1212 Manual en

Manual
Model 1212
Electronic Motor Controller
Curtis Instruments, Inc.

200 Kisco Avenue
Mt. Kisco, NY 10549
www.curtisinstruments.com
Read Instructions Carefully!
Specifications are subject to change without notice. © 2022 Curtis Instruments, Inc.
® Curtis is a registered trademark of Curtis Instruments, Inc. ® Kohler is a registered trademark of Kohler Co.
© The design and appearance of the products depicted herein are the copyright of Curtis Instruments, Inc. 53112 Rev G Sept. 2022
TABLE OF CONTENTS
1: OVERVIEW....................................................................................................................................... 1
2: INSTALLATION AND WIRING............................................................................................................. 4
MOUNTING THE CONTROLLER....................................................................................................... 4
CONNECTIONS: High Current ........................................................................................................ 5
CONNECTIONS: Low Current ......................................................................................................... 5
WIRING: STANDARD INSTALLATION............................................................................................... 6
THROTTLE WIRING......................................................................................................................... 7
SWITCHES AND OTHER HARDWARE............................................................................................... 9
3: PROGRAMMABLE PARAMETERS..................................................................................................... 12
DRIVE PARAMETERS..................................................................................................................... 13
SPEED PARAMETERS.................................................................................................................... 15
THROTTLE PARAMETERS.............................................................................................................. 16
CURRENT PARAMETERS............................................................................................................... 19
INHIBIT PARAMETERS................................................................................................................... 19
BRAKE PARAMETERS.................................................................................................................... 20
HORN PARAMETERS..................................................................................................................... 20
MOTOR PARAMETERS.................................................................................................................. 21
STALL PARAMETERS..................................................................................................................... 21
BDI PARAMETERS......................................................................................................................... 22
COMPENSATION PARAMETERS..................................................................................................... 23
MISCELLANEOUS PARAMETERS ................................................................................................... 23
4: MONITOR MENU............................................................................................................................. 24
5: INITIAL SETUP................................................................................................................................ 25
6: VEHICLE PERFORMANCE ADJUSTMENT.......................................................................................... 28
pg. ii 1212 Manual – Sept. 2022

TABLE OF CONTENTS CONT’D
7: DIAGNOSTICS AND TROUBLESHOOTING.......................................................................................... 34

PROGRAMMER DIAGNOSTICS....................................................................................................... 34
LED DIAGNOSTICS........................................................................................................................ 34
FAULT HANDLING.......................................................................................................................... 34
8: MAINTENANCE............................................................................................................................... 37
DIAGNOSTIC HISTORY................................................................................................................... 37
APPENDIX A: VEHICLE DESIGN CONSIDERATIONS................................................................................ 38
APPENDIX B: BATTERY DISCHARGE INDICATOR (BDI) SETUP................................................................ 40
APPENDIX C: PROGRAMMING DEVICES............................................................................................... 42
APPENDIX D: SPECIFICATIONS............................................................................................................ 43
FIGURES
FIGURE 1: CURTIS 1212 MOTOR CONTROLLER ................................................................................... 1
FIGURE 2: MOUNTING DIMENSIONS .................................................................................................... 4
FIGURE 3: STANDARD WIRING CONFIGURATION................................................................................... 6
FIGURE 4: WIRING FOR 3-WIRE, 5KΩ POTENTIOMETER THROTTLE....................................................... 7
FIGURE 5: WIRING FOR VOLTAGE THROTTLE......................................................................................... 8
FIGURE 6: WIRING TO INHIBIT OPERATION DURING BATTERY CHARGING.............................................. 10
FIGURE 7: EFFECT OF THROTTLE ADJUSTMENT PARAMETERS ........................................................... 17
FIGURE 8: WIRING FOR BRAKE LIGHT ................................................................................................. 20
1212 Manual – Sept. 2022 pg. iii

TABLE OF CONTENTS CONT’D
TABLES
TABLE 1 PROGRAMMABLE PARAMETER MENUS........................................................................... 12
TABLE 2 STATUS LED FAULT CODES.............................................................................................. 35
TABLE 3 TROUBLESHOOTING CHART............................................................................................ 36
TABLE D-1 SPECIFICATIONS......................................................................................................... 43
pg. iv 1212 Manual – Sept. 2022

Return to TOC 1212 Manual – Sept. 2022
1 — OVERVIEW
The Curtis 1212 motor speed controller provides precise and smooth control of permanent magnet drive
motors for battery powered vehicles. The 1212 is designed for use in low power DME applications such
as micro-scooters, mini-scooters, foldable scooters, and low-end personal mobility vehicles. Although
it is optimized for use on modern 3-wheel and 4-wheel mobility aid scooters, its programmable
options also allow it to be used on any low power permanent magnet motor application.
The controller is 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
Motor
Controller.
Like all Curtis motor controllers, the 1212 offers superior operator control 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 current ensures smooth control, with no sudden loss of power during
undervoltage or overtemperature.
• Optional speed limit potentiometer provides direct and linear control of the maximum vehicle speed.
• Proprietary algorithms help prevent gearbox wear while providing smooth starts and reversals.
• The vehicle is brought to a complete stop before the electromagnetic brake is applied, ensuring
safe and secure stops under all conditions.
1 — OVERVIEW pg. 1
1212 Manual – Sept. 2022 Return to TOC
• 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 while
driving or when a fault occurs that requires the vehicle to stop.
• Anti-Rollback/Roll-forward function provides smooth and safe vehicle control on hills and ramps.
• Internal main relay provides secure power-off.
• Boost current gives a brief boost of current greatly improving transient loads such as starting
on a hill, crossing thresholds, etc.
Easy Installation and Setup

• Industry standard footprint, mounting centers, and wiring allows drop-in replacement of
other controllers.
• Easily programmed with a Curtis programming 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.
• Push-Too-Fast feature restricts the vehicle’s speed while it is being pushed, even with the key
off or the batteries disconnected.
• Automatic compensation for changes in motor condition to ensure optimum drive
performance at all times.
• Multi-mode provides for two distinct and programmable control modes (indoor/outdoor).
• Power Saver function prevents the controller draining the battery when the vehicle is inactive.
• Battery Discharge Indicator output.
• Optional Speed Inhibit input offers flexibility to reduce speed or prevent drive under certain
conditions, such as when the seat is lifted.
• Adjustable brake hold voltage reduces heating of the brake coil.
• Reverse Beeper function alerts bystanders.
• Electronics sealed to IP54.
pg. 2 1 — OVERVIEW
Robust Safety and Reliability

• High RF immunity prevents speed variation and shutdowns in noisy RF environments.
• Controller power circuits and microprocessor software are continuously monitored for
proper operation.
• On power-up, system automatically checks the throttle, brake, and associated wiring, and
disables drive if a fault is found.
Meets or Complies with Relevant US and International regulations

For details on regulatory compliance, see the Specifications.
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.
Working on electric vehicles is potentially dangerous. You should protect yourself against
runaways and high current arcs:
RUNAWAYS — Some conditions could cause the vehicle to run out of control. Disconnect the
CAUTION motor or jack up the vehicle and get the drive wheels off the ground before attempting any
work on the motor control circuitry.
HIGH CURRENT ARCS — Always open the battery circuit before working on the motor control
circuit. Wear safety glasses, and use properly insulated tools to prevent shorts.
1 — OVERVIEW pg. 3
2 — INSTALLATION AND WIRING
MOUNTING THE CONTROLLER

The 1212 controller can be oriented in any position, but the location should be carefully chosen
to keep the controller clean and dry. If a clean, dry mounting location cannot be found, a cover
must be used to 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 9.0
Dimensions,
Curtis 1212
Controller.
54.0
72±1
9.0 Ø 5.0 2PL

113.0
131±1
38.4±1
18.2
Dimensions in millimeters
You will need to take steps during the design and development of your end product to ensure that its
EMC performance complies with applicable regulations; suggestions are presented in Appendix A.
pg. 4 2 — INSTALLATION AND WIRING

CONNECTIONS: High Current

Four 1/4" Faston terminals are provided for the high current connections.
The motor connections (M1, M2) and battery connections M1 M2 B– B+
(B+, B–) have one terminal each.
CONNECTIONS: Low Current

The low current logic control connections are provided by a 14-pin connector. The mating connector
is a Molex Mini-Fit-Jr. receptacle p/n 39-01-2140 with appropriate 45750-series crimp terminals.
J1
1 2 3 4 5 6 7
8 9 10 11 12 13 14
J1 Pin 1 pot wiper

J1 Pin 2 pot high
J1 Pin 3 horn
J1 Pin 4 mode switch (open=M1, closed=M2)
J1 Pin 5 keyswitch input (KSI)
J1 Pin 6 speed inhibit
J1 Pin 7 B+
J1 Pin 8 pot low

