throttles (“Type 2”in the programming menu), the controller looks

for a voltage signal at either the pot wiper/0–5V input (Pin 15) or the 0–10V

input (Pin 5). Zero speed corresponds to 0V and full speed corresponds to either

5V or 10V. Pot Low (Pin 14) is the current return path for all Type 2 throttles.

It is 200 mV above B- and must have at least 0.1 mA ﬂowing into it to prevent

pot faults.

14 1315161718192021222324

121110987654321

Pin 16

Pin 14

2-Wire Pot

Pot Low

PIN KEY

0–5kΩ

FASTER

Curtis 1214-/15-/19-8 Manual 10

0–5V Throttle

Two ways of wiring the 0–5V throttle are shown in Figure 7. 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 0–5V throttle input (Pin

15) exceeds 8 volts, the controller output will be disabled. NOTE: In Figure 7(a),

the throttle’s voltage input signal is in reference to Pot Low.

2 — INSTALLATION & WIRING

0–10V Throttle

Two ways of wiring the 0–10V throttle are shown in Figure 8. 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 Figure 8(a),

the throttle’s voltage input signal is in reference to Pot Low.

Fig. 7 Wiring for 0–5V

throttle (“Type 2”).

(b) 0–5V throttle sensor

(a) Ground-referenced 0–5V throttle

14 1315161718192021222324

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14 1315161718192021222324

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SENSOR OUTPUT

SENSOR GROUND

0–5V

SENSOR

-B-

4.7 kΩ

(Shunt impedance 150 k

Ω

to ground)

Pin 15

Pin 14

Pin 13

0–5V Input

Pot Low

Pot High

PIN KEY

Pin 15

Pin 14 0–5V Input

Pot Low

PIN KEY

Curtis 1214-/15-/19-8 Manual 11

3-Wire Potentiometer (500

Ω

–10k

Ω

) Throttle

The 3-wire potentiometer is used in its voltage divider mode—with the voltage

source and return being provided by the controller. Pot High provides a current-

limited 5V source to the potentiometer, and Pot Low provides the return path.

Wiring is shown in Figure 9.

2 — INSTALLATION & WIRING

Fig. 9 Wiring for 3-wire

potentiometer throttle

(“Type 2”).

As with the 2-wire throttles, 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. NOTE: The Pot Low pin (Pin 14) must not be tied to ground.

14 1315161718192021222324

121110987654321

OFF

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) Ground-referenced 0–10V throttle

14 1315161718192021222324

121110987654321

14 1315161718192021222324

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SENSOR OUTPUT

SENSOR GROUND

0–10V

SENSOR

-B-

4.7 kΩ

Pin 14

Pin 13

Pin 5

Pot Low

Pot High

0–10V Input

PIN KEY

Pot Low

0–10V Input

Pin 14

Pin 5

Curtis 1214-/15-/19-8 Manual 12

Curtis ET-XXX Electronic Throttle

The Curtis ET-XXX provides throttle and forward/reverse inputs; wiring is

shown in Figure 10.

2 — INSTALLATION & WIRING

Fig. 10 Wiring for Curtis

ET-XXX electronic throttle

(“Type 2”).

14 1315161718192021222324

121110987654321

GREEN

ORANGE

BLACK

BLACK/WHITE

WHITE

WHT/BRN

B-

KEYSWITCH

B+

Pin 15

Pin 14

Pin 11

Pin 10

Pin 1

0–5V Input

Pot Low

Reverse

Forward

KSI Input

PIN KEY

WHT/

GRN

WIRING: Emergency Reverse Check

An optional wire 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 check wire is not connected, the vehicle

speed is limited to 15%. If the option is not selected and the check wire is

connected, no harm will occur—but continuity will not be checked.

The emergency reverse check output wire is connected to Pin 24, as shown

by the dotted line in the basic wiring diagram (Figure 3).

Curtis 1214-/15-/19-8 Manual 13

2 — INSTALLATION & WIRING

CONTACTORS, SWITCHES, and OTHER HARDWARE

Main Contactor

A main contactor allows the controller to be disconnected from the battery. In

24V applications a main contactor is optional, but in 36–48V applications a

main contactor is required. A heavy-duty single-pole, single-throw (SPST)

contactor with silver-alloy contacts is recommended.

After initial closing of the contacts, inrush currents flow as the controller’s

internal ﬁlter capacitors are charged. A 250Ω, 5W resistor can be used across the

contactor to precharge the capacitors and reduce the inrush current through the

contacts.

A built-in coil suppression diode is connected between the main contactor

coil output and the brake/seat switch input.

Forward/Reverse Contactors

For forward/reverse, a paired single-pole, double-throw (2×SPDT) contactor is

recommended. With 4-terminal split ﬁeld motors, two single-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-throw (SPST) switch

capable of switching the battery voltage at 10 mA.

Keyswitch

The vehicle should have a master on/off switch to turn the system off when not

in use. The keyswitch provides logic power for the controller, and coil current for

the contactors. The keyswitch must be capable of carrying these currents.

Circuitry Protection Devices

For reverse polarity protection, a diode should be added to the control circuit. It

must be sized appropriately for the maximum contactor coil currents. To protect

the control wiring from accidental shorts, a low current fuse (appropriate for the

maximum current draw) should be connected in series with the battery feed.

These devices are both shown in the wiring diagrams.

Curtis 1214-/15-/19-8 Manual 14

INSTALLATION CHECKOUT

Before operating the vehicle, carefully complete the following checkout proce-

dure. If you ﬁnd a problem during the checkout, refer to the diagnostics and

troubleshooting section (Section 5) for further information.

