Curtis 1204M Manual Download

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Manual

Models

1204M/05M/09M/21M

Electronic Motor Controllers

with Universal Logic Board

Read Instructions Carefully!

Specifications are subject to change without notice.

53121 Rev B 8/16

Curtis Instruments, Inc.

200 Kisco Avenue

Mt. Kisco, NY 10549

www.curtisinstruments.com

Summary of Contents for 1204M

Page 1: ...s are subject to change without notice 2012 Curtis Instruments Inc Curtis is a registered trademark of Curtis Instruments Inc The design and appearance of the products depicted herein are the copyrigh...

Page 2: ......

Page 3: ...ive reverse input 8 KSI Wiring 8 Forward Reverse Wiring 9 Throttle Wiring 10 Wiring Configuration for Pump Applications 14 Installation Checkout 15 3 PROGRAMMABLE PARAMETERS 17 Voltage Parameters 18 C...

Page 4: ...active reverse input 8 fig 6 Wiring to inhibit plug braking 9 fig 7 Wiring for mechanical reversing 10 fig 8 Wiring for Type 0 throttles 10 fig 9 Wiring for Type 1 3 4 and 5 throttles 11 fig 10 Wirin...

Page 5: ...their length the 1204M and 1205M look the same as do the 1209M and 1221M Like all Curtis controllers the 1204M 05M 09M 21M models offer superior operator control of motor drive performance Features i...

Page 6: ...ds 3 Easily programmable through the Curtis handheld programmer or PC programming station Familiarity with your Curtis 1204M 05M 09M 21M controller will help you install and operate it properly We enc...

Page 7: ...sible It is recommended that the controller be fastened to a clean flat metal surface with four M6 bolts using the holes provided The mounting surface is an integral part of the overall heatsinking of...

Page 8: ...nd before attempting any work on the motor control circuitry HIGH CURRENT ARCS Batteries can supply very high power and arcing can occur if they are short circuited Always open the battery circuit bef...

Page 9: ...ailure to use the double wrench technique could cause undue strain to be placed on the internal connections and could also result in cracked seals around the busbars Low current connections These cont...

Page 10: ...G Connections Table 3 J4 Connector Pinout PIN PROGRAMMER STATUS LED J4 1 Data input from programmer Rx Status LED enable J4 2 Ground Ground J4 3 Data output to programmer Tx Status LED output J4 4 15...

Page 11: ...you wish to limit reverse speed you will need to add a speed reduction resistor Wiring with active reverse input For this option set the Rev Input Main Driver parameter 1 see page 24 and wire the cont...

Page 12: ...is used KSI draws up to 130 mA with the programmer connected and up to 70 mA without the programmer In its simplest form KSI is operated by a keyswitch that turns the ve hicle off and prevents unautho...

Page 13: ...keyswitch and any interlocks The coil of one contactor or the other is energized to select the direction desired Freewheeling wiring to inhibit plug braking If plug braking is not desired the vehicle...

Page 14: ...6 V input Type 8 single ended 6 12 V input Type 9 single ended 3 wire potentiometer 0 5k Throttle Type 0 Wiring forType 0 throttles is simple just connect the two wires to the J2 and J3 push on termi...

Page 15: ...that the accelerator pedal hit a mechanical stop at its full on position just before 1 mm the potbox lever hits its own full on stop This mechanical stop will prevent the potbox lever arm from bending...

Page 16: ...resistor should be sized to provide a 0 5V signal variation over the full current range It is the responsibil ity of the OEM to provide appropriate throttle fault detection The Curtis ET XXX electroni...

Page 17: ...2 INSTALLATION WIRING Throttle Wiring Fig 10 Wiring for Type 2 throttles Curtis ET XXX Electronic Throttle Voltage Source Current Source Curtis 1204M 1205M 1209M 1221M Manual 13...

Page 18: ...ON WIRING Throttle Wiring Pump Applications Fig 11 Basic wiring diagram Curtis 1204M 6302 motor controller for pump applications STATUS LED MOTOR FIELD A2 5k THROTTLE PRECHARGE RESISTOR 250 5 W MOTOR...