J1 Pin 9 speed pot
J1 Pin 10 status LED
J1 Pin 11 BDI
J1 Pin 12 reverse switch
J1 Pin 13 I/O GND
J1 Pin 14 push switch
J2
J2 Pin 1 Rx A 4-pin low power connector is provided for the programmer and the battery
1 2
J2 Pin 2 I/O GND charger. The mating connector is a Molex Mini-Fit-Jr. receptacle p/n 39-01-2040 with
J2 Pin 3 Tx/charge inhibit 3 4 appropriate 45750-series crimp terminals. (A mating connector is provided with the
J2 Pin 4 B+
handheld programmer.).
J3 A 2-pin low power connector is provided for the electromagnetic brake. The mating
J3 Pin 1 Brake + connector is a Molex Mini-Fit-Jr. receptacle p/n 39‑01‑2020 with appropriate
1
J3 Pin 2 Brake - 45750-series crimp terminals.
2
2 — INSTALLATION AND WIRING pg. 5

WIRING: STANDARD INSTALLATION

The wiring diagram presented in Figure 3 shows a typical installation for a DME application. This
installation is shown with a single-ended 3‑wire 5kΩ potentiometer throttle and a reverse switch.
With wigwag throttles, a reverse switch is not used and Pin J1-12 is left unconnected.
The optional speed inhibit input can be wired into the circuit in various ways; in the standard
installation shown here, it is B‒ active (Inhibit Type parameter set to 0).
The J2 connector can be used interchangeably for the programmer or for the battery charger.
CONTROL
KEYSWITCH FUSE J1-7
B+ B+
POWER
J1-5 FUSE
KSI
BATTERY
J1-3
HORN
HORN
HORN SW
J1-13
I/O GND B–
M1
J1-11
BDI(0-5V)
MOTOR
INHIBIT SW
J1-6
SPEED INHIBIT M2
MODE SW
J1-4
MODE (M1,M2) BRAKE SW(optional)
J3-1
BRAKE +
REVERSE SW
J1-12 EM BRAKE
REVERSE J3-2
BRAKE –
PUSH SW
J1-14
PUSH
STATUS LED B+
J2-4
R B+
J1-10
STATUS LED CHARGER
J2-2 SOCKET
I/O GND
J1-2 J2-3 B–
100kΩ POT HIGH CHARGE INHIBIT
SPEED
POT 5KΩ J1-1
THROTTLE POT WIPER J2-4
B+
POT
J2-3
J1-8 Tx
POT LOW J2-2 Programmer
I/O GND
J1-9 Rx J2-1
SPEED LIMIT POT
1212 Controller
Figure 3
Standard Wiring Configuration, Curtis 1212 Controller.

THROTTLE WIRING
Either a 3-wire potentiometer throttle or a voltage throttle can be used with the controller. The
controller can accept a single-ended, inverse single-ended, wigwag, inverse wigwag, or unipolar input
signal from the throttle, depending on how the Throttle Type parameter is programmed; see page 16.
Throttle wiring is described in the following text. If the throttle you are planning to use is not covered,
contact the Curtis office nearest you.
5kΩ, 3-Wire Potentiometer

A 5kΩ, 3-wire potentiometer is shown in the wiring diagrams (Figure 3) as well as in Figure 4. With
this throttle, the controller can be programmed for a Throttle Type 0–4 input signal; see page 16.
Figure 4
Wiring for 3-Wire,
5KΩ Potentiometer
Throttle.
Ω 1 2 3 4 5 6 7
8 9 10 11 12 13 14
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 18).
The controller provides full pot fault protection against open or shorted wires anywhere in the
throttle assembly. The overall pot resistance should be 4.3 to 7.0 kΩ. Values outside this range will
trigger a fault condition. If a pot fault occurs while the vehicle is moving, the controller will decelerate
the vehicle to a smooth stop using the decel rate set by the Key Off Decel parameter. If the fault is
corrected while the throttle is still applied, an HPD fault will be issued and driving is disabled until
throttle is reduced to neutral.

Voltage Throttle
Wiring for a voltage throttle is shown in Figure 5. With this throttle, the controller can be programmed for
a Throttle Type 5–9 input signal; see page 16.
Figure 5
Wiring for Voltage Pot Wiper input (Pin 1)
Throttle.
+
VOLTAGE 1 2 3 4 5 6 7
THROTTLE
− 8 9 10 11 12 13 14
B−
The PotHigh and PotLow parameters are used to set the voltage range of these throttles. If 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 able to detect out-of-range
throttle faults, the throttle must have a range within the limits of 0.4–4.6 V.
Note: If a 0–5V throttle is used, it is the responsibility of the OEM to provide appropriate throttle fault
detection.
Speed Limit Pot

A speed limit pot allows the operator to adjust the speed of the vehicle at full throttle. The speed limit pot
should be sized so that 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 at its minimum speed setting when its wiper is shorted to the throttle’s pot low
connection (Pin 8). When the speed limit pot is in its minimum speed position, the vehicle’s speed at full
throttle corresponds to the programmed minimum speed setting. For information on the programmable
speed parameters, see Chapter 3.
The speed limit pot varies the vehicle’s speed linearly over the range between the minimum and maximum
speed settings in each mode, in forward and in reverse.
If a speed limit pot is not used, the Speed Limit Pot parameter should be programmed Off to disable the
fault check at the speed limit pot.

SWITCHES AND OTHER HARDWARE
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 for the other control input switches. It must be sized to
carry the 150 mA quiescent logic current plus the current necessary to drive the precharge function
(1.5 A for 0.5 seconds) and the status LED, horn, and any other accessories powered from the
keyswitch circuit.
Push Switch
A push switch can be used to electrically release the electromagnetic brake and inhibit driving.
Maximum speed in push mode is set by the Push Max Speed parameter. If a push input is applied at
power-up, it will not be acknowledged until it has been released and reapplied. The vehicle can enter
push mode only when it is in neutral or when the controller is not powered on.
Brake 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 operator attempts to drive the vehicle
with the brake mechanically released. This safety feature ensures that the vehicle cannot be driven
when the brake cannot be engaged.
Mode Switch
A mode switch is used 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 is in the On position (input connected to B+). Leaving the mode
input floating or actively switching it Off (pulling it to B–) puts the controller in Mode 1.
Battery Discharge Indicator (BDI)

The controller can drive a BDI panel meter to show the battery pack’s state of charge as a percentage
of the ampere-hour capacity of the batteries. The batteries must be put through a full charge cycle
with the controller installed before the BDI will begin operation.

Charger Inhibit
Typically, battery chargers have a dedicated third terminal that automatically provides inhibit. When
the charger is connected to the controller’s J2 connector, the controller disables the drive functions
and engages the EM brake while the charger is connected. Inhibit is provided through J2 Pin 3; see
wiring diagram (Figure 3). The charger inhibit automatically powers up the controller without the
keyswitch on 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.
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 3.
Figure 6
Wiring to Inhibit
B−
Operation During −
Battery Charging 1 2
(For Battery Chargers 3 4
Without a Dedicated
Inhibit Terminal).
Speed Inhibit
A speed inhibit switch can be used to limit drive speed, or even to prevent drive altogether, in certain
conditions; see Inhibit menu. The maximum speed allowed during inhibit operation is also set in the
Inhibit menu, with a setting of zero preventing drive.
Circuitry Protection Devices

To protect the control wiring from accidental shorts, a low current fuse (appropriately sized for the
maximum control circuit current draw) should be connected in series with the B+ logic supply. A
fuse is also recommended in the high power circuit from the battery to the controller’s B+ terminal.
This fuse will protect the power system from external shorts and should be sized appropriately for
the maximum rated current of the controller.

Status LED
The controller has the capability to drive a panel indicator LED, which can be used to tell the operator,
at a glance, the controller’s status. This LED always indicates whether the controller is powered on or
off. It will also provide diagnostics information via flash codes (see Chapter 7).
If a status LED is used, it should be installed with the proper resistor in series. The controller’s LED
driver is capable of a maximum current of 15 mA. The recommended resistor—designed to limit
driver current to 15 mA when active—is 2.4 kΩ, 0.5 W. Alternatively, an LED with a built-in resistor
can be used; it should be rated for 24V operation.
Horn
The controller’s horn driver—Pin 3—is designed to drive a low current DC horn at 1 Hz. The horn
sounds a warning when the reverse direction is selected and when the throttle autocalibration feature
is being used. The horn driver sinks a maximum current of 15 mA. 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.
Reverse Switch
If a single-ended or unipolar throttle is used, a reverse switch connected to Pin 12 can be used to
change the driving direction to reverse.

