SepEx 1266 Controller Manual

12 6 6
MODEL
MOTOR CONTROLLER
© 2006 CURTIS INSTRUMENTS, INC.
DESIGN OF CURTIS 1200 SERIES

CONTROLLERS PROTECTED BY U.S.
PATENT NO. 4626750.
1266 Manual, p/n 38228

Rev. A: October 2006
CURTIS INSTRUMENTS, INC.

200 Kisco Avenue
Mt. Kisco, New York 10549 USA
Tel. 914.666.2971
Fax 914.666.2188
www.curtisinstruments.com
CONTENTS
CONTENTS
1. OVERVIEW ..............................................................................1
2. INSTALLATION AND WIRING.............................................4

Mounting the Controller .....................................................4
Connections: Low Current..................................................6
Connections: High Current ................................................7
Wiring: Controller ..............................................................8
Wiring: Throttle................................................................10
Wiring: Drivers .................................................................12
Wiring: Pedal Interlock Switch..........................................13
Contactor, Switches, and Other Hardware .........................14
3. PROGRAMMABLE PARAMETERS ......................................15

Acceleration/Deceleration Parameters.................................17
Acceleration Rate: M1, M2, Reverse
Deceleration Rate: M1, M2, Reverse
Field Brake
Field Brake Speed
Field Brake Max
Field Brake Rate
Speed Parameters ...............................................................19
Max Forward Speed: M1, M2
Max Reverse Speed
RPM To Speed
Tacho Poles
Throttle Parameters............................................................20
Throttle 0%
Throttle 100%
Throttle Map
Throttle Fault Low
Throttle Fault High
Current Limit Parameters...................................................21
Main Current Limit: M1, M2
Regen Current Limit
Plug Braking Current Limit
WalkAway™ Current Limit
Brake Mapping Parameters ................................................22
Brake Minimum: M1, M2, Reverse
Brake Maximum: M1, M2, Reverse
Brake Start: M1, M2, Reverse
Brake End: M1, M2, Reverse
Brake Map: M1, M2, Reverse
Field Mapping Parameters..................................................25
Forward Field Minimum: M1, M2
Reverse Field Minimum
Field Max
Negative Field Maximum
Curtis 1266 Manual, Rev. A iii

CONTENTS
Field Map Start / Negative Field Map Start

Field Map End / Negative Field Map End
Field Ramp / Negative Field Ramp
Fault Parameters .................................................................26
KSI SRO Enable
Mode After KSI
Overvoltage
Low Voltage
Warning Option
Output Driver Parameters ..................................................28
Auxiliary Driver Mode
Auxiliary Pull-In Voltage
Auxiliary Holding Voltage
Electromagnetic Brake Delay
Electromagnetic Brake Speed Check
Electromagnetic Brake at Speed Value
4. INSTALLATION CHECKOUT .............................................30
5. TUNING GUIDE ..................................................................32

Major Tuning .....................................................................32
1 Tuning the active throttle range ..............................32
2 Calibrating the controller speed measurement ........34
3 Tuning the controller to the motor ........................34
4 Equalizing loaded and unloaded vehicle speed .......37
5 Confirming loaded vehicle speed on downhill ........38
Fine Tuning........................................................................39
6 Response to increased throttle ................................39
7 Response to full throttle release ..............................40
8 Transitioning from flat ground to downhill ............42
9 Hill climbing ..........................................................42
bk WalkAway™ braking ...............................................43
bl Low-speed field braking .........................................43
bm EM brake operation ...............................................44
6. DIAGNOSTICS AND TROUBLESHOOTING....................46
7. MAINTENANCE ...................................................................49
APPENDIX A Vehicle Design Considerations

APPENDIX B 1311 Programmer Operation
APPENDIX C Programmable Parameter Index
APPENDIX D Specifications, 1266 Controller
iv Curtis 1266 Manual, Rev. A

FIGURES
FIGURES
FIG. 1: Curtis 1266 electronic motor controller.............................. 1
FIG. 2: Mounting dimensions, Curtis 1266 controller ................... 4
FIG. 3a: Standard wiring configuration —

with aux driver used for an EM brake ................................. 8
FIG. 3b: Standard wiring configuration —

with aux driver used for a WalkAway™ relay ....................... 9
FIG. 4: Wiring for 3-wire potentiometer throttle ......................... 10
FIG. 5: Wiring for 0–5V throttle ................................................. 10
FIG. 6: Wiring for ITS throttle .................................................... 11
FIG. 7: Throttle map structure .................................................... 20
FIG. 8: Brake map structure ......................................................... 23
FIG. 9: Field map structure .......................................................... 25
FIG. B-1: Curtis 1311 handheld programmer ................................. B-1
Curtis 1266 Manual, Rev. A v

1 — OVERVIEW
1
OVERVIEW
Curtis 1266 controllers are separately excited motor speed controllers designed
for use in a variety of transport vehicles. These programmable controllers are
simple to install, efficient, and cost effective. Typical applications include golf
carts and small utility vehicles.
The 1266 controller offers smooth, silent, cost effective control of motor
speed and torque. The speed sensor input allows superior closed-loop control
for regulating vehicle speed. Unique braking parameters allow simple, intuitive
deceleration tuning. A full-bridge field winding control stage is combined with
a half-bridge armature power stage to provide solid state motor reversing and
regenerative braking power without additional relays or contactors.
Fig. 1 Curtis 1266

electronic motor controller.
These controllers are fully programmable by means of the optional 1311

handheld programmer or 1314 PC programming station. Use of a programmer
provides diagnostic and test capability as well as configuration flexibility and
the ability to easily transfer settings from one controller to another.
Curtis 1266 Manual, Rev. A 1

1 — OVERVIEW
Like all Curtis motor controllers, the 1266 offers superior operator control of
the vehicle’s motor drive speed. Features include:
✓ Regenerative braking, providing longer operation on a single

battery charge and reducing motor brush wear and motor
heating
✓ Adjustable brake rates, for smooth pedal-release braking
✓ Two user-selectable vehicle operating personalities, with
vehicle top speed controlled and limited in each mode
✓ Motor parameters are programmable to match the
characteristics of the specific motor being used
✓ Vehicle speed control is enhanced through feedback from a
Hall effect speed sensor
✓ Anti-rollback function, providing improved control when
throttle is released on hills
✓ Anti-stall function helps prevent motor commutator damage
✓ High pedal disable (HPD) and static return to off (SRO)
interlocks prevent vehicle runaway at startup
✓ WalkAway™ braking feature limits any stopped or key-off
rolling to a very low speed
✓ Auxiliary driver can be programmed for either an
electromagnetic (EM) brake or a WalkAway™ relay
✓ Coil driver provides adjustable pull-in and holding voltages
to WalkAway™ relay or EM brake
✓ Reverse signal driver provides a low signal any time the
vehicle is traveling in reverse
2 Curtis 1266 Manual, Rev. A

1 — OVERVIEW
✓ Driver outputs are short circuit protected and provide built-in

coil spike protection
✓ Warning buzzer sounds steady in reverse, intermittent during
WalkAway™ braking
✓ Complete diagnostics through any of the optional
programmers and through the built-in Status LED
✓ Splash resistant plastic cover
✓ Meets or exceeds EEC fault detect requirements.
Familiarity with your Curtis controller will help you install and operate it
properly. We encourage you to read this manual carefully. If you have ques-
tions, please contact the Curtis office nearest you.

2 — INSTALLATION & WIRING: Controller
2
INSTALLATION AND WIRING
MOUNTING THE CONTROLLER

The outline and mounting hole dimensions for the 1266 controller are shown
in Figure 2.
The controller can be oriented in any position; however, the location
should be carefully chosen to keep the controller as clean and dry as pos-
sible. If a clean, dry mounting location cannot be found, a cover must be
used to shield the controller from water and contaminants. When selecting
the mounting position, be sure to also take into consideration (1) that access is
needed at the side of the controller to plug the programmer into its connector,
and (2) that the built-in Status LED is visible only through the view port in
the label on top of the controller.
Fig. 2 Mounting
dimensions, Curtis
1266 controller.
CL
Dimensions in millimeters (and inches)

To ensure full rated power, the controller should be fastened to a clean, flat
metal surface with three 6mm (1/4") diameter screws, using the holes provided.
Although not required, a thermal joint compound can be used to improve heat
conduction from the controller heatsink to the mounting surface.
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.
The 1266 controller contains ESD-sensitive components. Use appropri-
ate precautions in connecting, disconnecting, and handling the controller.
See installation suggestions in Appendix A for protecting the controller from
ESD damage.
☞
C AU T I O N Working on electric vehicles is potentially dangerous. You should
protect yourself against runaways, high current arcs, and outgassing from
lead acid batteries:
RUNAWAYS — Some conditions could cause the vehicle to run out of control.
Disconnect the 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 — 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.

CONNECTIONS
Low Current Connections
Two low current connectors are built into the 1266 controller: a 16-pin con-
nector and a 4-pin connector. They are located on the side of the controller.
The 16-pin connector provides the logic control connections. The mat-
ing connector is a 16-pin Molex Mini-Fit Jr. connector p/n 39-01-2165 using
type 5556 terminals. The appropriate wire gauge is 18–24 AWG.
Note: The +15V supply (Pin 10) should only be used with the speed
sensor and not to power any other external systems.
16 15 14 13 12 11 10 9
8 7 6 5 4 3 2 1
Pin 1 Hall Signal input signal from motor speed sensor

Pin 2 Auxiliary Driver WalkAway™/EMB driver low-side output
Pin 3 Reverse Alarm alarm low-side driver output
Pin 4 Pot High +5V supply through 453Ω (or ITS input)
Pin 5 Pot Wiper throttle wiper input
Pin 6 Pot Low 453Ω to ground
Pin 7 Main Contactor contactor coil driver low-side output
Pin 8 Logic Enable input from run/store switch
Pin 9 Hall - B- ground for motor speed sensor

Pin 10 Hall + +15V supply for motor speed sensor
Pin 11 Reverse input from reverse switch
Pin 12 Forward input from forward switch
Pin 13 Pedal Interlock Switch input from pedal switch, wired to throttle
Pin 14 Mode Switch input from mode switch
Pin 15 Keyswitch Input (KSI) throttle wiper input (or ITS input)
Pin 16 Logic Power power to controller logic

A 4-pin low power connector is provided for an optional programmer. A com-

1 Rx Data 4 3
2 B- plete handheld programmer kit, including the appropriate connecting cable
3 Tx Data with mating connector, can be ordered from Curtis:
2 1
4 +15V p/n 168961101 for the User Programmer (model 1311-1101)
p/n 168962101 for the OEM Programmer (model 1311-4401).
If a handheld programmer is already available (such as the now discontinued
1307) but has an incompatible cable, the appropriate connecting cable can be
ordered as a separate part: p/n 16185.
If a 1314 PC programming station is used, the 1309 interface box and cable
connect the computer to the controller:
p/n 117465704 1314-1101, 1314 PC Programming Station (User) CD-ROM
p/n 117465707 1314-4401, 1314 PC Programming Station (OEM) CD-ROM
p/n 16994001 1309 Interface Box
p/n 16185 Molex cable for 1309 Interface Box.
High Current Connections

Three tin-plated solid copper bus bars are provided for the high current con-
nections to the battery (B+ and B-) and the motor armature (M-). Cables are
fastened to the bus bars by M8 bolts. The 1266 case provides the capture
nuts required for the M8 bolts. The maximum bolt insertion depth below
the surface of the bus bar is 13 mm (1/2"). Bolt shafts exceeding this length
may damage the controller. The torque applied to the bolts should not exceed
16.3 N·m (12 ft-lbs).
S1 S2
B- M- B+
Two 1/4" quick connect terminals (S1 and S1) are provided for the con-
nections to the motor field winding.