Page 19: ...to 200 ohms 5 watts or a 100 watt light bulb The voltage at the controller should rise to approximately 90 of the full battery voltage C If A and B do not check out troubleshoot the wiring connections...

Page 20: ...at are intended to plug brake test the plug braking by driv ing forward at moderate speed and shifting into reverse without letting up on the throttle The vehicle should smoothly brake to a stop and a...

Page 21: ...ry Voltage Undervoltage Cutback Undervoltage Cutback Rate Undervoltage Cutoff Current Main Current Limit Plug Current Limit Speed Accel Rate Quick Start Max Speed Rev Speed Throttle Throttle Type Thro...

Page 22: ...Under Voltage Cutback Rate 0 110 A The Under Voltage Cutback Rate determines how quickly the controller output will be reduced when battery voltage falls below the programmed Under Voltage Cutback th...

Page 23: ...ottle The vehicle brakes smoothly to a stop and then accelerates in the other direction The plug braking current limit is set by this parameter Plug braking can be either fixed or throttle variable se...

Page 24: ...Accel Rate Max Speed 20 100 Defines the maximum requested motor speed at full forward throttle as PWM Partially applied throttle is scaled proportionately e g 40 applied throttle corresponds to a req...

Page 25: ...fined wide enough to ensure that the controller goes into neutral when the throttle mechanism is released Throttle Max 10 100 The Throttle Max parameter defines the percentage of throttle movement at...

Page 26: ...full range THROTTL E COMMAN D percenta ge of Max Speed Map adjusts the knee in the output this knee is at an 80 Map setting Deadband parameter adjusts this endpoint 100 80 60 40 20 0 100 90 80 70 60...

Page 27: ...cts that the motor is about to stall the boost feature provides a short burst of extra torque by briefly applying a current higher than the rated current This can be useful for occasionally getting th...

Page 28: ...function included here Select Get settings from controller to copy the settings into the programmer Plug the programmer into the controller that you want to have these same settings and select Write s...

Page 29: ...C Heatsink temperature Throttle Throttle request as percentage of full throttle Duty Cycle Controller s PWM output as percentage of programmed Max Speed Cap Voltage V Voltage of controller s internal...

Page 30: ...LT CODES LED CODES EXPLANATION LED off no power or defective controller solid on controller or microprocessor fault 0 1 controller operational no known faults 1 1 EEPROM fault 1 2 MOSFET short fault 1...

Page 31: ...controller to operate in a manner that is safe in the presence of that fault Depending on the severity of the fault the response can range from reducing current to complete shutdown The troubleshootin...

Page 32: ...Fault PWM output and main Check the connections and 1 Main contactor coil is shorted contactor disabled replace the main contactor 2 Internal driver transistor is if necessary shorted 3 2 Main Weld F...

Page 33: ...nts 5 Controller thermistor damaged 4 4 Over Temperature PWM output disabled Heatsink temperature 1 Heatsink temperature exceeds 100 C the Temperature Cutoff threshold 110 C Note Faults related to the...

Page 34: ...controller 1 Remove power by disconnecting the battery 2 Discharge the capacitors in the controller by connecting a load such as a contactor coil across the controller s B and B terminals 3 Remove any...

Page 35: ...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 switc...

Page 36: ...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 Farad...

Page 37: ...providing suf cient 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...

Page 38: ...ly the User level whereas an OEM programmer has full access PC PROGRAMMING STATION 1314 The Programming Station is an MS Windows 32 bit application that runs on a standard Windows PC Instructions for...

Page 39: ...2A electronics sealed to IP54 Dimensions L W H Weight 1204M 173 146 77 mm 2 3 kg 1205M 199 146 77 mm 2 7 kg 1209M 229 180 80 mm 3 8 kg 1221M 281 180 80 mm 4 9 kg Regulatory compliance Designed to the...

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