3 — PROGRAMMABLE PARAMETERS
The controller has a number of parameters that can be programmed using a Curtis handheld
programmer or Curtis PC Programming Station. These programmable parameters allow the vehicle’s
performance to be customized to best fit the needs of individual vehicle operators.
For information on programmming devices, see Appendix C.
For information on how to use the parameters to optimize performance, see Chapter 6.
The programmable parameters are grouped hierarchically into menus, as shown in Table 1. Not all
of these parameters are displayed on all controllers; the list for any given controller depends on its
specifications.
Table 1 Programmable Parameter Menus
DRIVE MENU...................................... p. 13 THROTTLE MENU............................. p. 16 MOTOR MENU.................................... p. 21

— Accel Max Speed — Type — System Resistance
— Accel Min Speed — PotHigh — Resistance Auto Comp
— Decel High Speed — PotLow — Auto Comp Current Limit
— Decel Low Speed — Neutral Deadband — Speed Scaler
— Rev Accel Max Speed — Throttle Max — Current Rating
— Rev Accel Min Speed — HPD — Max Current Time
— Rev Decel High Speed — Speed Limit Pot — Cutback Gain
— Rev Decel Low Speed — Throttle Map STALL MENU.................................... p. 21
— Key Off Decel — Tremor Suppression — Stall Speed
— E Stop Decel — Calibration
— Stall PWM
— E Stop Pause
CURRENT MENU............................... p. 19 — Stall Timeout
— Soft Start
— Gear Soften — Main Current Limit
— Braking Current Limit BDI MENU...................................... p. 22
— Creep Speed
— Full Voltage
— Push Max Speed — Boost Current
— Empty Voltage
— Soft Stop Speed — Boost Time
— Full Charge Voltage
— Speed................................ p. 15 INHIBIT MENU.................................. p. 19 — Start Charge Voltage
— Mode 1 — Reset Voltage
— Type
— Max Speed — Discharge Factor
— Speed
— Min Speed — Charge Factor
— Rev Max Speed BRAKE MENU.................................. p. 20 — Low BDI Level
— Rev Min Speed — Delay — Low BDI Max Speed
— Mode 2 — Fault Check
COMPENSATION MENU..................... p. 23
— Max Speed — Hold Voltage
— IR Comp
— Min Speed — Brake Light
— Anti-Rollback Comp
— Rev Max Speed
HORN MENU..................................... p. 20
— Rev Min Speed MISCELLANEOUS MENU.................. p. 23
— Fault Beep
— Reverse Beep — Sleep
— Beep Constant — Reset Drive Time
pg. 12 3 — PROGRAMMABLE PARAMETERS

DRIVE MENU
PARAMETER ALLOWABLE RANGE DESCRIPTION
Accel Max Speed 0.2–8.0 s Sets the rate (in seconds) at which the speed command increases when
throttle is applied with the speed limit pot is in its maximum speed position,
and the vehicle is traveling forward. Larger values represent slower response.
Note: Allowable range is restricted by the Accel Min Speed setting.
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 forward. Larger values represent slower response
Note: Allowable range is restricted by the Accel Max Speed setting.
Decel High Speed 0.2–8.0 s Sets the rate (in seconds) that is used to slow down the vehicle when it
is traveling forward at high speed and throttle is reduced. Larger values
represent slower response.
Note: Allowable range is restricted by the Decel Low Speed setting.
Decel Low Speed 0.2–8.0 s Sets the rate (in seconds) that is used to slow down the vehicle when it
is traveling forward at low speed and throttle is reduced. Larger values
Note: Allowable range is restricted by the Decel High Speed setting.
Rev Accel Max 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 maximum speed position,
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 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 High Speed 0.2–8.0 s Sets the rate (in seconds) that is used to slow down the vehicle when it is
traveling in reverse at high speed and throttle is reduced. Larger values
Note: Allowable range is restricted by Rev Decel Low Speed setting.
Rev Decel Low Speed 0.2–8.0 s Sets the rate (in seconds) that is used to slow down the vehicle when it
is traveling in reverse at low speed and throttle is reduced. Larger values
Note: Allowable range is restricted by Rev Decel High Speed setting.
Key Off Decel 0.2–4.0 s Sets the rate (in seconds) that is used to slow down the vehicle at key-off or
in the event of a major fault.
E Stop Decel 0.2–4.0 s Sets the rate (in seconds) that is used to slow down the vehicle during
emergency reverse, i.e., when a throttle command >80% in the reverse
direction is given while the vehicle is moving forward. This gives the operator
a way to stop more quickly when unexpected conditions arise.
E Stop Pause 0.0–1.0 s Sets a pause before reversing direction after an emergency reverse stop.
This gives the operator time to return the throttle to neutral without moving
backwards.
Soft Start 0–100 % This parameter can be used to soften the bump associated with gear slack
in the transaxle when throttle is applied from the neutral state. Larger values
provide a softer slack take-up.
3 — PROGRAMMABLE PARAMETERS pg. 13

DRIVE MENU, cont’d

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 provide a softer slack take-up.
Creep Speed 0–10 % Creep Speed helps to prevent vehicle rollback on inclines when the brake
is released with very little throttle applied. It is activated when the throttle
request exceeds the throttle deadband threshold.
Push Max Speed 25–50 % 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 is mechanically released
to enable pushing, Push Max Speed still applies. Once sufficient voltage is
generated by the motor, speed will be limited by the controller.
Soft Stop Speed 0–30 % Sets the speed at which a gentler deceleration is initiated when the throttle is
released to neutral; larger values start the soft stop deceleration sooner.

SPEED MODES
The controller’s Multi-ModeTM feature allows operation in two distinct modes: Mode 1 and Mode 2.
These modes can be programmed to provide two 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 maneuvering, and Mode 2 programmed for higher
speed, long distance travel outdoors.
The controller is in Mode 2 when the mode switch is in the On position (input connected to B+).
Leaving the mode input floating or actively switching it Off (pulling it to B-) puts the controller in
Mode 1.
The Speed menu allows the maximum speed in forward and reverse to be set independently in Mode
1 and Mode 2. The position of the speed limit pot determines whether the programmed Max Speed or
Min Speed—or a speed between these two programmed speeds—is in effect. Speed is varied linearly
over the range between the two speeds in each mode, in forward and reverse.
SPEED MENU
M1/M2 Max Speed 0–100 % 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 programmed Max Speed.
Note: Allowable range is restricted by the M1/M2 Max Speed setting. Note:
For this parameter to apply, a speed limit pot must be installed in parallel with
the throttle and the Speed Limit Pot parameter must be programmed On (see
Throttle menu).
M1/M2 Rev Max Speed 0–100 % During reverse 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 M1/M2 Rev Min Speed setting.
M1/M2 Rev Min Speed 0–100 % During reverse operation, defines the requested speed command at full
throttle when the speed limit pot is in its minimum speed position. Rev Min
Speed cannot be set higher than the programmed Rev Max Speed.
Note: Allowable range is restricted by M1/M2 Rev Max Speed setting. Note: For
this parameter to apply, a speed limit pot must be installed in parallel with
the throttle and the Speed Limit Pot parameter must be programmed On (see
Throttle menu).

THROTTLE MENU
Type 0–9 The controller can accept inputs from both 5kΩ, 3-wire pot throttles and
voltage throttles. Set the throttle type parameter to match the throttle used in
your application.
5kΩ, 3-wire pot throttles
0 = wigwag
1 = inverted wigwag
2 = single-ended; neutral when wiper at PotLow
3 = inverted single-ended; neutral when wiper at PotHigh
4 = unipolar.
Voltage throttles
5 = wigwag
6 = inverted wigwag
7 = single-ended; neutral when wiper ≤ PotLow
8 = inverted single-ended voltage; neutral when wiper ≥ PotHigh
9 = unipolar
Note: If Throttle Type 5–9 is used, see note on page 8.
PotHigh 3–5V Sets the maximum voltage for voltage throttles (Types 5–9).
(For 5kΩ, 3-wire pot throttles, PotHigh is determined by the throttle itself.)
PotLow 0–2V Sets the minimum voltage 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.
Guidelines for adjusting this parameter are provided in Chapter 5.
Throttle Max 40–100 % Sets the pot wiper voltage required to produce 100% controller output.
Increasing the Throttle Max setting reduces the wiper voltage required, and
therefore reduces the stroke necessary to produce full output. This feature
allows reduced-range throttle assemblies to be used.
Guidelines for setting Throttle Max are provided in Chapter 5.
HPD On/Off When programmed On, vehicle drive is inhibited if a throttle command outside
the neutral deadband is issued before the controller is powered up. Drive
will continue to be inhibited until the throttle is returned to within the neutral
deadband. If the HPD fault is not cleared within 10 seconds, a wiring fault is
declared and a power cycle is required.