WIRING: Standard Configuration

Figures 3a and 3b show typical wiring. The system can include an electromag-
netic brake or a WalkAway™ relay, but not both. Figure 3a shows a system with
an EM brake; Figure 3b shows a system with a WalkAway™ relay.
Standard Power Wiring

Motor armature winding is straightforward, with the armature’s A1 connection
going to the controller’s B+ bus bar and the armature’s A2 connection going
to the controller’s M- bus bar.
The motor’s field connections (F1 and F2) to the controller are less
obvious. The direction of vehicle travel with the forward direction selected
will depend on how the F1 and F2 connections are made to the controller’s
two field terminals and how the motor shaft is connected to the drive wheels
through the vehicle’s drive train.
KEYSWITCH
F Pin 15 KSI
FORWARD
Pin 12
N REVERSE MAIN CONTACTOR
Pin 11 Pin 7
R
+ - REVERSE ALARM Pin 3

CHARGER INTERLOCK
EM BRAKE SWITCH
Pin 2 (optional)
LOGIC ENABLE
Pin 8
MODE (M1, M2) LOGIC POWER
Pin 14 Pin 16
PEDAL INTERLOCK
Pin 13 RUN /
PRECHARGE RESISTOR STORE
(500Ω, 5W) SWITCH
(10 A)
MAIN
THROTTLE POT
POT HIGH
Pin 4 B+
POT WIPER A1
Pin 5 F1
POT LOW
Pin 6 A
F2 BATTERY
A2
M-
F1
F2
B-
PROGRAMMER
RX DATA
PROG Pin 1
B-
PROG Pin 2
TX DATA
PROG Pin 3
+15V GROUND
PROG Pin 4 Pin 9
Pin 1
INPUT SPEED
+15V SENSOR
Pin 10
1266 CONTROLLER
Fig. 3a Standard wiring configuration for Curtis 1266 controller,

in an application with an EM brake.

Standard Control Wiring

Wiring is shown in Figures 3a and 3b for the most commonly used components.
Wiring for alternative throttles is shown in the following pages.
The main contactor coil must be wired directly to the controller as shown
in Figures 3a and 3b. The controller uses the main contactor coil driver output
to remove power from the controller and motor in the event of various faults.
If the main contactor coil is not wired to Pin 7, the controller will not be
able to open the main contactor in serious fault conditions and the system
will therefore not meet EEC safety requirements.
WALKAWAY DRIVER WALKAWAY

Pin 2 - FUSE
F (10A)
FORWARD
Pin 12
N REVERSE
Pin 11
R
KEYSWITCH
Pin 15 KSI
+ - REVERSE ALARM Pin 7 MAIN CONTACTOR
Pin 3
CHARGER INTERLOCK
SWITCH (optional)
MODE (M1, M2) LOGIC ENABLE
Pin 14 Pin 8
PEDAL INTERLOCK LOGIC POWER
Pin 13 Pin 16
RUN /
PRECHARGE RESISTOR STORE
(500Ω, 5W) SWITCH
THROTTLE POT
POT HIGH (10 A)

Pin 4
POT WIPER Pin 5
MAIN
POT LOW B+
Pin 6
A1
F1
A
F2 BATTERY
A2
M-
F1
F2
B-
PROGRAMMER
RX DATA
PROG Pin 1
B-
PROG Pin 2
TX DATA
PROG Pin 3
+15V GROUND
PROG Pin 4 Pin 9
Pin 1
INPUT SPEED
+15V SENSOR
Pin 10
1266 CONTROLLER
Fig. 3b Standard wiring configuration for Curtis 1266 controller,

in an application with the WalkAway™ function.

2 — INSTALLATION & WIRING: Throttle
WIRING: Throttle
Various throttles can be used with the 1266 controller, including 5kΩ 3-wire
potentiometers and 0–5V throttles. Some 1266 controller models are specifi-
cally designed to be compatible with ITS throttles.
The controller looks for a voltage signal at the wiper input (Pin 15), with
vehicle speed increasing with increased throttle voltage. All throttle fault pro-
tection is accomplished by monitoring the wiper input. This provides throttle
fault protection that meets all EEC requirements. Thus, no additional fault
protection is required on any throttle type used with the 1266 controller.
If the throttle you are planning to use is not covered, contact the Curtis
office nearest you.
3-Wire Potentiometer (5kΩ–10kΩ) 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 (Pin 4) provides
a current limited 5V source to the pot, and Pot Low (Pin 6) provides the
return path. The pot wiper is then connected to the Wiper Input (Pin 5).
Potentiometers with total resistance values between 5kΩ and 10kΩ can be
used. Wiring is shown in Figure 4.
Fig. 4 Wiring for 3-wire
potentiometer throttle.
This wiring is also shown in the standard wiring diagrams, Figs. 3a and 3b.
0–5V Throttle
The active range for the 0–5V throttle is set by the parameters Throttle 0% and
Throttle 100%, and is measured relative to B-. Wiring is shown in Figure 5.
Fig. 5 Wiring for 0–5V
throttle.
+

ITS Throttle
The ITS throttle is a 2-wire electronic throttle that connects between the Pot
High and Pot Wiper pins (Pins 4 and 5), as shown in Figure 6. The Hall sen-
sor circuit within the throttle creates an output current between 0.7mA and
1.6mA from min to max throttle. The two wires are interchangeable.
Fig. 6 Wiring for ITS
throttle. Pot High input (Pin 4)
Pot Low input (Pin 5)
Note: ITS throttles can only be used with 1266 models that are specifi-
cally designed for them.

WIRING: Drivers
The 1266 controller provides three drivers (at Pins 2, 3, 7) for the aux contac-
tor/relay, reverse alarm, and main contactor. These three outputs are low-side
drivers, designed to energize inductive coils or a piezoelectric reverse alarm.
The reverse alarm and aux are optional functions.
With the exception of the coil used at the aux driver (Pin 2), it is necessary
to specify the connected coil voltage at the nominal battery pack voltage. The
aux driver can be set to either 100%, 60%, or 35% of system voltage. These
fixed percentages are used for the Coil Pull-In Voltage and Holding Voltage.
See Section 3 for more information on programming these parameters.
A coil suppression diode is provided internally to protect two of the driv-
ers (2, 7) from inductive spikes generated at turn-off. To take advantage of the
controller’s internal coil suppression diode, the coils must be wired such that
the return path to the drivers cannot be opened by any switches or contactors,
as shown in the standard wiring diagrams (pages 8, 9).
RATED INTERNAL
RATED LOAD DIODE
DRIVER PIN CURRENT VOLTAGE PROTECTION
Main Contactor 7 2.0 A B+ yes
Reverse Alarm 3 0.02 A B+ no
Aux (EMB/WalkAway™) 2 2.0 A B+, 36V, 24V yes
The driver loads are not limited to contactor coils. Any load can be connected
to a Pin 3 or 7 driver as long as it does not exceed the current rating.
For information on programming the various driver-related parameters,
see Section 3: Programmable Parameters.
Main Contactor Driver

The main contactor driver (Pin 7) pulls low when (a) the tow/store switch,
keyswitch input, and pedal interlock switch are enabled, (b) a direction is
selected, and (c) throttle is applied; it stays low until near zero speed at zero
throttle, or until a critical fault occurs. This wiring is shown in the standard
wiring diagrams (pages 8, 9).
Reverse Alarm Driver

The reverse alarm driver (Pin 3) pulls low when the reverse direction switch
is applied. This driver is designed to drive a reverse signal beeper or piezo-
electric buzzer that operates when the vehicle is traveling in reverse or during
WalkAway™ operation. It can also be programmed to give a warning during
anti-rollback and/or to warn of an overvoltage condition (see Warning Option
parameter).

Auxiliary Driver
The condition for which the auxiliary driver (Pin 2) pulls low depends on how
it is being used. With an EM brake, the driver becomes active (low) when the
vehicle is commanded into motion so as to activate the brake coil and pull in
the brake. In a WalkAway™ system, the driver becomes active when the vehicle
is rolling while the main contactor is not engaged.
The aux driver’s output is pulse width modulated at the coil holding
voltage set by the Holding Voltage parameter. The pull-in voltage set by the
Pull-In Voltage parameter is used in place of the holding voltage for the first
100 milliseconds.
When the aux driver is used with an EM brake, the EMB Delay param-
eter allows for the adjustment of a time delay before the brake engages after
the vehicle is stopped or has slowed below the threshold set by the EMB Speed
Value parameter.
WIRING: Pedal Interlock Switch

Controller output is possible only when the pedal interlock input (Pin 13) is
pulled to B+. The pedal interlock switch is connected to the throttle mecha-
nism, thus guaranteeing zero controller output when the operator releases the
throttle. This adds a safety feature to protect against throttle failures that could
otherwise cause unintended controller output (vehicle motion).

2 — INSTALLATION & WIRING: Switches, etc.
CONTACTOR, SWITCHES, and OTHER HARDWARE

Main Contactor
A main contactor is required for use with any 1266 controller. The main contac-
tor allows the controller and motor to be disconnected from the battery. This
provides a significant safety feature in that the battery power can be removed
from the drive system if a controller or wiring fault is detected. A single-pole,
single-throw (SPST) contactor with silver-alloy contacts is recommended for
use as the main contactor. The coils must be specified at the nominal battery
pack voltage, with a continuous rating.
A 500Ω 5W resistor must be used across the contactor to precharge the
capacitors.
Keyswitch and Run/Store Switch

The vehicle should have a keyswitch to enable/disable driving each time the
vehicle is used. The run/store switch, on the other hand, is typically located in
an out-of-the-way location and left on except when the vehicle will be stored
(during the winter, for example) or is being towed. The keyswitch and the run/
store switch provide current to drive the various coils as well as the controller’s
internal logic circuitry and must be rated to carry these currents.
Forward, Reverse, Mode Select, and Pedal Interlock Switches

These input switches can be any type of single-pole, single-throw (SPST) switch
capable of switching the battery voltage at 25 mA.
Circuitry Protection Devices

To protect the control circuitry from accidental shorts, a low current fuse (ap-
propriate for the maximum current draw) should be connected in series with
the battery feed to the run/store switch. Additionally, a high current fuse should
be wired in series with the main contactor to protect the motor, controller,
and batteries from accidental shorts in the power system. The appropriate
fuse for each application should be selected with the help of a reputable fuse
manufacturer or dealer. The standard wiring diagrams (see pages 8, 9) show
the recommended fuse locations.
Speed Sensor
A speed sensor is required for use with any 1266 controller. The speed sensor
must be of a pulse type, and must interface to the controller with an open col-
lector NPN transistor output. The most common sensor type will be a Hall
effect switch IC, such as the Allegro type UGN3132 or Micro Switch type
SS11; these work with an eight-pole (four pulses per revolution) ring magnet
attached to the motor shaft. Other pole configurations can be accommodated
by programming the Tacho Poles parameter to match the sensor magnet. Linear
output sensors such as PM tachogenerators and variable reluctance gear tooth
sensors (“magnetic pickups”) are unsuitable.
A Curtis Application Note is available with more detailed information
on the speed sensor requirements.

3 — PROGRAMMABLE PARAMETERS
3
PROGRAMMABLE PARAMETERS
The 1266 controller’s programmable parameters allow the vehicle’s performance

characteristics to be customized to fit the needs of individual vehicles or vehicle
operators. Programming can be done with a 1311 handheld programmer or a
1314 PC Programming Station. The discontinued 1307 handheld programmer
is also fully compatible with the 1266 controller.
Curtis offers two versions of the 1311 programmer: the 1311-1101 is the
User programmer (which can adjust only those parameters with User access
rights) and the 1311-4401 is the OEM programmer (which can adjust all the
programmable parameters). Similarly, the 1314 PC Programming Station soft-
ware is available in two versions: 1314-1101 and 1314-4401. See Appendix B
for more information about the programmers.
The 1266 controllers allow 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 operating in different condi-
tions—such as slow precise indoor maneuvering in one mode, and faster, long
distance, outdoor travel in the other mode.
Ten parameters can be configured independently in the two modes:
— Main Current Limit (M1, M2)

— Acceleration Rate (M1, M2)
— Deceleration Rate (M1, M2)
— Brake Minimum (M1, M2)
— Brake Maximum (M1, M2)
— Brake Map (M1, M2)
— Brake Start (M1, M2)
— Brake End (M1, M2)
— Forward Speed (M1, M2)
— Forward Field Minimum (M1, M2).
In the following descriptions, the 1266’s parameters are grouped into

categories of related parameters. Many of the parameters are interdependent.
In the descriptions in this section, these interdependencies are only briefly
noted. For a more thorough discussion of how they work together, see
Section 5: Tuning Guide.