The installation checkout can be conducted with or without the handheld

programmer. The checkout procedure is easier with a programmer. Otherwise,

observe the LED for diagnostic codes. (The codes are listed in Section 5.)

Put the vehicle up on blocks to get the drive wheels off

the ground before beginning these tests.

Do not stand, or allow anyone else to stand, directly in

front of or behind the vehicle during the checkout.

Make sure the keyswitch is off and the brake is applied

(brake switch open), the throttle is in neutral, and the

forward/reverse switches are open.

Wear safety glasses and use well-insulated 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 the DIAGNOSTICS key. The display should indicate “No Faults

Found.”

Close the brake/seat switch. To do this on a walkie, pull the tiller

down to the operating position. The LED should continue blinking a

single flash and the programmer should continue to indicate no faults.

If there is a problem, the LED will ﬂash a diagnostic code and the

programmer will display a diagnostic message. If you are conducting the

checkout without a programmer, look up the LED diagnostic code in

Section 5 (Diagnostics and Troubleshooting).

When the problem has been corrected, it may be necessary to cycle

the brake/seat switch in order to clear the fault code.

2 — INSTALLATION & WIRING

☞

CAUTION

Curtis 1214-/15-/19-8 Manual 15

4. With the brake/seat switch closed, 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 forward/reverse switches, forward/

reverse contactors, and motor. The motor should run proportionally

faster with increasing throttle. If not, refer to Section 5.

5. If you are using a programmer, put it into the test mode by pressing

the TEST key. Scroll down to observe the status of the forward, reverse,

brake, emergency reverse, and mode switches. Cycle each switch in

turn, observing the programmer. Each input should show the correct

state on the programmer.

6. Speciﬁc material handling directives, such as prEN1175, require testing

of the controller’s fault detection circuitry. This can be done as follows:

a) Disconnect the battery and make sure the keyswitch is off.

b) Using an inline fuse holder ﬁtted with a 10-amp fuse and

alligator clips, connect the controller’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 vehicle off the blocks and drive it in a clear area. It should have

smooth acceleration and good top speed.

8. Test the plug braking of the vehicle. Verify that the plug braking option

is as desired (variable or ﬁxed).

9. Verify that all options, such as high pedal disable (HPD), static return

to off (SRO), and anti-tiedown, are as desired.

10. On walkies, check to see whether the emergency reverse (belly button)

feature is working correctly. If you have the optional emergency reverse

check wiring, verify that the circuit is operational by momentarily

disconnecting one of the emergency reverse wires. The vehicle should

be limited to 15% speed and a fault indicated.

11. If you used a programmer, disconnect it when you have completed the

checkout procedure.

2 — INSTALLATION & WIRING

Curtis 1214-/15-/19-8 Manual 16

3 — PROGRAMMING & ADJUSTMENT

PROGRAMMING AND ADJUSTMENT

To change a parameter using the programmer, press the PROGRAM key, and scroll

down the Program Menu until the desired parameter is the top line of the display.

Press the appropriate CHANGE VALUE key (“up”or “down”) until the desired num-

ber is reached. The parameter is now set at the desired value. All programming

occurs in real time. In other words, the parameters can be changed while the

vehicle is in operation.

The upper and lower limits of parameters are set at the factory. When the

programmer is used to adjust a parameter and a limit is reached, the display stops

changing. To see why the display has stopped changing, press the MORE INFO key.

If the limit is related to another parameter, that information will be displayed;

changing the value of the related parameter may allow the original parameter to

be adjusted further. Otherwise, the display says “Max Limit”or “Min Limit.”

In addition to adjusting parameters, the programmer can be used to change

various options—such as throttle type, HPD, SRO, etc. Typically, 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 can read all the information from a 1215-

8105 controller and write it to other 1215-8105 controllers. However, it cannot

write that same information to 1215-8106 controllers. If this is attempted, an

error message will be displayed.

PEACE-OF-MIND PROGRAMMING

Each time the programmer is connected to the controller, it acquires all the

controller’s parameters and stores them in its temporary memory. You can revert

back to these original settings at any time during a programming session via the

Special Program Menu. Select “Reset All Settings”by scrolling it to the top of the

display window, press the MORE INFO key, and follow the instructions displayed.

Any inadvertent changing of parameters can be “undone”using this procedure—

even if you can’t remember what the previous settings were—as long as the

programmer has not been unplugged and power has not been removed from

the controller.

Curtis 1214-/15-/19-8 Manual 17

4 — MAINTENANCE

MAINTENANCE

There are no user-serviceable parts inside Curtis controllers. No attempt should

be made to open the controller. Opening the controller may damage it and will

void the warranty.

However, it is recommended that the controller exterior be cleaned periodi-

cally, and—if a handheld programmer is available—this periodic cleaning pro-

vides a good opportunity to check the controller’s diagnostic history ﬁle.

The 1214-/15-/19-8 controller is inherently a high power device. When work-

ing around any battery powered vehicle, proper safety precautions should be

taken. These include, but are not limited to: proper training, wearing eye

protection, avoiding loose clothing and jewelry, and using insulated wrenches.

CLEANING

Although the 1214-/15-/19-8 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

should be wiped clean with a moist rag. Allow it to dry before recon-

necting the battery.

4. Make sure the connections to the bus bars are tight. Use two wrenches

for this task in order to avoid stressing the bus bars; the wrenches should

be well insulated.

DIAGNOSTIC HISTORY

The handheld programmer can be used to access the controller’s diagnostic

history ﬁle. Connect the programmer, press the MORE INFO key, and then—while

continuing to hold the MORE INFO key—press the DIAGNOSTICS key. The program-

mer will read out all the faults that the controller has experienced since the last

☞

CAUTION

This manual suits for next models

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