THROTTLE MENU, cont’d

Speed Limit Pot On/Off This parameter is used to enable/disable the speed limit pot. If no speed limit
pot is used, set Speed Limit Pot to Off.
Throttle Map 20–80 % The throttle map parameter adjusts the static throttle map. The parameter
setting corresponds to the throttle command at half throttle, as shown in
Figure 7.
A setting of 50% provides linear response. Values below 50% reduce the
throttle command at low throttle positions, 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 throttle request. There is thus a trade-off between crispness of
response (low Tremor Suppression settings) and steady speed in the presence
of tremors (high settings).
Figure 7
Effect of Throttle Adjustment
Parameters. These Four
Parameters Determine The
Controller’s Response to
Throttle Position, in Forward
and Reverse.
Here,
Deadband = 10%
Throttle Max = 90%
Creep = 0%.

THROTTLE MENU, cont’d

Calibration On/Off Wigwag and unipolar throttle pots should be centered. Setting this parameter
to On inhibits driving and puts the controller into throttle autocalibration
mode; see procedure below.
Setting the parameter Off returns the controller to normal operation.
CALIBRATION OF WIGWAG AND UNIPOLAR THROTTLE POTS

The Calibration parameter provides a means of easily and reliably centering wigwag and unipolar
throttle pots. A horn must be connected to the horn driver during the procedure. The controller
inhibits driving while in calibration mode, enabling the throttle pot to be adjusted safely.
1. Jack the vehicle drive wheels off the ground or disconnect the motor leads.
2. Completely assemble the throttle mechanism but do not tighten the clamping mechanism
that secures the potentiometer shaft to the throttle lever.
3. Plug the programmer into the controller, and turn the keyswitch on.
4. Select the program mode and scroll down to the throttle autocalibration 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 neutral position, adjust the potentiometer in one direction
until the horn turns off. Note this position. Adjust the pot in the other direction until the
horn turns off. Note this position. Set the pot halfway between the two noted positions.
The pot is now adjusted to the proper value for neutral.
7. Tighten the clamping mechanism that secures the throttle lever to the potentiometer
shaft. Depress and release the throttle to verify the mechanical return to neutral; the horn
should turn off with the same amount of motion in both directions.
8. Set the calibration parameter Off, or cycle the keyswitch to reset it to Off. (If you are
performing the reset by cycling the keyswitch, note that KSI must remain off for at least 4
seconds.) The vehicle will not drive if the throttle autocalibration parameter is left On.

CURRENT MENU
Main Current Limit model dependent Sets the maximum current the controller will supply to the motor during
normal driving. By limiting the current supplied, this parameter can be used
to protect the motor from potentially damaging currents or to reduce the
maximum torque applied to the drive system.
For 1212-22xx controllers, it is adjustable from 10 to 45 amperes.
Braking Current Limit model dependent Sets the maximum current the controller will supply to the motor during
braking. By limiting the current supplied, this parameter can be used to
protect the motor from potentially damaging currents or to reduce the
maximum braking torque applied to the drive system.
Boost Current model dependent Boost current gives a brief boost of 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 current boost of a set
amount for a set time.
The Boost Current parameter defines the motor current limit during the
boost period.
Boost Time 0–10 s This parameter sets the maximum time that the boost current is allowed.
INHIBIT MENU
Type 0–5 The flexible speed input at J1 Pin 6 can be used to limit or to inhibit speed
under certain conditions. For example, a switch could be installed under the
seat so that the max speed will be limited if the operator drives the vehicle
while standing.
The Inhibit Type parameter is used to select how the inhibit function will be
implemented. Depending on how the inhibit switch is wired into the system,
set this parameter to:
0 = B− active
1 = B+ active
2 = Open circuit active
3 = B− inactive
4 = B+ inactive
5 = Open circuit inactive.
Speed 0–100 % This parameter limits the maximum speed allowed during speed inhibit mode.
A setting of 0 prevents drive during inhibit mode.

BRAKE MENU
Delay 0–1 s Sets the length of delay between when zero speed is commanded and the
electromagnetic brake is engaged.
Fault Check On/Off Enables/disables the fault detection on the EM brake.
Hold Voltage 10–24V A high initial voltage is applied to the brake coil when the brake is first
released. After approximately 1 second, this peak voltage drops to the
programmed Hold Voltage. The parameter should be set high enough to hold
the brake released under all the shock and vibration conditions the vehicle
will be subjected to.
Brake Light On/Off When set to On, the horn output (J1 Pin 3) will act as a brake light driver. The
brake light must be driven by a relay, as shown in Figure 8.
The brake light will be turned on when the throttle is returned 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.
Figure 8
Wiring for brake light.
min. coil 1 2 3 4 5 6 7
resistance
2kΩ 8 9 10 11 12 13 14
B−
HORN MENU
Fault Beep On/Off When programmed On, the horn will be used to provide audible fault codes
whenever faults are present. These are the same fault codes that are flashed
by the status LED. If a fault should occur while the vehicle is driving in reverse
with the reverse beep active, the fault signal will take precedence. If this
audible fault alarm is not wanted, set Fault Beep to Off.
Reverse Beep On/Off When programmed On, the horn will sound whenever the vehicle is being
driven in reverse. On vehicles with reverse switches, the horn will sound when
the reverse switch is activated.
Beep Constant On/Off Sets the reverse beep to be a constant tone (when programmed On) or a 1Hz
pulse (when programmed Off).

MOTOR MENU
System Resistance 0–800 mΩ Sets the system resistance (motor + brushes + wiring + connections) used
for load compensation and speed estimation. Control system performance
depends on this parameter being set correctly; it must be set to the actual
cold motor resistance.
For instructions, see initial setup procedure 4, on page 25.
Resistance Auto Comp On/Off Resistance is 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/disables this automatic
function.
Auto Comp Current Limit 5–50 % Sets the current limit used for automatic resistance testing, as a percentage
of the Main Current Limit (see Current menu).
Speed Scaler 20–27V The Speed Scaler parameter sets the maximum voltage that can be applied
to the motor. It can be used to eliminate variations in maximum speed
that would otherwise result when driving with a fully charged battery vs. a
partially discharged battery. If Speed Scaler is set to 23 volts, for example, the
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.
Max Current Time 0–120 s Sets the maximum amount of time the motor is allowed to run at the main
current limit.
Cutback Gain 0–100 % When the motor overheats, the drive current is cut back until it reaches the
programmed Current Rating. The Cutback Gain determines how quickly this
cutback will occur, once the programmed Max Current Time has expired.
STALL MENU
Stall Speed 0–255 Sets the Stall Speed that will be used to determine a Motor Stalled fault.
A Motor Stalled fault is issued when the estimated speed < Stall Speed and
the duty cycle is < Stall PWM for longer than Stall Timeout.
Stall PWM 0–100 % Sets the Stall PWM that will be used to determine a Motor Stalled fault; see
description in Stall Speed parameter description.
Stall Timeout 16–32 s Sets the Stall Timeout that will be used to determine a Motor Stalled fault; see
description in Stall Speed parameter description.

The Battery menu allows any lead acid battery to be installed and the BDI algorithm tailored to match
it. Actual usage duty cycle greatly affects the settings and the overall accuracy of the BDI algorithm.
The power level and type of battery charger used also affect the BDI algorithm, and therefore testing
must be done to match the charger as well.
See Appendix B for guidelines on setting up these BDI parameters.
BDI MENU
Full Voltage 20.0–28.0V Voltage when the battery is fully charged.
Note: Allowable range is restricted by the Empty Voltage, Start Charge Voltage,
and Reset Voltage settings.
Empty Voltage 16.0–24.0V Voltage when the battery is fully discharged.
Note: Allowable range is restricted by the Full Voltage setting.
Full Charge Voltage 24.0–32.0V Voltage, when a charger is connected, above which the battery is considered
finished charging.
Note: Allowable range is restricted by the Start Charge setting.
Start Charge Voltage 21.0–29.0V Voltage above which the battery is considered to start charging.
Note: Allowable range is restricted by the Full Voltage and Full Charge Voltage
settings.
Reset Voltage 20.0–28.0V Voltage at which the BDI calculator will be reset to 100%, after the charger is
disconnected and the controller is powered up.
Note: Allowable range is restricted by the Full Voltage setting.
Discharge Factor 0.1–10.0 Discharge rate of the battery. Larger values are for larger batteries, which
discharge more slowly.
Charge Factor 0.1–10.0 Charge rate of the battery. Larger values are for larger batteries, which charge
more slowly.
Low BDI Level 0–100 % Sets the battery charge level at which maximum vehicle speed will be limited
in order to protect the battery 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.