3 — PROGRAMMABLE PARAMETERS
The parameter names are listed here in the abbreviated forms that appear on
the handheld programmer’s 14-character LCD screen. Not all of these param-
eters are available on all controllers; the parameters for any given controller are
dependent on its specifications.
For a list of the parameters in the order in which they are displayed in
the Program menu, see Appendix B.
For an alphabetical list and index of the parameters, see Appendix C.
Acceleration Parameters Field Mapping Parameters

ACCEL (M1, M2, REV) FWD FLD MIN (M1, M2)
DECEL (M1, M2, REV) REV FIELD MIN
FLD BRAKE FIELD MAX
FLD BRAKE SPD NEG FIELD MAX
FLD BRAKE MAX FLD MAP START / NEG FLD MAP ST
FLD BRAKE RATE FIELD MAP END / NEG FLD MAP EN
FIELD RAMP / NEG FLD RAMP
Speed Parameters
Fault Parameters
FWD SPEED (M1, M2)
REV SPEED KSI SRO ENABLE
RPM TO SPEED MODE AFTER KEY
TACHO POLES OVERVOLTAGE
LOW VOLTAGE
Throttle Parameters WARNING OPTION
THROTTLE 0%
Output Driver Parameters
THROTTLE 100%
THROTTLE MAP AUX DRVR MODE
THROT FAULT LO AUX PULL IN
THROT FAULT HI AUX HOLDING
EMB DELAY
Current Limit Parameters EMB SPD CHECK
MAIN C/L (M1, M2) EMB SPD VALUE
REGEN C/L
PLUG C/L
WALKAWAY C/L
Brake Mapping Parameters

BRAKE MIN (M1, M2, REV)
BRAKE MAX (M1, M2, REV)
BRAKE START (M1, M2, REV)
BRAKE END (M1, M2, REV)
BRAKE MAP (M1, M2, REV)

3 — PROGRAMMABLE PARAMETERS: Acceleration Parameters
Acceleration Parameters
M1/M2/REV ACCEL RATE

The acceleration rate defines the time, in seconds, for the controller to ac-
celerate from 0% output to 100% output. A larger value represents a longer
acceleration time and a gentler start. Fast starts can be achieved by reducing the
acceleration time, i.e., by adjusting the accel rate to a smaller value. The forward
accel rate can be set independently for each of the two operating modes; the
reverse accel rate applies to both M1 and M2.
M1/M2/REV DECEL RATE

The deceleration rate defines the time, in seconds, for the controller to reduce
the average voltage at the armature output from 100% PWM to 0% PWM.
A larger value represents a longer deceleration time and gentler vehicle slow-
ing. Quick stops can be achieved by reducing the deceleration time, i.e., by
adjusting the decel rate to a smaller value. The forward decel rate can be set
independently for each of the two operating modes; the reverse decel rate ap-
plies to both M1 and M2.
If the vehicle is slowing quicker than the decel rate (for example, at zero
throttle, traveling up a hill) the output will decay at a rate of 0.8 seconds.
FLD BRAKE
The field brake parameter enables or disables the field braking function. When
set to On, the field brake routine is enabled and will increase the vehicle brak-
ing near zero speed.
Related parameters: When FLD BRAKE is On, the Field Brake SPD, MAX, and RATE
parameters apply; they have no effect when FLD BRAKE is programmed Off.
FLD BRAKE SPD

The field brake speed parameter sets the speed threshold below which field
braking will occur when FLD BRAKE is On. When the throttle has been released
and vehicle speed is detected to have fallen below FLD BRAKE SPD, the field current
starts to increase toward the value specified by FLD BRAKE MAX at a rate specified
by FLD BRAKE RATE. If the threshold speed is set very low, field braking will occur
only at the very end of vehicle deceleration. If the vehicle does not slow to the
speed defined by FLD BRAKE SPD (down a steep hill, for example) field braking
will not occur as the threshold will not be reached.

3 — PROGRAMMABLE PARAMETERS: Acceleration Parameters
FLD BRAKE MAX

The field brake max parameter sets the maximum value of field current per-
mitted during field braking when FLD BRAKE is On. The field current defined by
FLD BRAKE MAX overrides the standard field map current below the speed defined
by FLD BRAKE SPD.
When an EM brake is used, the amount of field current programmed by
FLD BRAKE MAX is applied for the max amount of time specified by EMB DELAY (see
Output Driver parameters) prior to locking the EM brake. A high value of FLD
BRAKE MAX helps to ensure the vehicle uses sufficient braking to slow to a stop
before locking the EM brake.
When the auxiliary output is used for a WalkAway relay™ instead of an
EM brake, lower FLD BRAKE MAX values are useful in providing softer braking
near zero speed. Setting the value too low may render the controller incapable
of sensing vehicle rollback. However, even though the anti-rollback function
may not be activated, the plug braking generated by the field current will still
act to slow the vehicle.
FLD BRAKE RATE

The field brake rate parameter defines how quickly the field current rises during
field braking when FLD BRAKE is On, and is adjustable from 0 to 6. This index
value defines the time for the field current to rise to the programmed FLD BRAKE
MAX, as shown in the examples below. The higher the setting, the faster the rise.
(In these examples, FLD BRAKE MAX = 50.0 amps.)
INDEX FIELD CURRENT RANGE TIME OF RISE

STRONGER
1 0.0 – 50.0 A 3.2 seconds

BRAKING
6 0.0 – 50.0 A 0.5 seconds
When an EM brake is used, the field current rises until it reaches FLD BRAKE
MAX, maintains that current for the duration of EMB DELAY, at the end of which
the EM brake driver turns off, causing the brake to engage—if it has not already
been applied due to the vehicle having stopped or started to roll back.

3 — PROGRAMMABLE PARAMETERS: Speed Parameters
Speed Parameters
M1/M2 FWD SPEED

The forward speed parameter defines the maximum speed limit in the forward
direction. It is adjustable from 4.0 to 40.0, in units of mph or km/h (depending
on RPM TO SPEED the setting).
REV SPEED
The reverse speed parameter defines the maximum speed limit in the reverse
direction. It is adjustable from 4.0 to 16.0, in units of mph or km/h (depend-
ing on RPM TO SPEED the setting).
RPM TO SPEED
The rpm to speed parameter is a conversion factor used to generate a vehicle
speed estimate from the speed sensor input (motor RPM signal). Use these
equations to calculate the value to enter for RPM TO SPEED:
tire diameter (inches)

For English units (mph): × 63
gear ratio
tire diameter (cm)

For metric units (km/h): × 40
gear ratio
TACHO POLES
The tachometer poles parameter configures the speed sensor, and should be
set to the number of magnetic poles in the speed sensor magnet. TACHO POLES is
adjustable from 4 to 20; see speed sensor description (page 14) for information
about sensor types.

3 — PROGRAMMABLE PARAMETERS: Throttle Parameters
Throttle Parameters
THROTTLE 0%
The throttle 0% parameter defines the throttle input voltage at which a throttle
command begins. Voltages lower than the programmed value (but higher than
THRTL FAULT LO) are interpreted to be in a 0% deadband.
THROTTLE 100%
The throttle 100% parameter defines the throttle input voltage that gives a full
throttle command. Input voltages above this value (but lower than THRTL FAULT
HI) are interpreted as 100% throttle command.
THROTTLE MAP
The throttle map parameter modifies the vehicle’s response to the throttle
input. As shown in Figure 7, this parameter determines the controller output
for a given amount of applied throttle. The THROTTLE MAP setting refers to the
controller output at half throttle, the midpoint of the throttle’s full active range
(the range between THROTTLE 0% and THROTTLE 100%).
Fig. 7 Throttle maps for
controller with the Throttle
Map parameter set at vari-
ous values.
Setting THROTTLE MAP at 50% provides a linear output response to throttle

position. Values below 50% reduce the controller output at low throttle settings,
providing enhanced slow speed control. Values above 50% give the vehicle a
faster, jumpier feel at low throttle settings.
Controller output begins when the throttle is moved beyond THROTTLE 0%,
and continues to increase—following the curve defined by the THROTTLE MAP
setting—as the throttle input increases, and reaches maximum output when
the throttle input crosses the THROTTLE 100% threshold.

3 — PROGRAMMABLE PARAMETERS: Current Limit Parameters
THROT FAULT LO
The throttle fault low parameter sets the lower throttle fault threshold; throttle
input voltages below this threshold will signal a throttle fault.
THROT FAULT HI
The throttle fault high parameter sets the upper throttle fault threshold; throttle
input voltages above this threshold will signal a throttle fault.
Current Limit Parameters
M1/M2 MAIN C/L

The main current limit parameter allows adjustment of the maximum current
the controller will supply to the motor during drive operation. This parameter
can be used to reduce the maximum torque applied to the drive system by the
motor in either of the modes. The drive current limit is adjustable from 100
amps up to the controller’s full rated current. The full rated current depends
on the controller model.
REGEN C/L
The regenerative current limit parameter allows adjustment of the maximum
current the controller will supply to the motor during regen braking opera-
tion. During regen braking, this parameter controls the regen current from the
motor’s armature into the battery. The braking current limit is adjustable from
0 amps up to the controller’s full rated current. The full rated current depends
on the controller model.
Regen is the normal mode of braking.
PLUG C/L
The plug current limit parameter allows adjustment of the maximum current
the controller will supply to the motor during plug braking operation. During
plug braking, this parameter controls the plug current from the motor’s armature.
The plug current limit is adjustable from 0 amps up to the controller’s full rated
current. The full rated current depends on the controller model.
Plug braking is used during WalkAway™ and Anti-Rollback operation.
WALKAWAY C/L
The WalkAway current limit parameter sets the maximum field current
applied during WalkAway™ operation. The WalkAway™ function applies field
current to slow a vehicle that is detected as moving while the main contactor
is open. The motor force created from this function is intended to limit the
vehicle’s rolling speed, but may not be sufficient to slow heavy vehicles on steep

3 — PROGRAMMABLE PARAMETERS: Brake Mapping Parameters
slopes. The warning buzzer is pulsed to create an audible indication that the
vehicle is rolling.
Brake Mapping Parameters
The brake mapping parameters determine the maximum braking power that
can be applied at a given vehicle speed. BRAKE MAX should be set higher than
BRAKE MIN, and BRAKE END higher than BRAKE START.
M1/M2/REV BRAKE MIN

The brake minimum parameter sets the max regen current at low speeds, and
is applicable from BRAKE START speed to zero speed. The value is a percentage of
the full regen current.
BRAKE MIN is used to soften vehicle braking at low speeds. A low value will
limit the braking at low speeds to provide a soft deceleration. A very low value
may prevent the vehicle from coming to a stop from pedal-up braking on an
incline, while a very high value may cause the vehicle to brake abruptly.
M1/M2/REV BRAKE MAX

The brake maximum parameter is used to set the max regen current at high
speeds, and is applicable at speeds at and above the BRAKE END speed. The value
is a percentage of the full regen current.
BRAKE MAX is used to strengthen vehicle braking at high speeds. A high
value will provide greater braking power at high speeds. A very low value may
prevent the vehicle from successfully limiting speed down a hill, while a very
high value may cause excessive braking force at high speeds.
M1/M2/REV BRAKE START

The brake map start parameter defines the vehicle speed at which the brake
map starts to increase from the BRAKE MIN value. Increasing the BRAKE START value
increases the speed at which the controller’s braking power reaches the BRAKE
MIN setting, resulting in a larger speed range with soft braking.
M1/M2/REV BRAKE END

The brake map end parameter defines the vehicle speed at which the brake map
reaches the BRAKE MAX value. This parameter can be set to allow the controller
to use a higher braking power at higher speeds.
Decreasing the BRAKE END value increases the braking torque the vehicle
can produce at medium speeds.

3 — PROGRAMMABLE PARAMETERS: Brake Mapping Parameters
M1/M2/REV BRAKE MAP

The brake map parameter defines the shape of the brake map curve. The value
set for this parameter is a percentage of the regen current between the BRAKE MIN
and BRAKE MAX values, at the point that is halfway between the BRAKE END and
BRAKE START speeds (the “Brake Map Midpoint”), as shown in Figure 8.
The BRAKE MAP curve is the max allowed regen current, and the shaded
gray area below it is the operating range.
Fig. 8 Brake map structure.
Note: Brake Map START

and Brake Map END refer
to the vehicle speeds at
which the regen current
“starts” to increase and
“ends” increasing.
From the operator’s
perspective, however,
braking begins at the With the BRAKE MAP set at 50%, the motor’s regen current limit decreases
point on the curve linearly with decreasing speed (from BRAKE END to BRAKE START), providing a
corresponding to the
vehicle’s speed when consistent rate of softening in braking power. Decreasing the BRAKE MAP setting
braking is initiated, and reduces the regen current attainable at medium speeds. Because the regen cur-
then follows the curve rent limit is reduced as the speed is reduced, the motor will brake more gently
toward “Brake Start.” The
braking force is typically as the vehicle approaches a stop.
set to decrease as the
vehicle slows down.