COMPENSATION MENU
IR Comp 0–100 % Sets the motor load compensation. Higher values provide stronger
disturbance rejection, while lower values provide smoother operation.
Note: Allowable range is restricted by the Anti-Rollback Comp setting.
Anti-Rollback Comp 0–125 % Sets the motor load compensation after the throttle is released to neutral and
the speed is estimated to be near zero. Higher values provide more hill-
holding force.
Note: Allowable range is restricted by the IR Comp setting.
MISCELLANEOUS MENU
Sleep 0–60 minutes Sets the delay time between the last throttle request or serial communication
and when the controller goes into sleep mode. Setting the delay to zero
disables the sleep function.
Reset Drive Time On/Off The controller’s hourmeter logs the total drive time since the last reset; this
record is accessible through the Monitor menu. Setting this parameter On
zeroes the hourmeter and starts a new log; this is typically done when the
vehicle is serviced. Reset Drive Time is automatically set to Off after the
hourmeter is reset.

4 — MONITOR MENU
Through its Monitor menu, a Curtis programmer provides access to real-time data during vehicle
operation. This information is helpful during diagnostics and troubleshooting, and also while
adjusting programmable parameters.
MONITOR MENU
VARIABLE DISPLAY RANGE DESCRIPTION
Temp −55 – +127 °C Controller’s internal temperature.
Battery Voltage 0–38.2V Battery voltage.
Motor Voltage −27.4 – +27.4V Voltage drop between the motor terminals.
Motor Thermal Cutback 0–100 % Current cutback during motor over-temperature, as a percentage of max
current. 100% = no cutback.
Armature Current −90 – +90 A Measured 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 reverse switch (at J1-12).
Inhibit On/Off Status of the speed inhibit switch (at J1-6).
Push Input On/Off Status of the push switch (at J1-14).
Main Contactor On/Off Status of the main contactor driver.
Brake On/Off Status of the EM brake driver.
BDI 0–100 % Status of battery capacity.
Drive Time 0–65535 hours Hours of operation since the hourmeter was last reset (Reset Drive Time = On).
pg. 24 4 — MONITOR MENU

5 — INITIAL SETUP
Before operating the vehicle, carefully complete the following initial setup procedures. If you find a
problem during the checkout, refer to the diagnostics and troubleshooting chapter (Chapter 7) for
further information.
Before starting the setup procedures, jack the vehicle drive wheels up off the ground so that
they spin freely. Double-check all wiring to ensure that it is consistent with the wiring guidelines
presented in Chapter 2. Make sure all connections are tight.
Step 1: Begin the Setup Procedures

1.1 Put the throttle in neutral, and open the forward/reverse switches.
1.2 Turn on the controller and plug in the programming device. The programmer should power up
with an initial display, and the status LED should light steadily. If neither happens, check for
continuity in the keyswitch circuit and controller ground.
Step 2: Throttle
Set the Throttle Type parameter (Program » Throttle » Type) to match the throttle you are using; see
page 16.
It is important to ensure that the controller output is operating over its full range. The following
tuning procedures will establish the Neutral Deadband and Throttle Max parameter values that
correspond 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 set to its default value, adjust this parameter if necessary to provide
a good balance. The deadband should be wide enough for the throttle to reliably return to neutral when
released, yet without an excessive amount of travel in the “dead” zone before power is applied.
2.1 If the throttle travels too far when starting out of neutral before the brake disengages, decrease
the Neutral Deadband value. If the brake sometimes doesn’t engage when the throttle is returned
to neutral, increase the Neutral Deadband value. The default setting of 10% should work for
most applications.
2.2 If a wigwag or unipolar throttle assembly is being used, the procedure should be repeated for
the reverse direction. The Neutral Deadband value should be set such that the throttle operates
correctly in both forward and reverse.
* If you are using a wigwag or unipolar throttle, you should center it before proceeding with the throttle tuning procedures.
Instructions for centering, using the Throttle Calibration parameter, are presented on page 18.
5 — INITIAL SETUP pg. 25

Tuning the Throttle Max

2.3 Apply full throttle and observe the Throttle value. This value should be 100%. If it is less than
100%, the Throttle Max value should be decreased to get 100% throttle. After entering a smaller
Throttle Max value (Program » Throttle » Throttle Max), return to the Monitor menu and repeat
this step until the Throttle % value is 100% at maximum throttle position.
2.4 Now that the full throttle position results in a 100% value for Throttle, slowly reduce throttle until
the Throttle value drops below 100% and note the throttle position. This represents the extra range
of motion allowed by the throttle mechanism. If this range is large, you may wish to decrease it
by increasing Throttle Max. Entering a larger Throttle Max value (Program » Throttle » Throttle
Max) will provide a larger active throttle range and more vehicle control. Return to the Monitor
menu and repeat this step until an appropriate amount of extra range is attained.
2.5 If a wigwag or unipolar throttle is being used, repeat the procedure for the reverse direction.
Throttle Max should be set such 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 Chapter 7.
Step 3: Basic Vehicle Checkout

Using the Monitor menu, observe the status of each of the switches included in your application:
mode, reverse, push and speed inhibit. Cycle each input in turn, observing the programmer. The
programmer should display the correct status for each input.
Similarly, check the throttle and speed limit pot inputs. The correct value for each input should
be displayed.
Verify that all options, such as HPD, are as desired.
To verify the status of the charger inhibit input, plug in the charger and apply the throttle; the motor
should not run.
If everything checks out, lower the vehicle drive wheels onto the ground.
pg. 26 5 — INITIAL SETUP

Step 4: Setting System Resistance

It is very important that the System Resistance parameter be set accurately. This procedure must be
conducted quickly and with the motor cold. If the procedure needs to be repeated, ample time must
be allowed for the motor to cool completely. Conducting the procedure with a warm motor will lead
to erroneous settings.
The correct System Resistance value is determined as follows.
4.1 Position the vehicle up against a wall, high curb, or some other immovable object.
4.2 Plug in the programmer and turn the keyswitch on.
4.3 Set the Main Current Limit parameter (Program » Current » Main Current Limit) to 25 amps
(1212-22xx models) or to 35 amps (1212-24xx models).
4.4 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 models.
4.5 In the Monitor menu, scroll down to the Resistance field.
4.6 With the speed limit pot set at maximum, apply the throttle full forward, driving the vehicle
against the immovable object.
4.7 Observe the Resistance value displayed in the Monitor menu.
4.8 Repeat steps 4.6 and 4.7 three more times. Do these measurements quickly, to minimize motor
heating, and note all four Resistance values.
4.9 Program the System Resistance parameter (Program » Motor » System Resistance) to the
average of the four Resistance values that were displayed in the Monitor menu.
4.10 Before moving on to Chapter 6, Vehicle Performance Adjustment, be sure to set the Main
Current Limit and Boost Current Limit back to their default settings.
5 — INITIAL SETUP pg. 27

6 — VEHICLE PERFORMANCE ADJUSTMENT

The controller’s adjustable parameters allow many aspects of vehicle performance to be optimized.
Once a vehicle/motor/controller combination has been tuned, the parameter values can be made
standard for that system or vehicle model. Any changes in the motor, the vehicle drive system, or the
controller will require that the system be tuned again to provide optimum performance.
The tuning procedures should be conducted in the sequence given, because successive steps build
upon the ones before. It is important that the effect of these programmable parameters be understood
in order to take full advantage of the controller’s features. Please refer to the descriptions of the
applicable parameters in Chapter 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.
Step 5: Setting the Maximum Speeds

The four maximum speeds with the speed limit pot in its maximum speed position are set by the
four Max Speed parameters:
M1/M2 Max Speed and M1/M2 Rev Max Speed.
The four maximum speeds with the speed limit pot in its minimum speed position are set by the
four Min Speed parameters:
M1/M2 Min Speed and M1/M2 Rev Min Speed.
Each of the maximum speeds is programmed as a percentage of the maximum possible speed. Set
each of the eight maximum speed parameters to give the desired performance.
pg. 28 6 — VEHICLE PERFORMANCE ADJUSTMENT

Step 6: Setting the Acceleration and Deceleration Rates

The acceleration and deceleration functions have been designed to provide smooth throttle response
when maneuvering at low speeds and snappy throttle response when traveling at high speeds. This
is accomplished by defining acceleration/deceleration rates at each end of the speed limit pot’s
range. The rates are scaled linearly between these two endpoints. Four pairs of parameters define
the endpoints of the acceleration/deceleration curves:
Forward acceleration: Accel Min Speed — Accel Max Speed
Forward deceleration: Decel Low Speed — Decel High Speed
Reverse acceleration: Rev Accel Min Speed — Rev Accel Max Speed
Reverse deceleration: Rev Decel Low Speed — Rev Decel High Speed.
The programmed acceleration and deceleration rates are independent of mode. However, it makes
sense to adjust the low speed rates under the slowest speed conditions (Mode 1) and the high speed
rates under the fastest speed conditions (Mode 2). Tuning the rates under the most extreme (slowest,
fastest) conditions will most likely result in good performance throughout the entire driving range.
Note: Smaller values provide faster response.
Forward acceleration and deceleration rates