3 — PROGRAMMABLE PARAMETERS: Field Mapping Parameters
Field Mapping Parameters
The field mapping parameters determine how much field current is applied for
a given armature current.
M1/M2 FWD FIELD MIN

The forward minimum field current limit parameter defines the minimum
allowed current in the motor’s field winding when the vehicle is traveling in
the forward direction. Its setting may affect the vehicle’s maximum speed and,
to some extent, the smoothness with which the vehicle starts and transitions
between drive and regen. If FWD FIELD MIN is set high, the vehicle’s top speed will
be reduced, but torque bumps may be evident when the vehicle is inched or
changes direction.
One of the greatest advantages of the FIELD MIN parameter is that it will
prevent uncontrolled acceleration when the vehicle goes down ramps or when
it is unloaded from trucks, etc.
REV FIELD MIN

The reverse minimum field current limit parameter defines the minimum
allowed current in the motor’s field winding when the vehicle is traveling in
the reverse direction.
FIELD MAX
The maximum field current limit parameter defines the maximum allowed
current in the motor’s field winding. Its setting will determine the motor’s
maximum torque during drive operation, and will limit the power dissipation
in the field winding itself.
NEG FIELD MAX

The negative maximum field current limit parameter defines maximum al-
lowed current in the motor’s field winding during regen braking.
FLD MAP START / NEG FLD MAP ST

The field map start parameter defines the armature current at which the field
current starts to increase from the FIELD MIN value (see current limit parameters).
The negative field map start parameter works similarly; it defines the negative
armature current at which the field current starts to increase from the FIELD MIN
value.
Care should be taken to ensure that high FIELD MAP START values do not
move the motor’s operating characteristics outside its safe commutation area.

3 — PROGRAMMABLE PARAMETERS: Field Mapping Parameters
FIELD MAP END / NEG FLD MAP EN

The field map end parameter defines the armature current at which the field
map clamps to the FIELD MAX value (see current limit parameters).
Care should be taken to ensure that high FIELD MAP END values do not move
the motor’s operating characteristics outside its safe commutation region.
FIELD RAMP / NEG FLD RAMP

The field ramp parameter defines the shape of the field map curve. It is set as
a percentage of the field current between the FIELD MIN and FIELD MAX values.
As shown in Figure 9, the FIELD RAMP parameter sets the field current at
the armature current that is halfway between the FIELD MAP START current and
the FIELD MAP END current. This halfway point is referred to as the Field Map
Midpoint.
Fig. 9 Field map structure.
With FIELD RAMP set at 50% and FIELD MAP START set at zero, the motor’s field
current increases linearly with increasing armature current—thus emulating a
series wound motor. Decreasing the FIELD RAMP setting reduces the field current
at a given armature current, i.e., it weakens the field. As the field current is
reduced, the motor will be able to achieve higher speeds.
Care should be taken to ensure that excessively low FIELD RAMP values do
not move the motor’s operating characteristics outside its safe commutation
region.

3 — PROGRAMMABLE PARAMETERS: Fault Parameters
Fault Parameters
KSI SRO ENABLE

The keyswitch static return to off (SRO) feature prevents the vehicle from be-
ing started when “in gear.” When this parameter is enabled, the controller must
initially sense the KSI input in the Off position (upon vehicle power-up) prior
to it being switched to the On position. This feature is used to prevent vehicle
motion due to a KSI short circuit or due to the keyswitch being permanently
locked in the On position.
MODE AFTER KEY

The mode change after keyswitch parameter determines whether the operat-
ing mode (M1, M2) can be changed after KSI has been activated. If MODE AFTER
KEY is enabled, the mode can be changed while the vehicle is being operated.
The settings are gradually slewed between the two modes so as to reduce the
abruptness of the transition. However, if the settings for Mode 1 greatly differ
from those of Mode 2, switching from one mode to the other while driving
may cause the vehicle performance to change drastically.
If MODE AFTER KEY is not enabled, the mode can be changed only when
keyswitch is off.
OVERVOLTAGE
The overvoltage parameter sets the overvoltage protection threshold for the
electronic system. This parameter determines when regen should be cut back
to prevent damage to batteries and other electrical system components due to
overvoltage.
A non-adjustable internal threshold also exists, to prevent damage within
the controller.
LOW VOLTAGE
The low voltage parameter sets the undervoltage threshold to protect the system
from operating at voltages lower than its electronics were designed for. At this
threshold voltage, the drive current will taper off until it reaches the controller’s
internal threshold for safe operation. This will ensure proper operation of all
electronics whenever the vehicle is driven.

3 — PROGRAMMABLE PARAMETERS: Fault Parameters
WARNING OPTION
The warning option parameter sets the output pattern—flash or solid—of
the built-in LED and the warning beep conditions during anti-rollback and
overvoltage. WARNING OPTION is programmable from 0 to 7:
LED ANTI-ROLLBACK OVERVOLTAGE
SETTING OUTPUT BEEP BEEP
0 flash no no
1 flash no yes
2 flash yes no
3 flash yes yes
4 solid no no
5 solid no yes
6 solid yes no
7 solid yes yes

3 — PROGRAMMABLE PARAMETERS: Output Driver Parameters
Output Driver Parameters
AUX DRVR MODE

The auxiliary driver mode parameter determines whether the auxiliary function
will be an electromagnetic brake or a WalkAway™ relay or neither (no auxiliary
function). It is programmable from 0 to 2:
0 auxiliary driver Off
1 external WalkAway relay
2 electromagnetic brake
A WalkAway™ relay provides an alternative path for the current to the
controller so that it can maintain braking to slow a vehicle that begins to roll
after the main contactor has opened.
An EM brake keeps the vehicle from moving after coming to rest, which
can be very useful when stopping on a hill.
Both options require appropriate hardware. See the wiring diagrams,
pages 8 and 9.
AUX PULL IN
The auxiliary pull-in voltage parameter sets the peak voltage momentarily
applied to the load connected to the aux driver. The pull-in parameter allows
a high initial voltage to be supplied for 0.1 second when the driver first turns
on, to ensure proper closure. Values for this parameter should be determined
from relay/EMB specifications or advice from the device manufacturer.
AUX PULL IN is programmable from 1 to 3, representing these fixed battery
voltage percentages:
1 100% battery voltage
AUX HOLDING
The auxiliary holding voltage parameter sets the continuous voltage applied
to the load connected to the aux driver, after the initial 0.1 second pull-in.
AUX HOLDING is programmable from 1 to 3. The driver output is pulse width
modulated at one of three battery voltage percentages:
Using this parameter, the average applied voltage can be reduced so that a coil
that is not rated for the full battery voltage can be used. For example, a relay
coil rated for 24V could be used in a 48V system if AUX HOLDING is set to 3
(48V * 0.35 = 16.8V), as 16.8V is well above typical dropout voltage. The

3 — PROGRAMMABLE PARAMETERS: Output Driver Parameters
resulting voltage must be set high enough to hold the relay closed under all
shock and vibration conditions the vehicle will be subjected to. Low settings
minimize the current required to power the coil, thereby reducing coil heating
and increasing battery life.
Values for AUX HOLDING should be determined with specifications or advice
from the relay or brake manufacturer.
Example: To use a 24V brake in a 48V vehicle, try
AUX PULL IN = 2 (28.8V)
AUX HOLDING = 3 (16.8V)
EMB DELAY
The electromagnetic brake dropout delay sets a delay time before the EM
brake drops. The delay countdown begins either (1) when the vehicle has come
to rest and the main contactor has opened or (2) during field braking, when
the vehicle has slowed below the FLD BRK SPD.
Related parameter: The FLD BRAKE parameter defines when the EM brake
delay will begin—see (1) and (2) above.
EMB SPD CHECK

The electromagnetic brake speed check parameter adds extra measures to
prevent the locking of the EM brake at high vehicle speeds under conditions
when the main contactor is open (for example, if the keyswitch is turned off
during driving or a fault is detected). When it is enabled, the controller over-
rides the EMB DELAY in an attempt to allow the vehicle to slow down prior to
engaging the EM brake.
EMB SPD VALUE

The electromagnetic brake at speed value parameter sets the speed at which
the EM brake is permitted to lock. It is programmable from 0 to 40.0 mph,
and is typically set at the extreme low end of that range. The purpose of EMB
SPD VALUE is to prevent dropping the EM brake at high speed, which could be
dangerous on certain terrain (e.g., wet grass).
In the event of main contactor failure (or fault detection that commands
the contactor to open) the EM brake parameters control the brake as follows.
EMB SPD CHECK = off
EM brake driver will turn off after EMB DELAY time has expired.
EMB SPD CHECK = on
EM brake driver will not turn off until vehicle speed is detected
as having reduced to the set EMB SPD VALUE.
If EMB SPD VALUE is set below 1.0 mph, the EM brake driver will
not turn off until the vehicle reaches rest.

4 — INSTALLATION CHECKOUT
4
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 6) 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 Status LED (located in the controller’s label area) for diagnostic
codes. The codes are listed in Section 6.
☞
C AU T I O N Put the vehicle up on blocks to get the drive wheels
up 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, the throttle is released,

and the forward and 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 run/store switch on. The programmer should power up with
an initial display. If it does not, check for continuity in the run/store
switch circuit and controller ground.
If a programmer is not available, controller power-up can be veri-
fied by momentarily selecting reverse and listening for the sound of the
reverse alarm.
3. If you are using a programmer, go to the Faults Menu. The display

should indicate “No Known 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 6: Diagnostics and Troubleshooting.
When the problem has been corrected, it may be necessary to cycle
the run/store switch in order to clear the fault.
4. Turn the keyswitch on, select a direction, and operate the throttle.
The motor should begin to turn in the selected direction. If it turns in
the wrong direction, first verify the wiring to the forward and reverse
switches. If the wiring is correct, turn off the controller, disconnect the

4 — INSTALLATION CHECKOUT
battery, and exchange the motor’s field connections (F1 and F2) on the
controller. The motor should now turn in the proper direction. The
motor should run proportionally faster with increasing throttle. If not,
refer to Section 6.
5. If you are using a programmer, go to the Monitor menu. Scroll down

to observe the status of the switches:
Mode *
Foot Input (pedal switch)
Key Input
Forward Input
Reverse Input
Mode Switch *
Cycle each switch in turn, observing the programmer. The programmer
should display the correct status for each switch.
* “Mode Switch” tells you the physical status of the mode switch (open
or closed). “Mode” is a monitor value that tells you the mode in which
the vehicle is currently operating. This may not correspond to the status
of the mode switch—for example, if the MODE AFTER KEY parameter is set
to Off and the mode switch was flipped while the vehicle was being
operated.
6. Take the vehicle down off the blocks and drive it in a clear area. It
should have smooth acceleration and good top speed. Recommended
procedures for tuning the vehicle’s driving characteristics are presented
in Section 5: Tuning Guide.
7. Test the deceleration and braking of the vehicle.
8. Verify that all options, such as static return to off (SRO), electromagnetic
brake (or WalkAway™), and reverse signal are as desired.
9. If you used a programmer, disconnect it when you have completed the

checkout procedure, to minimize battery discharge.

5 — TUNING GUIDE
5
TUNING GUIDE
The 1266 controller is a very powerful vehicle control system. Its wide variety
of adjustable parameters allow many aspects of vehicle performance to be opti-
mized. This section provides explanations of what the major tuning parameters
do and instructions on how to use these parameters to optimize the performance
of your vehicle. 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. The tuning procedures instruct per-
sonnel how to adjust various programmable parameters to accomplish specific
performance goals. It is important that the effect of these programmable pa-
rameters be understood in order to take full advantage of the 1266 controller’s
powerful features. Please refer to the descriptions of the applicable parameters
in Section 3 if there is any question about what any of them do.
MAJOR TUNING
Five major performance characteristics are usually tuned on a vehicle:
1 Tuning the Active Throttle Range
2 Calibrating the Controller Speed Measurement
3 Tuning the Controller to the Motor (Field Mapping)
4 Equalizing Loaded/Unloaded Vehicle Speed on Flat Ground
5 Confirming Loaded Vehicle Speed on Downhill Grade.
These five characteristics should be tuned in the order listed.
1 Tuning the Active Throttle Range

Before attempting to optimize any specific vehicle performance characteristics,
it is important to ensure that the controller input is operating over its full range.
To do this, the throttle should be tuned using the 1311 handheld programmer
and a voltmeter. The procedures that follow will establish zero throttle, full
throttle, and throttle fault parameter values that correspond to the absolute
full range of your particular throttle mechanism. Note: These parameters are
expressed in absolute voltages between 0 and 5 volts.
It is advisable to provide 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. This will form areas at the top and bottom of
the throttle movement range that the controller reads as 0% and 100%.

5 — TUNING GUIDE
STEP 1. Jack the vehicle wheels up off the ground so that they spin freely.
Note: Most of the throttle tuning can be done without driving
the motor, but it is advisable to check that the throttle range is
still fully active when motor currents are being produced.
STEP 2. Plug the 1311 programmer into the controller and turn on the
controller with the run/store switch.
STEP 3. Using the programmer’s Program menu, initially set the
THROTTLE MAP parameter to 50%. This will provide a lin-
ear relationship between the throttle input voltage and the
Throttle % displayed in the programmer’s Monitor menu.
STEP 4. Select the Monitor menu. Throttle % should be visible at the top
of the display. You will need to reference the value displayed here.
STEP 5. Use a voltmeter and test clip to measure the throttle input volt-
age at Pin 5.
STEP 6. Measure and note the voltage when the throttle is fully released.
STEP 7. If the pedal switch is wired into the mechanical throttle
mechanism, scroll down the Monitor menu to Foot Input.
The display should indicate that the pedal switch is Off.
Slowly apply throttle until the display indicates that the
pedal switch is On. Measure the throttle voltage that is be-
ing produced at this threshold, and make a note of this value.
STEP 8. Measure the voltage when the throttle is fully depressed, and
make a note of this value.
STEP 9. Return to the Program menu.
Set THROT FAULT LO lower than the fully released voltage mea-
sured in Step 6.
If the pedal switch is wired into the throttle mechanism,
set THROTTLE 0% close to the voltage measured in Step 7. (Setting
THROTTLE 0% too far below this voltage will result in loss of low-
end throttle range.) If the pedal switch is not part of the throttle
assembly, set THROTTLE 0% above the fully released voltage measured
in Step 6.
Set THROTTLE 100% lower than the fully depressed voltage
measured in Step 8. Set the THROT FAULT HI parameter above the
fully depressed voltage (but no higher than 4.7 V).
STEP 10. Apply the keyswitch and forward switch and depress the throttle
slowly through the full range of motion, causing the wheels to
spin. Ensure that the Throttle % reaches 100% when the pedal is
fully depressed. Ensure that the Throttle % returns to 0% when
the throttle is released and that no throttle fault appears in the
Faults menu.
STEP 11. Refer to Section 3, page 20, and set the THROTTLE MAP parameter
for desired performance.

5 — TUNING GUIDE
2 Calibrating the Controller Speed Measurement

to the Vehicle
The RPM TO SPEED parameter is a conversion factor used to generate a vehicle
speed estimate from the speed sensor input (motor RPM signal). This conver-
sion factor allows the vehicle to be configured for various gear ratios and tire
sizes. It can also be used to convert the displayed vehicle speed values (in the
Program and Monitor menus) between English and metric units. Use the equa-
tions below to calculate the correct value for this parameter.
tire diameter (inches)

For English units (mph): × 63
gear ratio
tire diameter (cm)

For metric units (km/h): × 40
gear ratio
STEP 1. Using the Program menu, set RPM TO SPEED to the correct value
for the vehicle tire size and gear ratio.
STEP 2. Set TACHO POLES To the number of poles in the motor’s speed
sensor (typically 8).
STEP 3. Set the M1 FWD SPEED, M2 FWD SPEED and REVERSE SPEED to the desired
top vehicle speeds (in either mph or km/h).
3 Tuning the Controller to the Motor

The 1266 controller has the flexibility to be tuned to nearly any separately
excited motor from any manufacturer. The programmable parameters allow
full control of the motor’s maximum armature current during driving and
braking; they also allow full control of the motor’s maximum and minimum
field current as well as the field current relationship to the armature current.
This flexibility allows motor performance to be maximized while protecting it
from operating outside its safe commutation region.
In order to properly tune the controller, the following information should
be obtained from the motor manufacturer:
Maximum Armature Current Rating
Maximum Field Current Rating
Minimum Field Current Rating
Field Resistance (hot and cold)
Positive and Negative Field Maps.
The performance of a separately excited motor changes depending on tem-
perature. This is due to the change in field winding resistance as the motor
heats up through use. When the field winding temperature increases, so does
its resistance and therefore the maximum current that can be forced through

5 — TUNING GUIDE
the winding is reduced. Reductions in the field current over the motor’s typical
operating temperature range can be 10% to 50%. Since the maximum avail-
able field current determines the maximum torque that can be produced by
the motor, the vehicle’s performance under load and up inclines will change
as the motor heats up. The change in performance can be limited by tuning
the motor when it is hot rather than cold. We therefore recommend that this
procedure be performed with a hot motor.
STEP 1. Using the programmer’s Program Menu, set the drive current
limit (MAIN C/L) for both modes to the smaller of: (a) the motor’s
peak armature current rating, or (b) the maximum controller
drive current limit. This value can later be adjusted to establish
the desired vehicle driving feel in each mode.
STEP 2. Set the REGEN C/L value in each mode to the smaller of: (a) the
maximum motor armature current rating, or (b) the maximum
controller braking current limit. This value can later be adjusted
to establish the desired vehicle braking feel (see Fine Tuning).
STEP 3. To set FIELD MAX, first decide whether you want to maintain con-
sistent vehicle operation throughout the motor’s temperature
range. If you do, proceed to Step 4. If, however, maintaining
operational consistency across motor temperature is not a concern
and achieving maximum torque is, skip to Step 5.
STEP 4. For the most consistent operation across temperature, set the
FIELD MAX to the maximum field current available at low battery
voltage with a hot motor. To determine this current, divide the
low battery voltage (typically 70% of nominal) by the high
temperature field winding resistance specification provided by
the manufacturer. Set FIELD MAX to this value. This will provide
good consistency between motor performance in both hot and
cold states. Skip to Step 6.
STEP 5. For the maximum torque regardless of temperature, set FIELD MAX
to the motor’s rated absolute maximum field current. To deter-
mine the absolute maximum field current, divide the nominal
battery voltage by the low temperature field winding resistance
specification provided by the manufacturer. Set FIELD MAX to this
value. This will provide the maximum possible torque under all
conditions.
This has now set the FIELD MAX parameter.
The next step is to set the FIELD MIN parameter. FIELD MIN should never be set
below the rated value specified by the manufacturer. Operating the motor
at lower field currents than specified will result in operation outside the motor’s
safe commutation region and will cause arcing between the brushes and com-
mutator, significantly reducing motor and brush life.

5 — TUNING GUIDE
STEP 6. Set NEG FIELD MAX at or below the FIELD MAX setting.
If the controller is tuned such that the system is operating
outside the motor’s safe commutation region, there will be au-
dible and visual indications. Under normal operation, the mo-
tor will emit a whine with a pitch that increases with increasing
rotation speed. If a “scratchy” sound is also heard, this is usually
an indication that pin arcing is occurring in the motor and it is
operating outside its safe commutation region. This operation is
normally accompanied by a strong smell from the motor. If the
brushes and commutator bars are visible, arcing may be visible.
The further outside the safe commutation region the motor is
operating, the worse the arcing will be. Operation outside the
safe commutation region is very detrimental to the motor.
The FIELD MIN and possibly also the FIELD RAMP should be increased
until the indications of arcing stop. Decreasing FIELD MAP START
will also help to move operation back into the safe commutation
region.
The typical default field map settings are as follows.
Further tuning of the field maps is described in procedures 5,

7 , and 9.

5 — TUNING GUIDE
4 Equalizing the Loaded/Unloaded Vehicle Top Speed

on Flat Ground
The controller and vehicle should be configured as follows prior to setting the
maximum vehicle speed:
• DRIVE C/L as established in tuning procedure 3
• FIELD RAMP = 50%
• FLD MAP START = 20% of the specified drive current limit
• FIELD MIN = manufacturer’s specified minimum or 3 amps
• The vehicle can be loaded or loaded
If full closed loop speed control is required in both loaded
and unloaded operation, conduct this procedure with the
vehicle loaded.
• The vehicle battery should be fully charged.
Drive the vehicle on a flat surface in a clear area during this procedure. Precautions
should be taken to ensure safety of test personnel and anyone in the test area.
STEP 1. Select the programmer’s Program menu and scroll down until
M1 FWD SPEED parameter is displayed, and set this to the desired
top forward speed for Mode 1. Confirm that Mode 1 is selected
by reading the Mode value in the Monitor menu.
STEP 2. Turn on the keyswitch and the Forward switch and apply full
throttle. While driving the vehicle with full throttle applied, ob-
serve the Speed In and Arm PWM readings in the Monitor menu.
(Note: vehicle speed will display as 0.8 for speeds below 1.0.)
If the speed is being limited by the field map parameters,
the Arm PWM will be 100%. In this case, skip to Step 4.
If the vehicle is truly in closed loop speed control, the Arm
PWM will be less than 100%. The controller will be limiting the
vehicle speed to the programmed maximum speed by reducing
the applied armature voltage below the value commanded by
the throttle. In this case, proceed to Step 3.
STEP 3. Observe the Arm PWM and Arm Current readings while driving
at top speed. Set the FLD MAP START to a value above the Arm Cur-
rent reading. With the vehicle unloaded, increase the M1 FWD FLD
MIN until the Arm PWM is between 60–70%. When the vehicle
is loaded the controller will output a higher value of Arm PWM
to achieve this speed.
For slow speeds, a higher FIELD MIN is preferable, in order to
ensure a smooth transition between the drive and regen states.
For high speeds, a lower FIELD MIN is usually necessary to allow
the vehicle to achieve true closed loop speed control and not be
limited by the field current.
Skip to Step 5.

5 — TUNING GUIDE
STEP 4. In this case, the vehicle’s top speed is being limited by the field
mapping parameters. Observe the Arm Current in the Monitor
menu, and set the FIELD MAP START to a value above the Arm Cur-
rent reading. Reduce the M1 FWD FLD MIN until the Speed Input
shows the programmed maximum speed (i.e., the speed set by
M1 FWD SPEED) and the Arm PWM reading drops below 100%,
indicating that the controller is in closed loop speed control.
When the vehicle is unloaded the controller will output a lower
value of Arm PWM to maintain this speed.
Do not set the field mapping parameters outside the motor’s
safe commutation limits.
STEP 5. Repeat from Step 1 for the Mode 2 forward speed and for reverse
speed. Separate field minimum parameters are provided for all
three speeds (M1 FWD SPEED, M2 FWD SPEED, REV SPEED).
5 Confirming Loaded Vehicle Speed on Downhill Grade

STEP 1. Set the following parameters:
• REGEN C/L = maximum specified by the motor specs
• NEG FLD MAP EN = at or below REGEN C/L
• NEG FIELD MAX = FIELD MAX (as set in procedure 3, step 6)
• M1 BRAKE END = at least 1–2 mph or km/h below M1 FWD SPEED
• M1 BRAKE MAX = 100%.
STEP 2. With the vehicle fully loaded, drive down the steepest required
grade. Observe the Arm Current displayed in the Monitor menu
(it will be a negative value). This value is the regen current re-
quired to prevent exceeding the programmed top speed. It is an
important value to be aware of when adjusting the brake map-
ping parameters for optimum compression braking feel.
If the vehicle top speed is exceeded, increase the NEG FIELD
MAX and NEG FLD RAMP or decrease NEG FLD MAP EN to help provide
additional braking torque earlier.
See brake mapping examples on page 41.
STEP 3. Repeat the procedure for the Mode 2 forward speed and for
reverse speed. Separate brake mapping parameters are provided
for each speed (M1 FWD SPEED, M2 FWD SPEED, REV SPEED).