6.1 First, adjust Accel Min Speed. Select Mode 1 and set the speed limit pot to its minimum
speed position. For low speed testing, we suggest 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.
6.2 Now adjust Decel Low Speed. Driving at full throttle with the speed limit pot still in its minimum
speed position, release the throttle to neutral. Depending on how you liked the deceleration you
experienced, increase or decrease the Decel Low Speed value. Continue testing and adjusting
this value until you are satisfied with the vehicle’s low speed forward deceleration.
6.3 Next, adjust Accel Max Speed. Select Mode 2 and set the speed limit pot to its maximum
speed position. Apply full throttle. Depending on how you liked the forward acceleration you
experienced, increase or decrease the Accel Max Speed value. Continue testing and adjusting
this value until you are satisfied with the vehicle’s high speed forward acceleration.
6.4 Driving at full throttle with the speed limit pot still in its maximum speed position, release the
throttle to neutral. Depending on how you liked the deceleration you experienced, increase or
decrease the Decel High Speed value. Continue testing and adjusting this value until you are
satisfied with the vehicle’s high speed forward deceleration.
Reverse acceleration and deceleration rates

6.5 ‒ 6.8 A
djust Rev Accel Min Speed, Rev Decel Low Speed, Rev Accel Max Speed, and Rev Decel
High Speed using the same procedures as for the corresponding Forward parameters.
6 — VEHICLE PERFORMANCE ADJUSTMENT pg. 29

Fine tuning the acceleration and deceleration rates

6.9 Drive around in both Mode 1 and Mode 2, while varying the position of the throttle and the
speed limit pot. In most cases, setting the acceleration and deceleration rates as described in
Steps 6.1 through 6.8 will provide good performance throughout. However, you may want to
make further adjustments to them.
6.10 For additional softening of the deceleration response, you could adjust the Soft Stop Speed
parameter to a larger value (see page 14).
6.11 In rare cases, it may be desirable to adjust the Throttle Map parameter. This parameter can
be used, for example, to extend the throttle’s gentle acceleration range to further enhance
maneuverability in confined areas. See page 17 for a description of Throttle Map.
Key Off deceleration rate

The Key Off Decel parameter sets the decel rate that will be used to slow the vehicle at key-off or in
the event of a major fault.
6.12 Drive fast and turn the key off. The deceleration you experience is determined by Key Off Decel.
6.13 Adjust the Key Off Decel value to produce the desirable “feel” for emergency stops: typically
as fast as possible without making the vehicle unstable.
6.14 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 throttle request. This
provides a way to stop more quickly when unexpected conditions arise.
6.15 Drive fast and throw the throttle into >80% reverse. The deceleration you experience is
determined by E Stop Decel.
6.16 Adjust the E Stop Decel value to produce the desirable “feel” for emergency reverse stops:
typically as fast as possible without making the vehicle unstable.
6.17 Note that the E Stop Decel rate should always be set faster than (or equal to) the fastest
forward deceleration rate, Decel High Speed.
6.18 The E Stop Pause parameter can be used to create a pause after the vehicle has come to an
emergency stop, thus giving the operator a chance to return the throttle to neutral before the
vehicle starts to travel backwards. Adjust the E Stop Pause value to provide the appropriate pause.
A longer pause might be preferred for a vehicle that will be mainly used indoors, whereas for a
vehicle that will be used outdoors a faster initiation of reverse travel might be desirable.

Step 7: Adjusting IR Compensation

The IR Comp parameter is used to set the percentage of the maximum motor resistance that will be
applied, i.e., (IR Comp) × (System Resistance), to compensate for increased load caused by uneven
terrain.
The trade-off in setting this parameter is that as ability to overcome load disturbances increases,
operating smoothness decreases. A high IR Comp value will allow the vehicle to continue creeping at
a low speed, even though it has just contacted a bump in the threshold of a doorway. But if IR Comp
is set too high, it may make the vehicle “jumpy” during normal driving. Small throttle movements
in this case may no longer provide gentle linear acceleration, but instead initiate accelerations with a
sharp jerk. Therefore, the tuning goal is a balance between adequate load disturbance response and
normal acceleration/deceleration response.
The normal range for IR Comp is approximately 50–80%. Larger 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 before stopping, when the throttle is in neutral, IR Comp is replaced by Anti-Rollback Comp.
Typically Anti-Rollback Comp is set about 20% higher than IR Comp.
Assuming that System Resistance is set correctly (within 10–20%), some general rules of thumb apply:
7.1 If the vehicle is extremely “jumpy” (i.e., responds abruptly to small throttle changes, IR Comp
could be set too high.
7.2 If the vehicle speed varies dramatically when cresting a hill, IR Comp is most likely set too low.
7.3 If the vehicle rolls the other direction near the end of a stop on flat ground, Anti-Rollback Comp
is set too high.
7.4 If the vehicle is still moving on a modest ramp when the brake gets set, Anti-Rollback Comp
is set too low.
7.5 If the vehicle seems to decelerate to a stop in a nonlinear fashion, Anti-Rollback Comp could
be set too high.

Step 8: Fine-tuning the Vehicle’s Response Smoothness

Three additional parameters—Gear Soften, Soft Start, and Tremor Suppression—are available for
softening and smoothing vehicle response. In most cases, these functions can be used to provide
smooth vehicle operation while still maintaining a high degree of responsiveness.
Gear Soften and Soft Start are in the Speed menu; Tremor Suppression is in the Throttle menu.
Gear Soften and Soft Start

These two parameters can be set from 0–100%, with 100% providing a great deal of softening and
0% eliminating the function. They have by far the most noticeable effect on older, worn transaxles.
8.1 Make sure Gear Soften and Soft Start are set to 0%.
8.2 While driving at both high and low speeds, release the throttle to neutral and then reapply it before
coming to a complete stop. Notice how the transaxle gears bump as you reapply the throttle.
8.3 Change the Gear Soften setting from 0% to 100% and repeat the same exercise. Notice how the
slop transition is softened, at the expense of a small bit of nonlinearity in the acceleration rate.
8.4 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 setting this parameter, you also may want to take into consideration that softened slack take-
up is easier on the transaxle gears and may extend the transaxle operating life.
8.5 Soft Start is the same as Gear Soften, except it applies to accelerations from zero speed. Note
that you’ll feel a transaxle bump only if the gears are meshed in the opposite direction when
torque is applied, so you may need to nudge the vehicle backwards against the brake when
experimenting with this parameter. We recommend relatively small values for the Soft Start
parameter (typically < 40%) to avoid excessive delay from a stop. Having separate parameters
for the soft start and gear soften functions allows you to set the Soft Start parameter lower than
the Gear Soften parameter. Setting the two parameters the same in effect collapses them into
a single parameter.

Tremor Suppression
Tremor Suppression adjusts vehicle response to sharp throttle movements, such as those resulting
inadvertently from hand tremors. This parameter can be set from 0–100%, with larger values
providing steadier response. The tremor compensation function somewhat overlaps the gear softening
functions. However, the tremor compensation function is active all the time, while the two gear
softening functions are active only during a gear slack transition, 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 neutral state to ensure
responsive linear deceleration when the driver commands a stop.
These setup and tuning procedures cover the most critical aspects of vehicle performance. Additional
parameters can be used to make further adjustments, if necessary. However, in most cases, the default
values of the other parameters prove satisfactory.