5 — TUNING GUIDE
FINE TUNING
Seven additional vehicle performance characteristics can be adjusted:
6 Response to Increased Throttle
7 Response to Full Throttle Release (Compression Braking)
8 Transitioning from Flat Ground to Downhill
9 Hill Climbing
bk WalkAway™ Braking
bl Low-Speed Field Braking
bm Applying the EM Brake.
These characteristics are related to the “feel” of the vehicle and will be different
for various applications. Once the fine tuning has been accomplished, it should
not have to be repeated on every vehicle.
6 Response to Increased Throttle

The vehicle’s response to throttle increases can be modified using the ACCEL,
THROTTLE MAP, and FIELD MAX parameters. Optimal vehicle response is tuned by
adjusting these parameters and then accelerating the vehicle from a dead stop
under various throttle transition conditions.
STEP 1. Set THROTTLE MAP as desired. In most applications a setting below
50% is used to provide greater control for low-speed maneuver-
ing.
STEP 2. Select Mode 1. While driving the vehicle, adjust M1 ACCEL for
the best overall acceleration response. If the vehicle starts too
slowly under all driving conditions, M1 ACCEL should be reduced.
(Remember, the accel rate parameter is in units of time.)
STEP 3. Increasing vehicle acceleration. If acceleration feels good for slow
or moderate throttle transitions but the vehicle initially starts
too slowly, set FIELD MAX higher. If acceleration is not satisfactory
when the throttle is transitioned quickly from zero to full speed,
decrease M1 ACCEL to obtain the desired fast throttle response.
STEP 4. Achieving better control at low speeds. If the vehicle responds well
for fast, full range throttle transitions but is too jumpy during
low speed maneuvering, reduce the THROTTLE MAP.
STEP 5. Select Mode 2 and repeat the procedure.
You may wish to dedicate one of the two modes for precision maneuvering.
The ACCEL, MAX SPEED, and MAIN C/L parameters can be tuned exclusively for this
precision-maneuvering mode to obtain comfortable vehicle response. Because
THROTTLE MAP and FIELD MAX are not mode-specific, you may need to re-tune Mode 1
if you make adjustments to these two parameters when tuning Mode 2.

5 — TUNING GUIDE
7 Response to Full Throttle Release (Compression Braking)

The way the vehicle responds when the throttle is completely released can be
modified using the DECEL, REGEN C/L, brake mapping, and negative field mapping
parameters. Braking parameters should be set for M1 and M2 forward speeds
and for reverse speed.
When the throttle is released, the DECEL rate acts to drive the armature
PWM down to zero, but the BRAKE MAP will ensure that the braking (regen)
current is limited to the value for the present vehicle speed. This allows a profile
to be specified that allows high initial braking torque, softening to a milder
torque as the vehicle slows down. Alternatively, you can set up a profile with
strong braking down to zero speed. A lower DECEL value will also provide a more
immediate strong braking feel.
STEP 1. Set the brake mapping parameters to the default values shown
in Example A on the next page.
Note: With the default settings, maximum braking torque
is specified at top speed, tailing off to a much milder torque at
low speeds.
STEP 2. Drive the vehicle at full speed on flat ground and release the
throttle, paying attention to the feel of vehicle braking. If the
initial braking is too sudden, increase the DECEL value. If the
initial braking is too strong, lower the BRAKE MAX or increase the
BRAKE MAP END.
When setting a very mild compression braking feel, beware
of setting the BRAKE MAX and REGEN C/L to values that will inhibit
the controller’s ability to maintain top speed braking—in both
throttle applied and throttle released conditions—on a downhill
grade.
If the braking torque remains too strong after the vehicle
has been brought to a slower speed, reduce the BRAKE MAP and
BRAKE MIN parameters, and increase the BRAKE MAP START. These
adjustments will act to limit the braking torque at the lower
speeds.
If, on the other hand, you want to increase braking torque
at lower speeds, increase the BRAKE MAP or BRAKE MIN parameters,
or reduce the BRAKE MAP START.
Note: The setting of the brake mapping and DECEL parameters will also affect the
feel of the vehicle deceleration during partial throttle releases. After completing
procedure 7 for full throttle release, make sure the deceleration during partial
throttle release is acceptable.

5 — TUNING GUIDE
Example B
This map has strong braking to vehicle rest.
250
REGEN CURRENT (amps)
200 REGEN C/L 200 A

M1 FWD SPEED 10 mph
150
M1 BRAKE MIN 40 % (80 A)
M1 BRAKE MAX 100 % (200 A)
100
M1 BRAKE START 4 mph
M1 BRAKE END 7 mph
50
M1 BRAKE MAP 50 % (140 A)
0
0 2 4 6 8 10 12
VEHICLE SPEED (mph)
Note: BRAKE MIN and BRAKE MAX are percentages of REGEN C/L.
BRAKE MAP is a percentage of the range between BRAKE MIN and BRAKE MAX.

5 — TUNING GUIDE
8 Transitioning from Flat Ground to Downhill

To ensure smoothness on transitions from positive drive current to negative
regen current, set the NEG FLD MAP ST (negative field map start) greater than zero
to provide a constant value of field current as the motor transitions between
drive and regen braking.
If speed “hunting” or oscillation occurs on downhill grades, reduce the NEG
FIELD MAX and NEG FLD RAMP parameters or increase the NEG FLD MAP EN parameter
to ensure an initally shallower negative field map profile.
Note: The “negative field map” refers to the field and armature (regen
braking) current relationship regardless of forward or reverse direction.
9 Hill Climbing
The vehicle response to increased gradients such as hills and loading ramps
can be tuned via the FIELD RAMP parameter. Decreasing the FIELD RAMP value
allows faster vehicle speeds while climbing, but it will also have the effect of
reducing the ability of the controller to generate torque in the vehicle’s mid
range speeds.
STEP 1. If faster vehicle speed is desired when climbing ramps, decrease
FIELD RAMP until the desired ramp climbing speed is attained. It
should be noted that if the motor’s torque capability is exceeded
under the conditions of load and ramp gradient, vehicle speed
will be limited by the motor’s capability and the desired vehicle
speed may not be attainable. The system will find a compromise
point at which sufficient motor torque is generated to climb the
ramp at an acceptable speed. If FIELD RAMP is reduced to 0% and
the desired speed is still not attained, the system is being limited
by the motor’s torque capability under these conditions.
Caution should be used in reducing FIELD RAMP since at low
FIELD RAMP values it is possible that the motor could be operated
outside its safe commutation region.
STEP 2. If the drive system cannot produce sufficient torque for a fully
loaded vehicle to climb the desired ramp, try increasing the FIELD
RAMP, FIELD MAX, and/or MAIN C/L. The impact of increasing these
values on other driving characteristics must be evaluated. Increas-
ing the FIELD MAX will provide more field current, and increasing
the MAIN C/L will provide more armature current. If FIELD MAX is
set at the manufacturer’s specified limit and the MAIN C/L is set at
the rated maximum, then vehicle speed up the ramp is limited
by the motor or the vehicle’s gearing and cannot be increased
by tuning the controller.
Note: To determine whether the controller’s armature current
is at its set value during ramp climbing, read the Arm Current
in the programmer’s Monitor menu.

5 — TUNING GUIDE
bk WalkAway™ Braking
If the WalkAway™ option is configured, WalkAway™ braking will occur whenever
vehicle movement is detected while the main contactor is open. In general this
is used to prevent uncontrolled vehicle rolling after the vehicle has reached rest.
It also is used to slow the vehicle if it is rolling when the keyswitch is turned
off or in certain fault conditions that cause the main contactor to open.
The strength of the WalkAway™ braking is controlled by the WALKAWAY C/L
and PLUG C/L parameters.
STEP 1. Drive the vehicle onto a steep grade, and hold it with the foot
brake until you hear the main contactor open.
STEP 2. Release the foot brake. The vehicle will begin to roll at a slow
pace, followed by WalkAway™ braking (indicated by a beeping
tone).
If the vehicle is rolling too fast, increase the WALKAWAY C/L
and/or the PLUG C/L.
STEP 3. Check that these braking parameter adjustments do not make
the braking feel too abrupt on milder slopes.
bl Low-Speed Field Braking

The FLD BRAKE parameter provides an additional mechanism for slowing the
vehicle down at slow speeds. There are three uses for field braking:
a. Providing extra braking torque as the vehicle slows to a stop.
b. Strengthening the anti-rollback braking in vehicles that do not have
an EM brake.
Note: The anti-rollback function can never hold a
vehicle perfectly stationary on an incline and is not
intended to replace a mechanical or electromagnetic
brake for this purpose. However, it will prevent
uncontrolled vehicle coasting in this situation.
c. On vehicles equipped with an EM brake, field braking and the EM
brake can be used together to stop the vehicle and to prevent the vehicle
from rolling back down a hill.
Note: This use of field braking is covered separately
in Procedure bm.
This procedure tunes the field braking parameters to provide additional braking
at low speeds in situations (a) and (b).

5 — TUNING GUIDE

• FLD BRAKE = On
• FLD BRAKE MAX = FIELD MIN
• FLD BRAKE SPD = a low value (e.g., 3 mph)
• FLD BRAKE RATE = 2.
STEP 2. Drive the vehicle up a grade.
STEP 3. Release the throttle. The vehicle will slow down and then roll
back down the hill under gravity. Depending on the setting of
the WARNING OPTION parameter, you may hear beeping.
If the vehicle is rolling too fast, increase the FLD BRAKE MAX
setting. This will cause a higher plug braking current. It will
also increase the braking feel as the vehicle initially slows down
before changing direction.
To make the low-speed braking occur earlier, increase the
FLD BRAKE SPD.
To increase the strength of the low-speed braking as the
vehicle is brought to a stop, increase the FLD BRAKE RATE and FLD
BRAKE MAX.
STEP 4. Drive the vehicle on flat ground to confirm that the extra brak-
ing feel provided by these adjustments is acceptable.
bm EM Brake Operation (with optional EM brake)

During normal operation, the EM brake is applied at the expiration of the
EMB DELAY. The FLD BRAKE setting (Off or On) determines when the EMB DELAY
countdown begins.
Note: For EM brake control during fault conditions, see EMB SPD VALUE,
page 29.
(1) FLD BRAKE = Off
Here the EMB DELAY sets the length of time between the main contactor opening
and the EM brake being applied.
• FLD BRAKE = Off
• EMB DELAY = <1.0 second
(2) FLD BRAKE = On
Here the EMB DELAY sets the length of time the field current is held at the FLD
BRAKE MAX before the EM brake is applied. This guarantees that the EM brake
will be applied some time after the vehicle has slowed below the FLD BRAKE SPD
(even though the main contactor may still be closed) and is useful in prevent-
ing the vehicle from continuing to roll forward. Additionally, if the controller

5 — TUNING GUIDE
detects that the vehicle has reached rest, or is starting to roll back, the EM brake
will be applied immediately to prevent further vehicle movement.
• FLD BRAKE = On
• EMB DELAY = a low value (e.g., 3 seconds)
• FLD BRAKE MAX = FIELD MIN, or higher
• FLD BRAKE RATE = a low value (e.g., 2).
STEP 2. Drive up a hill and release the throttle. The vehicle should slow
to a stop and the EM brake should drop just as the vehicle be-
gins to roll backwards. If the vehicle rolls backwards excessively,
increase the FLD BRAKE MAX.
STEP 3. Drive down a mild slope and release the throttle. The vehicle will
slow down but may not reach a complete stop depending on the
gradient of the slope. You should feel the field braking torque,
followed by the EM brake being applied. If the EM brake is
applied too early, increase the FLD BRAKE MAX and the EMB DELAY.
STEP 4. After adjusting these parameters, drive the vehicle on flat ground
to confirm that the EM brake timing is acceptable. To avoid
unnecessarily abrupt stops, the parameters should be set so that
when driving on flat ground the vehicle reaches rest before the
EM brake is applied.

6 — DIAGNOSTICS & TROUBLESHOOTING
6
DIAGNOSTICS AND TROUBLESHOOTING
The 1266 controller provides diagnostics information to assist technicians in

troubleshooting drive system problems. This information is displayed on the
handheld programmer (or PC Programming Station), and it is also available
in the form of fault codes issued by the controller’s built-in Status LED. Refer
to the troubleshooting chart for suggestions covering a wide range of possible
faults.
PROGRAMMER DIAGNOSTICS
The programmer presents complete diagnostic information in plain language.
Faults are displayed in the Faults menu (see column 2 in the troubleshoot-
ing chart), and the status of the controller inputs/outputs is displayed in the
Monitor Menu.
Accessing the Fault History menu provides a list of the faults that have
occurred since the fault history file was last cleared. Checking (and clearing)
the fault history file is recommended each time the vehicle is brought in for
maintenance.
The following 4-step process is recommended for diagnosing and trouble-
shooting an inoperative vehicle: (1) visually inspect the vehicle for obvious
problems; (2) diagnose the problem, using the programmer; (3) test the circuitry
with the programmer; and (4) correct the problem. Repeat the last three steps
as necessary until the vehicle is operational.
Example: A vehicle that does not operate in “forward” is brought in
for repair.
STEP 1: Examine the vehicle and its wiring for any obvious problems,
such as broken wires or loose connections.
STEP 2: Connect the programmer, select the Faults menu, and read
the displayed fault information. In this example, the display shows
“No Known Faults,” indicating that the controller has not detected
any problems.
STEP 3: Select the Monitor menu, and observe the status of the inputs
and outputs in the forward direction. In this example, the display
shows that the forward switch did not close when “forward” was
selected, which means the problem is either in the forward switch
or the switch wiring.
STEP 4: Check or replace the forward switch and wiring and repeat
the test. If the programmer shows the forward switch closing and
the vehicle now drives normally, the problem has been corrected.

TROUBLESHOOTING CHART
LED PROGRAMMER
CODE LCD DISPLAY EXPLANATION POSSIBLE CAUSE
1,1 HW FAILSAFE Self-test or watchdog fault. 1. Controller defective.

1,2 THROTTLE FAULT 1 Wiper signal out of range 1. Throttle input wire open.
(pot low fault). 2. Throttle input wire shorted to B+ or B-.
3. Throttle pot defective.
1,3 SPEED SENSOR FAULT No pulses from sensor. 1. Speed sensor not connected.
2. Speed sensor defective.
1,4 HPD High Pedal Disable fault. 1. Improper sequence of direction and
throttle inputs.
1,5 MOTOR STALL Motor stall at current. 1. Slope too steep for vehicle weight.
2. Mechanically locked motor.
3. EM brake wiring failure.
4. Speed sensor defective.
2,1 LOW BATTERY VOLTAGE Low battery voltage. 1. Battery voltage < undervoltage cutback
threshold.
2. Corroded battery terminal.
3. Loose battery or controller terminal.
2,2 OVERVOLTAGE Overvoltage. 1. Battery voltage > overvoltage shutdown
threshold.
2. Vehicle operating with charger attached.
3. Battery disconnected during regen
braking.
2,3 THERMAL CUTBACK Over-/undertemperature 1. Temperature > 85°C or < -25°C.
cutback. 2. Excessive load on vehicle.
3. Improper mounting of controller
4. Operation in extreme environments.
2,4 MAIN DRIVER ON Main contactor coil held low. 1. Main contactor missing or wire to coil
open.
2. Controller defective.
2,5 AUX COIL FAULT Missing aux (brake, relay) coil. 1. Aux coil open or not connected.
2. Breaker/fuse tripped or open.
3. Breaker/fuse defective.
3,1 MAIN DRIVER OFF Main contactor driver held high. 1. Main contactor coil shorted.
3,2 MAIN WELDED Main contactor welded. 1. Main contactor stuck closed.
2. Main contactor driver shorted.
3,3 PRECHARGE FAULT Internal voltage too low at 1. External precharge resistor missing.
startup. 2. External short, or leakage path to B-
on external B+ connection.
3,4 FIELD MISSING Field winding fault. 1. Motor field wiring loose.
2. Motor field wiring open.
3,5 AUX DRIVER OFF Aux (brake, relay) driver held 1. Aux coil shorted.
high. 2. Controller defective.
4,1 CURRENT SENSE FAULT Armature or field current 1. Controller defective.
sensor fault.
4,2 DRIVER OVERCURRENT Contactor driver or aux driver 1. Contactor or aux coil shorted.
overcurrent.

TROUBLESHOOTING CHART, cont’d

LED PROGRAMMER
CODE LCD DISPLAY EXPLANATION POSSIBLE CAUSE
4,3 M- SHORTED Internal M- short to B-. 1. Controller defective.

4,4 AUX RELAY DNC Aux relay did not close. 1. Aux relay missing or wire to coil open.
4,5 WELDED AUX RELAY Welded aux relay. 1. Aux relay stuck closed.
2. Aux relay shorted.
5,1 KEY SWITCH SRO SRO fault. 1. Keywswitch not off at power-up.
2. Keyswitch shorted.
5,2 MAIN COIL OPEN Missing main contactor. 1. Main contactor coil open or not
connected.
5,3 AUX DRIVER ON Aux (EM brake or WalkAway™ 1. Aux output short to ground.
relay) driver coil held low. 2. Controller defective.
5,5 MAIN DROPOUT Main contactor open. 1. Main contactor defective.
LED DIAGNOSTICS
A built-in Status LED is visible through a window in the label on top of the
controller. When the controller detects a fault, the Status LED flashes the
2-digit fault code. The code is flashed continuously until the fault is corrected.
For example, code “3,2”—welded main contactor—appears as:
¤ ¤ ¤ ¤ ¤ ¤ ¤ ¤ ¤ ¤ ¤ ¤ ¤ ¤ ¤ etc.
(3,2) (3,2) (3,2)
The codes are listed in the Troubleshooting Chart. Only one fault is indicated
at a time, and faults are not queued up. If multiple faults are active simultane-
ously, the code of the highest priority fault is flashed. After all faults have been
cleared, the code of the last active fault will continue to flash for one minute.
This feature is designed to help service personnel identify intermittent faults
when no programmer is available.

7 — MAINTENANCE
7
MAINTENANCE
There are no user serviceable parts in the Curtis 1266 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.
It is recommended that the controller be kept clean and dry that its
diagnostics history file be checked and cleared periodically.
CLEANING
Periodically cleaning the controller exterior will help protect it against cor-
rosion and possible electrical control problems created by dirt, grime, and
chemicals that are part of the operating environment and that normally exist
☞
C AU T I O N in battery powered systems. When working around any battery powered
vehicle, proper safety precautions should be taken. These include, but are
not limited to: proper training, wearing eye protection, and avoiding loose
clothing and jewelry.
Use the following cleaning procedure for routine maintenance. Never use a
high pressure washer to clean the controller.
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 power and signal connector areas.
The controller should be wiped clean with a moist rag. Dry it before
reconnecting the battery.
4. Make sure the connections are tight. Refer to Section 2, page 7, for
maximum tightening torque specifications for the battery and motor
connections.
FAULT HISTORY
The programmer’s Fault menu can be used to access the controller’s fault his-
tory file. The programmer will read out all the faults that the controller has
experienced since the last time the fault history file was cleared. The faults may
be intermittent faults, faults caused by loose wires, or faults caused by operator
errors. Faults such as contactor faults may be the result of loose wires; contactor
wiring should be carefully checked. Faults such as HPD or overtemperature
may be caused by operator habits or by overloading.
After a problem has been diagnosed and corrected, it is a good idea to
clear the fault history file. This allows the controller to accumulate a new file
of faults. By checking the new fault history file at a later date, you can readily
determine whether the problem was indeed fixed.

APPENDIX A: EMC & ESD DESIGN CONSIDERATIONS
APPENDIX A
VEHICLE DESIGN CONSIDERATIONS
REGARDING ELECTROMAGNETIC COMPATIBILITY (EMC)
AND ELECTROSTATIC DISCHARGE (ESD)
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 con-
nected 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 potenti-
ometer. 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.
Curtis 1266 Manual, Rev. A A-1

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.
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-con-
ductive 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.
A-2 Curtis 1266 Manual, Rev. A

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 control pan-
els—such as an electronic throttle, or control wires such as keyswitch, direction,
etc.—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.
ELECTROSTATIC DISCHARGE (ESD)

Curtis PMC motor controllers contain ESD-sensitive components, and it is
therefore necessary to protect them from ESD (electrostatic discharge) damage.
Most of these control lines have protection for moderate ESD events, but must
be protected from damage if higher levels exist in a particular application.
ESD immunity is achieved either by providing sufficient distance be-
tween conductors and the ESD source so that a discharge will not occur, or by
providing an intentional path for the discharge current such that the circuit
is isolated from the electric and magnetic fields produced by the discharge. In
general the guidelines presented above for increasing radiated immunity will
also provide increased ESD immunity.
It is usually easier to prevent the discharge from occurring than to divert
the current path. A fundamental technique for ESD prevention is to provide
adequately thick insulation between all metal conductors and the outside envi-
ronment so that the voltage gradient does not exceed the threshold required for
a discharge to occur. If the current diversion approach is used, all exposed metal
components must be grounded. The shielded enclosure, if properly grounded,
can be used to divert the discharge current; it should be noted that the loca-
tion of holes and seams can have a significant impact on ESD suppression. If
the enclosure is not grounded, the path of the discharge current becomes more
complex and less predictable, especially if holes and seams are involved. Some
experimentation may be required to optimize the selection and placement of
holes, wires, and grounding paths. Careful attention must be paid to the control
panel design so that it can tolerate a static discharge.
MOV, transorbs, or other devices can be placed between B- and offending
wires, plates, and touch points if ESD shock cannot be otherwise avoided.

APPENDIX A:
B: PROGRAMMER
EMC & ESD DESIGN
OPERATION
CONSIDERATIONS
& MENUS
APPENDIX B
PROGRAMMERS
Curtis programmers provide programming, diagnostic, and test capabilities for
the 1266 controller. The power for operating the programmer is supplied by
the host controller via a 4-pin connector. Two programmers are available: the
PC Programming Station (1314) and the handheld programmer (1311). The
Programming Station has features not available on the handheld unit; on the
other hand, the handheld programmer has the advantage of being more portable.
Typically the Programming Station is used to set up the parameters initially and
the handheld programmer is used to made adjustments in the field.
Two versions of each programmer are available: the User programmers
can adjust only User-access parameters, whereas the OEM programmers can
adjust all the parameters.
HANDHELD PROGRAMMER (1311)

The 1311 programmer is easy to use, with self-explanatory functions. After
plugging in the programmer, wait a few seconds for it to boot up and gather
Fig. B-1 Curtis 1311
handheld programmer.
A-4
B-1 Curtis 1266 Manual, Rev. A
APPENDIX
APPENDIXA:
B: EMC & ESD DESIGN
PROGRAMMER CONSIDERATIONS
OPERATION & MENUS
information from the controller. For experimenting with settings, the program-
mer can be left plugged in while the vehicle is driven.
The bookmark keys can make parameter adjustment more convenient.
For example, in setting the throttle parameters, you might set a bookmark at
the first of these parameters [Program » Throttle 100%] and another at the raw
throttle readout [Monitor » Throttle]; this way you can easily toggle between
the readout and the parameter.
To set a bookmark, press one of the three bookmark keys for more than
two seconds. To jump to a bookmarked location, press the appropriate book-
mark key quickly (for less than two seconds).
The bookmark keys also have another function that makes program-
ming easier. When setting the value of a parameter, you can use these keys to
adjust the increments by which the value changes—with Bookmark Key 1, the
value changes in 10-digit steps up or down; with Bookmark Key 2 pressed,
the value changes in 100-digit steps; and with Bookmark Key 3, in 1000-digit
steps—which, for most parameters, takes you from the maximum to the mini-
mum, or vice versa.
PC PROGRAMMING STATION (1314)

The Programming Station is an MS-Windows 32-bit application that runs on a
standard Windows PC. It can do everything the handheld programmer can do,
and more. Its additional capabilities include saving/restoring sets of parameters
to/from disk and updating software. Instructions for using the Programming
Station are included with the software.
PROGRAMMER MENUS
The programmers have six menus:
Program — provides access to the individual programmable parameters.
Monitor — presents real-time values during vehicle operation; these include all
inputs and outputs.
Faults — presents diagnostic information, and also a means to clear the fault
history file.
Functions — provides access to the controller-cloning commands and to the
“reset” command.
Information — displays data about the host controller: model and serial numbers,
date of manufacture, hardware and software revisions, and itemization of other
devices that may be associated with the controller’s operation.
Programmer Setup — displays data about the programmer: model and serial
numbers, and date of manufacture.

B-2
APPENDIX B:
A: PROGRAMMER OPERATION
EMC & ESD DESIGN & MENUS
CONSIDERATIONS
The Program Menu and Monitor Menu are presented here. For Faults,
see the Troubleshooting Chart in Section 6. The other three menus are self-
explanatory.
Program Menu (not all items available on all controllers)
Parameters are listed here in the order in which they appear in the Program
Menu displayed by the programmer.
M1 MAIN C/L Drive current limit in Mode 1.