7 — DIAGNOSTICS AND TROUBLESHOOTING

The 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 programmer or by observing the fault codes issued 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 3) for suggestions about possible causes of the various faults
For information on programming devices, see Appendix C.
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 identification code continuously until the fault
is corrected.
For example, code “1,4”—undervoltage—appears as:
¤ ¤ ¤ ¤ ¤ ¤ ¤ ¤ ¤ ¤ ¤ ¤ ¤ ¤ ¤

(1,4) (1,4) (1,4)
The fault codes are listed in Table 2. Refer to the troubleshooting chart (Table 3) 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.
pg. 34 7 — DIAGNOSTICS AND TROUBLESHOOTING

Table 2 Status LED Fault Codes
LED CODES FAULT

LED off no power or defective controller
solid on controller powered up; no faults
1,1 ¤ ¤ THERMAL FAULT

1,2 ¤ ¤¤ THROTTLE FAULT
1,3 ¤ ¤¤¤ SPEED POT FAULT
1,4 ¤ ¤¤¤¤ UNDERVOLTAGE FAULT
1,5 ¤ ¤¤¤¤¤ OVERVOLTAGE FAULT
2,1 ¤¤ ¤ MAIN OFF FAULT

2,2 ¤¤ ¤¤ MOTOR STALLED
2,3 ¤¤ ¤¤¤ MAIN FAULT*
2,4 ¤¤ ¤¤¤¤ MAIN ON 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 menu, alter data value of any
parameter, cycle keyswitch.
7 — DIAGNOSTICS AND TROUBLESHOOTING pg. 35

Table 3 TROUBLESHOOTING CHART
LED PROGRAMMER
CODE LCD DISPLAY EXPLANATION POSSIBLE CAUSE
over-/under-temperature cutback 1. Temperature >80°C or < −10°C.
2. Excessive load on vehicle.
1,1 THERMAL FAULT
3. Operation in extreme environments.
4. Electromagnetic brake not releasing.
PotLow and/or PotWiper out of range 1. Throttle input wire open or shorted.
1,2 THROTTLE FAULT 2. Throttle pot defective.
3. Wrong throttle type selected.
speed limit pot wiper out of range 1. Speed limit pot wire(s) broken or shorted.
1,3 SPEED POT FAULT
2. Broken speed limit pot.
battery voltage too low 1. Battery voltage <17 volts.
1,4 UNDERVOLTAGE FAULT
2. Bad connection at battery or controller.
battery voltage too high 1. Battery voltage >31 volts.
1,5 OVERVOLTAGE FAULT 2. Vehicle operating with charger attached.
3. Intermittent battery connection.
2,1 MAIN OFF FAULT main contactor driver Off fault 1. Main contactor driver failed open.
2,2 MOTOR STALLED motor stall fault 1. Motor is stalled.
main contactor fault 1. Main contactor welded or stuck open.
2,3 MAIN FAULT
2. Main contactor driver fault.
2,4 MAIN ON FAULT main contactor driver On fault 1. Main contactor driver failed closed.
HPD fault present >10 sec. 1. Misadjusted throttle.
3,1 WIRING FAULT
2. Broken throttle pot or throttle mechanism.
brake On fault 1. Electromagnetic brake driver shorted.
3,2 BRAKE ON FAULT
2. Electromagnetic brake coil open.
precharge fault 1. Brake driver shorted.
3,3 PRECHARGE FAULT 2. Precharge circuit damaged.
3. MOSFET failure.
brake Off fault 1. Electromagnetic brake driver open.
3,4 BRAKE OFF FAULT
2. Electromagnetic brake coil shorted.
HPD (High Pedal Disable) 1. Improper sequence of throttle and KSI, push, or inhibit
3,5 HPD FAULT inputs.
2. Misadjusted throttle pot.
current sense out of range 1. Short in motor or in motor wiring.
4,1 CURRENT SENSE FAULT
2. Controller failure.*
motor voltage out of range 1. Motor voltage does not correspond to throttle request.
4,2 HARDWARE FAILSAFE 2. Short in motor or in motor wiring.
3. Controller failure.*
4,3 EEPROM CHECKSUM FAULT EEPROM fault 1. EEPROM failure or fault.
4,4 MOTOR OPEN motor open fault 1. Motor wiring is open.
battery disconnected 1. Battery not connected.
4,5 BATTERY DISCONNECT FAULT
2. Poor connection to battery terminals.
*Jack up vehicle and retest to confirm diagnosis. Clean connections, inspect system wiring, and retest.
pg. 36 7 — DIAGNOSTICS AND TROUBLESHOOTING

8 — MAINTENANCE
There are no user serviceable parts in the controller. No attempt should be made to open, repair, or
otherwise modify the controller. Doing so may damage the controller and will void the warranty.
However, it is recommended that the controller’s fault history file be checked and cleared periodically,
as part of routine vehicle maintenance.
DIAGNOSTIC HISTORY
The handheld 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 problem has been diagnosed and corrected, clearing the history file is advisable. This allows
the controller to accumulate a new file of faults. By checking the new history file at a later date, you
can readily determine whether the problem was indeed completely fixed.
8 — MAINTENANCE pg. 37
APPENDIX A
VEHICLE DESIGN CONSIDERATIONS
REGARDING ELECTROMAGNETIC COMPATIBILITY (EMC)
Electromagnetic compatibility (EMC) encompasses two areas: emissions and immunity. Emissions
are radio frequency (RF) energy generated by a product. This energy has the potential to interfere
with communications systems such as radio, television, cellular phones, dispatching, aircraft, etc.
Immunity is the ability of a product to operate normally in the presence of RF energy.
EMC is ultimately a system design issue. Part of the EMC performance is designed into or inherent
in each component; another part is designed into or inherent in end product characteristics such as
shielding, wiring, and layout; and, finally, a portion is a function of the interactions between all these
parts. The design techniques presented below can enhance EMC performance in products that use
Curtis motor controllers.
Emissions
Signals with high frequency content can produce significant emissions if connected to a large enough
radiating area (created by long wires spaced far apart). Contactor drivers and the motor drive
output from Curtis controllers can contribute to RF emissions. Both types of output are pulse width
modulated square waves with fast rise and fall times that are rich in harmonics. (Note: contactor
drivers that are not modulated will not contribute to emissions.) The impact of these switching
waveforms can be minimized by making the wires from the controller to the contactor or motor as
short as possible and by placing the wires 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 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 radiated electric fields can be improved either by reducing overall circuit sensitivity
or by keeping undesired signals away from this circuitry. The controller circuitry itself cannot be
made less sensitive, since it must accurately detect and process low level signals from sensors such
as the throttle potentiometer. Thus immunity is generally achieved by preventing the external RF
energy from coupling into sensitive circuitry. This RF energy can get into the controller circuitry via
conducted paths and radiated paths.
Conducted paths are created by the wires connected to the controller. These wires act as antennas and
the amount of RF energy coupled into them is generally proportional to their length. The RF voltages
and currents induced in each wire are applied to the controller pin to which the wire is connected.
Curtis controllers include bypass capacitors on the printed circuit board’s throttle wires to reduce the
impact of this RF energy on the internal circuitry. In some applications, additional filtering in the
form of ferrite beads may also be required on various wires to achieve desired performance levels.
Radiated paths are created when the controller circuitry is immersed in an external field. This
coupling can be reduced by placing the controller as far as possible from the noise source or by
enclosing the controller in a metal box. Some Curtis controllers are enclosed by a heatsink that also
provides shielding around the controller circuitry, while others are partially shielded or unshielded.
pg. 38 APPENDIX A
In some applications, the vehicle designer will need to mount the controller within a shielded box on
the end product. The box can be constructed of just about any metal, although steel and aluminum
are most commonly used.
Most coated plastics do not provide good shielding because the coatings are not true metals, but
rather a mixture of small metal particles in a non-conductive binder. These relatively isolated particles
may appear to be good based on a dc resistance measurement but do not provide adequate electron
mobility to yield good shielding effectiveness. Electroless plating of plastic will yield a true metal and
can thus be effective as an RF shield, but it is usually more expensive than the coatings.
A contiguous metal enclosure without any holes or seams, known as a Faraday cage, provides the
best shielding for the given material and frequency. When a hole or holes are added, RF currents
flowing on the outside surface of the shield must take a longer path to get around the hole than if
the surface was contiguous. As more “bending” is required of these currents, more energy is coupled
to the inside surface, and thus the shielding effectiveness is reduced. The reduction in shielding is a
function of the longest linear dimension of a hole rather than the area. This concept is often applied
where ventilation 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 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. If the ohmic
contact itself is not continuous, the shielding effectiveness can be maximized by making the joints
between adjacent pieces overlapping rather than abutted.
The shielding effectiveness of an enclosure is further reduced when a wire passes through a hole in
the enclosure; RF energy on the wire from an external field is re-radiated into the interior of the
enclosure. This coupling mechanism can be reduced by filtering the wire where it passes through
the shield boundary. Given the safety considerations involved in connecting electrical components to
the chassis or frame in battery powered vehicles, such filtering will usually consist of a series inductor
(or ferrite bead) rather than a shunt capacitor. If a capacitor is used, it must have a voltage rating and
leakage characteristics that will allow the end product to meet applicable safety regulations.
The B+ (and B–, if applicable) wires that supply power to a control panel should be bundled with the
other control wires to the panel so that all these wires are routed together. If the wires to the control
panel are routed separately, a larger loop area is formed. Larger loop areas produce more efficient
antennas which will result in decreased immunity performance.
Keep all low power I/O separate from the motor and battery leads. When this is not possible, cross
them at right angles.
APPENDIX A pg. 39
APPENDIX B
BATTERY DISCHARGE INDICATOR (BDI) SETUP
The Battery Discharge Indicator used with the controller 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