M2 MAIN C/L Drive current limit in Mode 2.
REGEN C/L Current limit during regen braking.
PLUG C/L Current limit during plug braking.
AUX DRVR MODE 0=none, 1=WalkAway™, 2=EM brake.
AUX PULL IN Voltage at aux driver (pin 23) during first 0.1 second.
AUX HOLDING Voltage at aux driver (pin 23) after first 0.1 second.
EMB DELAY Delay before EM brake is applied.
FLD BRAKE Enable field braking, to slow vehicle near zero speed.
FLD BRAKE SPD Speed threshold below which field braking occurs.
FLD BRAKE MAX Max field current allowed during field braking.
FLD BRAKE RATE Sets how quickly field current rises during field braking.
EMB SPD CHECK Enable controller to attempt to stop vehicle before
locking EMB after main contactor fault.
EMB SPD VALUE Threshold speed at which EMB is allowed to lock
during a main contactor fault.
RPM TO SPEED Conversion factor for motor to vehicle speed.
TACHO POLES Number of poles in speed sensor magnet.
MODE AFTER KEY Mode change allowed after KSI activated (yes/no).
WARNING OPTION Sets conditions for warning signals.
M1 FWD SPEED Maximum forward speed in Mode 1.
M1 ACCEL Forward acceleration rate in Mode 1.
M1 DECEL Forward deceleration rate in Mode 1.
M1 BRAKE MIN % of Main C/L at start of brake map, Mode 1.
M1 BRAKE MAX % of Main C/L at end of brake map, Mode 1.
M1 BRAKE MAP % of Main C/L at midpoint of brake map, Mode 1.
M1 BRAKE START Vehicle speed at start of brake map, Mode 1.
M1 BRAKE END Vehicle speed at end of brake map, Mode 1.
REV SPEED Maximum reverse speed.
REV ACCEL Reverse acceleration rate.
REV DECEL Reverse deceleration rate.
REV BRAKE MIN % of Main C/L at start of reverse brake map.
REV BRAKE MAX % of Main C/L at end of reverse brake map.
B-3
A-6 Curtis 1266 Manual, Rev. A
APPENDIX
APPENDIXA:
B: EMC
PROGRAMMER
& ESD DESIGN
OPERATION
CONSIDERATIONS
& MENUS
Program Menu, cont’d
REV BRAKE MAP % of Main C/L at midpoint of reverse brake map.

REV BRK START Vehicle speed at start of reverse brake map.
REV BRAKE END Vehicle speed at end of reverse brake map.
M2 FWD SPEED Maximum forward speed in Mode 2.
M2 ACCEL Forward acceleration rate in Mode 2.
M2 DECEL Forward deceleration rate in Mode 2.
M2 BRAKE MIN % of Main C/L at start of brake map, Mode 2.
M2 BRAKE MAX % of Main C/L at end of brake map, Mode 2.
M2 BRAKE MAP % of Main C/L at midpoint of brake map, Mode 2.
M2 BRAKE START Vehicle speed at start of brake map, Mode 2.
M2 BRAKE END Vehicle speed at end of brake map, Mode 2.
OVERVOLTAGE Threshold above which regen current decreases.
LOW VOLTAGE Threshold below which drive current decreases.
THROTTLE MAP Midpoint value that shapes the throttle map.
THROTTLE 0% Voltage at which throttle command begins.
THROTTLE 100% Voltage at which throttle command is maxed out.
THROT FAULT LO Voltage under which a throttle fault occurs.
THROT FAULT HI Voltage over which a throttle fault occurs.
M1 FWD FLD MIN Minimum field current, forward direction, Mode 1.
REV FIELD MIN Minimum field current, reverse direction.
M2 FWD FLD MIN Minimum field current, forward direction, Mode 1.
FLD MAP START Positive armature current at which field map begins.
FIELD RAMP Midpoint value that shapes the field map.
FIELD MAX Maximum field current during drive.
FIELD MAP END Positive armature current at which field map ends.
NEG FLD MAP ST Neg. armature current at which neg. field map begins.
NEG FIELD RAMP Midpoint value that shapes the negative field map.
NEG FIELD MAX Maximum field current during regen braking.
NEG FLD MAP EN Neg. armature current at which neg. field map ends.
WALKAWAY C/L Field current during WalkAway™ operation.
KSI SRO ENABLE Keyswitch must be off at power-up (yes/no).

B-4
A: PROGRAMMER
APPENDIX B: EMC & ESD DESIGN CONSIDERATIONS
OPERATION & MENUS
Monitor Menu
Items are listed here in the order in which they appear in the Monitor Menu
displayed by the programmer.
SPEED INPUT Speed reading.

THROTTLE Throttle reading, as % of full throttle.
BATTERY VOLTS Voltage at Logic Power (pin 16).
HEATSINK TEMP Heatsink temperature, in °C.
MODE Controller operating mode: Mode 1 or Mode 2.
ARM CURRENT Motor armature current, in amps.
FIELD CURRENT Motor field current, in amps.
ARM PWM Motor armature applied duty cycle, as %.
FIELD PWM Motor field applied duty cycle, as %.
FOOT INPUT Pedal interlock switch: on/off.
KEY INPUT Keyswitch: on/off.
FORWARD INPUT Forward switch: on/off.
REVERSE INPUT Reverse switch: on/off.
MODE SWITCH Mode switch: on/off.
AUX CONTACTOR WalkAway™ relay or EM brake at pin 23: on/off.
MAIN DRIVER Main contactor driver: high/low.
A-8
B-5 Curtis 1266 Manual, Rev. A
APPENDIX
APPENDIX A: EMC & C: PARAMETER
ESD DESIGN INDEX
CONSIDERATIONS
APPENDIX C
PROGRAMMABLE PARAMETER INDEX
The 1266 controller’s programmable parameters are listed below in alphabetical order
(by programmer display name), with references provided to the parameter descriptions
and to the appropriate Tuning Guide procedures.
The parameters are described individually in Section 3. It is important also to read the
tuning procedures in Section 5, as many parameters are highly interdependent with
other parameters.
Note: The bulleted parameters (•) are not included in the Tuning Guide; the informa-
tion provided in Section 3 is sufficient for adjusting these parameters.
Sec. 3 Sec. 5 Sec. 3 Sec. 5

ACCEL, M1-M2-REV p. 17 6, p. 39 •KSI SRO ENABLE p. 26
•AUX DRVR MODE p. 28 •LOW VOLTAGE p. 26
•AUX PULL IN p. 28 MAIN C/L, M1-M2 p. 21 3, p. 34
•AUX HOLDING p. 28 •MODE AFTER KEY p. 26
BRAKE END, M1-M2-REV p. 22 7, p. 40 NEG FIELD MAX p. 24 5, p. 38
BRAKE MAX, M1-M2-REV p. 22 7, p. 40 NEG FIELD RAMP p. 25 5, p. 38
BRAKE MAP, M1-M2-REV p. 23 7, p. 40 NEG FLD MAP EN p. 25 5, p. 38
BRAKE MIN, M1-M2-REV p. 22 7, p. 40 NEG FLD MAP ST p. 24 5, p. 38
BRAKE START, M1-M2-REV p. 22 7, p. 40 •OVERVOLTAGE p. 26
DECEL, M1-M2-REV p. 17 7, p. 40 PLUG C/L p. 21 bk, p. 43
EMB DELAY p. 29 bm, p. 44 REGEN C/L p. 21 5, p. 38
•EMB SPD CHECK p. 29 REV FIELD MIN p. 24 4, p. 37
•EMB SPD VALUE p. 29 REV SPEED p. 19 2, p. 34
FIELD MAP END p. 25 3, p. 34 RPM TO SPEED p. 19 2, p. 34
FIELD MAX p. 24 3, p. 34 TACHO POLES p. 19 2, p. 34
FIELD RAMP p. 25 4, p. 37 THROT FAULT LO p. 21 1, p. 32
FLD BRAKE p. 17 bl, p. 43 THROT FAULT HI p. 21 1, p. 32
FLD BRAKE MAX p. 18 bl, p. 43 THROTTLE 0% p. 20 1, p. 32
FLD BRAKE RATE p. 18 bl, p. 43 THROTTLE 100% p. 20 1, p. 32
FLD BRAKE SPD p. 17 bl, p. 43 THROTTLE MAP p. 20 1, p. 32
FLD MAP START p. 24 4, p. 37 WALKAWAY C/L p. 21 bk, p. 43
FWD FLD MIN, M1-M2 p. 24 4, p. 37 •WARNING OPTION p. 26
FWD SPEED, M1-M2 p. 19 2, p. 34
Curtis 1266 Manual, Rev. A C-1

A-9
APPENDIX D:
A: EMC
SPECIFICATIONS
& ESD DESIGN CONSIDERATIONS
APPENDIX D
SPECIFICATIONS
SPECIFICATIONS: 1266 CONTROLLER
Nominal input voltage 36 V or 48V

PWM operating frequency 16 kHz
Electrical isolation to heatsink 500 V ac (minimum)
Logic enable and logic power input

voltage (minimum) 16.8 V
Logic enable and logic power input
current (no contactors engaged) 160 mA without programmer; 200 mA with programmer
Logic input voltage >20.0 V High; <7.5 V Low

Logic input current 10 mA
Operating ambient temperature range -40°C to 50°C (-40°F to 122°F)

Heatsink overtemperature cutback starts at 85°C (185°F); cutoff at 95°C (203°F)
Heatsink undertemperature cutback 50% armature current at -25°C (-13°F)
Package environmental rating IP5X

Weight 3.9 kg (8.5 lb)
Dimensions (L×W×H) 229 × 178 × 81 mm (9.0" × 7.0" × 3.2")
NOMINAL ARMATURE FIELD

BATTERY 2 MIN 2 MIN
MODEL VOLTAGE RATING RATING
NUMBER (volts) (amps) (amps)
1266-52XX 36–48 275 20
A-10
C-2
D-1 Curtis 1266 Manual, Rev. A

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12 6 6

© 2006 CURTIS INSTRUMENTS, INC.

DESIGN OF CURTIS 1200 SERIES

1266 Manual, p/n 38228

CURTIS INSTRUMENTS, INC.

2. INSTALLATION AND WIRING.............................................4

3. PROGRAMMABLE PARAMETERS ......................................15

Curtis 1266 Manual, Rev. A iii

Field Map Start / Negative Field Map Start

4. INSTALLATION CHECKOUT .............................................30

5. TUNING GUIDE ..................................................................32

6. DIAGNOSTICS AND TROUBLESHOOTING....................46

APPENDIX A Vehicle Design Considerations

iv Curtis 1266 Manual, Rev. A

FIG. 1: Curtis 1266 electronic motor controller.............................. 1

FIG. 2: Mounting dimensions, Curtis 1266 controller ................... 4

FIG. 3a: Standard wiring conﬁguration —

FIG. 3b: Standard wiring conﬁguration —

FIG. 4: Wiring for 3-wire potentiometer throttle ......................... 10

FIG. 5: Wiring for 0–5V throttle ................................................. 10

FIG. 6: Wiring for ITS throttle .................................................... 11

FIG. 7: Throttle map structure .................................................... 20

FIG. 8: Brake map structure ......................................................... 23

FIG. 9: Field map structure .......................................................... 25

FIG. B-1: Curtis 1311 handheld programmer ................................. B-1

Curtis 1266 Manual, Rev. A v

Fig. 1 Curtis 1266

These controllers are fully programmable by means of the optional 1311

Curtis 1266 Manual, Rev. A 1

✓ Regenerative braking, providing longer operation on a single

2 Curtis 1266 Manual, Rev. A

✓ Driver outputs are short circuit protected and provide built-in

Curtis 1266 Manual, Rev. A 3

MOUNTING THE CONTROLLER

Dimensions in millimeters (and inches)

4 Curtis 1266 Manual, Rev. A

LEAD ACID BATTERIES — Charging or discharging generates hydrogen gas,

Curtis 1266 Manual, Rev. A 5

Pin 1 Hall Signal input signal from motor speed sensor

Pin 9 Hall - B- ground for motor speed sensor

6 Curtis 1266 Manual, Rev. A

A 4-pin low power connector is provided for an optional programmer. A com-

High Current Connections

Curtis 1266 Manual, Rev. A 7

WIRING: Standard Conﬁguration

Standard Power Wiring

+ - REVERSE ALARM Pin 3

Fig. 3a Standard wiring conﬁguration for Curtis 1266 controller,

8 Curtis 1266 Manual, Rev. A

Standard Control Wiring

WALKAWAY DRIVER WALKAWAY

POT HIGH (10 A)

Fig. 3b Standard wiring conﬁguration for Curtis 1266 controller,

Curtis 1266 Manual, Rev. A 9

3-Wire Potentiometer (5kΩ–10kΩ) Throttle

10 Curtis 1266 Manual, Rev. A

Pot Low input (Pin 5)

Curtis 1266 Manual, Rev. A 11

Main Contactor 7 2.0 A B+ yes

Reverse Alarm 3 0.02 A B+ no