1.1 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).
1.2 Set the Full Charge Voltage 0.2 V lower than the measured value.
1.3 Turn off or disconnect the charger and let the batteries sit for 1 hour. Measure the battery
voltage again.
1.4 Set the Reset Voltage 0.2 V lower than the new measured value.
Step 2 — Setting the Full Voltage

2.1 Select a medium speed mode and drive the vehicle for 10–15 minutes.
2.2 After this time and while driving straight on a level surface, record the battery voltage displayed
in the Monitor menu.
2.3 Set the Full Voltage parameter to this value.
pg. 40 APPENDIX B
Step 3 — Setting the Empty Voltage

3.1 Normally a value of 1.7 volts per cell is used as the empty point. This corresponds to a setting
of 20.4 V. For some sealed batteries, this may be too low. Consult the battery manufacturer if
you are unsure.
Step 4 — Setting the Discharge Factor

4.1 Resume driving the vehicle, with a heavy load.
4.2 Pay attention to the battery voltage, BDI, and time.
4.3 At some point, you will feel the vehicle become sluggish and notice the battery voltage drop
significantly with basic maneuvers. This is the fully discharged point of the battery. Stop driving.
4.4 The BDI should have indicated 0% before this point, to prevent the battery pack from wearing
out prematurely.
4.5 If the BDI does not read 0%, reduce the Discharge Factor parameter proportionately
to the indicated remaining BDI. Use this formula to determine the new setting:
New Discharge Factor = Present Discharge Factor * (1 – BDI%),
with the BDI% being expressed decimally (e.g., 90% = 0.90).
Step 5 — Setting the Charge Factor and Start Charge Voltage

How you set the Charge Factor and Start Charge Voltage parameters depends on how you 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 controller 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:

5.1 Set the Charge Factor to 10.0.
5.2 Set the Start Charge Voltage equal to the Full Charge Voltage.
With these settings, the BDI will not recalculate until the very end of the charge cycle, and the Reset
Voltage—not the charge time—will trigger the BDI to 100%.
If you want to use the partial charge feature:

5.3 Based on the Amp Hour rating of the batteries and the charger’s average amp output, initially
calculate and set the Charge Factor using this formula:
Charge Factor = 1.5 * (Battery amp-hrs / Charger amps).
5.4 Starting with the dead battery from Step 4, plug in the charger. After 10 minutes of charging,
measure the battery voltage with a meter. Set the Start Charge Voltage parameter to this value.
Step 6 — Rerun and Verify

This procedure will give good initial settings for the BDI algorithm. You should test these settings
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 that battery age and driving conditions (hilliness, driving surface, weight of
user) will all affect the accuracy of the BDI measurement.
APPENDIX B pg. 41
APPENDIX C
PROGRAMMING DEVICES
Curtis programmers provide programming, diagnostic, and test capabilities for the controller. The power for
operating the programmer is supplied by the host controller via a 4-pin connector. When the programmer
powers up, it gathers information from the controller.
Two types of programming devices are available: the 1314 PC Programming Station and the 1313 handheld
programmer. The Programming Station has the advantage of a large, easily read screen; on the other hand,
the handheld programmer (with its 45×60mm screen) has the advantage of being more portable and hence
convenient for making adjustments in the field.
Both programmers are available in User, Service, Dealer, and OEM versions. Each programmer can perform
the actions available at its own level and the levels below that—a User-access programmer can operate at 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 are provided in the 1313 manual.
PROGRAMMER FUNCTIONS
Programmer functions include:
Parameter adjustment — provides access to the individual programmable parameters.
Monitoring — presents real-time values during vehicle operation; these include all inputs and outputs.
Diagnostics and troubleshooting — presents diagnostic information, and also a means to clear the fault
history file.
Programming — allows you to save/restore custom parameter settings files and also to update the system software.
Favorites — allows you to create shortcuts to your frequently-used adjustable parameters and monitor variables.
pg. 42 APPENDIX C
APPENDIX D
SPECIFICATIONS
Table D-1 SPECIFICATIONS

Nominal input voltage 24V
PWM operating frequency 15.6 kHz
Electrical isolation to heatsink (min.) 500V AC
Minimum motor resistance 160 mΩ (45 amp models); 120 mΩ (70 amp models)
B+, B– logic pin current (max.) 9 A (pins 7 and 13 on 14-pin connector)
KSI input current (typical) 80 mA
Logic input current (typical) 1 mA
Horn output current (max.) 15 mA
BDI output voltage, resistance (max.) 0–5V, 10 kΩ
LED output current (max.) 15 mA
Electromagnetic brake coil resistance 32 Ω
(min.)
Throttle type Resistance or voltage;
single-ended, inverted single-ended, wigwag, inverted wigwag, or unipolar
Storage ambient temperature range −40°C to 65°C (−40°F to 149°F)
Operating ambient temp. range −25°C to 50°C (−13°F to 122°F)
Heatsink overtemperature Linear cutback starts 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 14V
Overvoltage cutoff 34V
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 Designed to the requirements of EN 12184:1999, ISO7176-14:2008,
ISO7176-21:2003.
FDA documentation.
TÜV approved.
NOMINAL 20, 10 SECOND 2 MINUTE 1 HOUR PEAK MAX BOOST

BATTERY VOLTAGE CURRENT RATING CURRENT RATING CURRENT RATING BOOST CURRENT CURRENT DURATION
MODEL NUMBER (volts) (amps) (amps) (amps) (amps) (seconds)
1212-22xx 24 45 (20 s) 40 15 55 10
1212-24xx 24 70 (20 s) 50 20 80 10
NOTE:
All current ratings are rms values per motor phase. Internal algorithms automatically reduce maximum current limit when heatsink temperature is
>80°C or battery voltage is outside the allowed limits. Heatsink temperature is measured internally near the power MOSFETs.
APPENDIX D pg. 43

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Manual

Curtis Instruments, Inc.

Read Instructions Carefully!

pg. ii 1212 Manual – Sept. 2022

7: DIAGNOSTICS AND TROUBLESHOOTING.......................................................................................... 34

1212 Manual – Sept. 2022 pg. iii

pg. iv 1212 Manual – Sept. 2022

Smooth and Secure Control

• Charger inhibit input prevents driving while charger is attached.

Easy Installation and Setup

Valuable Additional Features

Robust Safety and Reliability

Meets or Complies with Relevant US and International regulations

2 — INSTALLATION AND WIRING

MOUNTING THE CONTROLLER

9.0 Ø 5.0 2PL

pg. 4 2 — INSTALLATION AND WIRING

CONNECTIONS: High Current

(B+, B–) have one terminal each.

CONNECTIONS: Low Current

J1 Pin 1 pot wiper

J1 Pin 8 pot low

2 — INSTALLATION AND WIRING pg. 5

WIRING: STANDARD INSTALLATION

pg. 6 2 — INSTALLATION AND WIRING

5kΩ, 3-Wire Potentiometer

2 — INSTALLATION AND WIRING pg. 7

Speed Limit Pot

pg. 8 2 — INSTALLATION AND WIRING

SWITCHES AND OTHER HARDWARE

Brake Release Switch (Brake Coil Disable Switch)

Battery Discharge Indicator (BDI)

2 — INSTALLATION AND WIRING pg. 9

Circuitry Protection Devices

pg. 10 2 — INSTALLATION AND WIRING

2 — INSTALLATION AND WIRING pg. 11

Table 1 Programmable Parameter Menus

DRIVE MENU...................................... p. 13 THROTTLE MENU............................. p. 16 MOTOR MENU.................................... p. 21

pg. 12 3 — PROGRAMMABLE PARAMETERS

3 — PROGRAMMABLE PARAMETERS pg. 13

DRIVE MENU, cont’d

pg. 14 3 — PROGRAMMABLE PARAMETERS

3 — PROGRAMMABLE PARAMETERS pg. 15

pg. 16 3 — PROGRAMMABLE PARAMETERS

THROTTLE MENU, cont’d

3 — PROGRAMMABLE PARAMETERS pg. 17

THROTTLE MENU, cont’d

CALIBRATION OF WIGWAG AND UNIPOLAR THROTTLE POTS

pg. 18 3 — PROGRAMMABLE PARAMETERS

3 — PROGRAMMABLE PARAMETERS pg. 19

pg. 20 3 — PROGRAMMABLE PARAMETERS

3 — PROGRAMMABLE PARAMETERS pg. 21

pg. 22 3 — PROGRAMMABLE PARAMETERS

3 — PROGRAMMABLE PARAMETERS pg. 23

pg. 24 4 — MONITOR MENU

Step 1: Begin the Setup Procedures

Tuning the Neutral Deadband

5 — INITIAL SETUP pg. 25

Tuning the Throttle Max