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Curtis PMC 1204 Series Manual
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Curtis PMC 1204 Series Manual

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CURTIS PMC
235 East Airway Boulevard
Livermore, California 94568 USA
Tel: 925-961-1088
Fax: 925-961-1099
www.curtisinst.com
MANUAL
1204X/1205X
and
MOTOR CONTROLLERS
© 1999 CURTIS INSTRUMENTS, INC.
DESIGN OF CURTIS PMC 1200 SERIES
CONTROLLERS PROTECTED BY U.S.
PATENT NO. 4626750.
1204X / 1205X / 1209 / 1221 Manual
1209/1221
p/n 98796, Rev. D: May 1999

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Summary of Contents for Curtis PMC 1204 Series

  • Page 1 MANUAL 1204X/1205X 1209/1221 MOTOR CONTROLLERS © 1999 CURTIS INSTRUMENTS, INC. DESIGN OF CURTIS PMC 1200 SERIES CONTROLLERS PROTECTED BY U.S. PATENT NO. 4626750. CURTIS PMC 235 East Airway Boulevard 1204X / 1205X / 1209 / 1221 Manual Livermore, California 94568 USA p/n 98796, Rev.
  • Page 2 1204X / 1205X / 1209 / 1221 Manual p/n 98796, Rev. D: May 1999 © 1999 CURTIS INSTRUMENTS, INC. This electronic version of the 1204X/1205X/1209/1221 manual is offered as a conve- nience to our customers. You may download any or all of it.
  • Page 3 1 2 3 4 5 6 7 8 9 0 1 1 2 3 4 5 6 7 8 9 0 1 Bypass wiring ............19 1 2 3 4 5 6 7 8 9 0 1 Curtis PMC 1204X/1205X/1209/1221 Manual...
  • Page 4 1 2 3 4 5 6 7 8 9 0 1 Electrical Specifications ........ C-1 APPENDIX C 1 2 3 4 5 6 7 8 9 0 1 1 2 3 4 5 6 7 8 9 0 1 Curtis PMC 1204X/1205X/1209/1221 Manual...
  • Page 5 . 3: Mounting dimensions, Curtis PMC 1209/21 controllers ........ 3 . 4: Mounting dimensions, Curtis PMC potboxes PB-5, -6, -9, and -10 ....6 . 5: Mounting dimensions, Curtis PMC footpedal ... 6 . 6: Mounting dimensions, Curtis electronic throttle (ET series) ......7 .
  • Page 6 FIGURES/TABLES . 14: Reduced speed operation (with standard (0–5kΩ pot) ............. 17 . 15: Curtis electronic throttle (ET series) with a controller having the optional 0–5V throttle input ..........18 . 16: Adjustment pots ............23 . 17: Guide to troubleshooting procedures ....... 27 .
  • Page 7 Models 1204X, 1209, and 1221 have identical connections. Like all Curtis PMC 1200 series controllers, the 1204X/1205X and 1209/1221 models offer superior operator control of the vehicle’s motor drive speed. Key features of these controllers include: Infinitely variable drive and brake control Power MOSFET design provides high efficiency (for reduced motor and...
  • Page 8 Tin-plated solid copper bus bars Push-on connectors for control wiring Familiarity with your Curtis PMC controller will help you to install and operate it properly. We encourage you to read this manual carefully. If you have questions, please contact the Curtis office nearest you.
  • Page 9 22 × 19 × 3 (0.85 × 0.75 × 0.125) 6 (0.25) male push-on, 2 plcs 133 (5.25) 1204X: 174 (6.85) MODEL 1205X: 225 (8.85) MODEL 1204X: 19 (0.75) 1205X: 44 (1.75) (0.13) Dimensions in millimeters and (inches) Curtis PMC 1204X/1205X/1209/1221 Manual...
  • Page 10 25 × 19 × 5 (1.0 × 0.75 × 0.187) 6 (0.25) male push-on, 2 plcs 37 (1.45) 1209: 152 (6.0) MODEL 1221: 203 (8.0) MODEL 1209: 231 (9.1) MODEL 1221: 282 (11.1) MODEL (0.13) Dimensions in millimeters and (inches) Curtis PMC 1204X/1205X/1209/1221 Manual...
  • Page 11 ≈300 ohms, full output is ≈4400 ohms) will work with the standard throttle input. For other types, contact your Curtis office. If a Curtis PMC potbox is used, it must be mounted so as to allow connection between the potbox lever arm and the vehicle accelerator linkage.
  • Page 12 = throttle input = switch, common (Note: The green wire is not used with BLACK BLUE = throttle input = switch, normally open 1204X/1205X/1209/1221 controllers) WHITE ORANGE Dimensions in millimeters and (inches) Curtis PMC footpedal FP-2. Fig. 5 Curtis PMC 1204X/1205X/1209/1221 Manual...
  • Page 13 The negative side of the 5V source should be referenced to B- and must be capable of driving an input impedance of 5kΩ. Curtis offers two bi-directional, wigwag electronic throttle assemblies de- signed for use with the 0–5V input: the ET series and the CH series.
  • Page 14 BYPASS CONTACTOR PRECHARGE RESISTOR, such as Curtis PMC p/n MP-2 SERIES MOTOR COIL SUPPRESSION DIODE, such as Curtis PMC p/n MP-1 Pedal microswitch not used with SRO controllers.) See Figure 10 for emergency reverse.) Typical installation, Curtis PMC 1204X/1205X/1209/1221 controllers.
  • Page 15 Albright SW80 or SW180 (available from Curtis). A coil suppression diode, such as a Curtis PMC p/n MP-1 (which is rated at 100 volts, 3 amps), should be used on the contactor coil. The rapid charging of the controller’s internal filter capacitors causes a high inrush current to flow briefly when the contactor closes.
  • Page 16 B+ feed to the control circuitry wiring is recommended. Power Wiring Fuse To protect the power wiring circuit, a fuse appropriate for the controller’s rated current (see Appendix C) is recommended. Curtis PMC 1204X/1205X/1209/1221 Manual...
  • Page 17 PART NUMBER DESCRIPTION #640426-7 locking, insulation displacement terminals, wires at right angle to connector Methode #3300-107-218 locking, insulation displacement terminals Molex #09-50-3071 locking, crimp terminals Panduit #CE156F18-7 locking, insulation displacement terminals, wires at right angle to connector Curtis PMC 1204X/1205X/1209/1221 Manual...
  • Page 18 WIRING: TYPICAL INSTALLATION Curtis PMC 1204X/1205X/1209/1221 controllers are designed to satisfy the requirements of material handling applications using series motors. Figure 8 is a schematic diagram of the installation shown in Figure 7. Wired this way, the vehicle will plug brake if the direction is changed with the vehicle moving and the throttle applied.
  • Page 19 field winding. Be careful if you are replacing this type of controller. When using the Curtis PMC controller it is essential that the field be reversed and that the armature be connected directly to the controller’s B+ and A2 terminals, because the plug diode inside is connected to these terminals.
  • Page 20 Bypass cont. output Emergency reverse (see Fig. 10) FWD input REV input Plug braking can be reactivated during freewheeling by releasing the throttle and reapplying it. : Contact factory for information on wiring SRO controllers for NOTE freewheeling. Curtis PMC 1204X/1205X/1209/1221 Manual...
  • Page 21 REVERSE RELAY – EMERGENCY REVERSE: EMERGENCY REVERSE: 5kΩ–0 pot 0–5kΩ pot 0–5kΩ 5kΩ–0 F/R cont. output Bypass cont. output Emergency reverse 5kΩ FWD input REV input Wiring for emergency reverse (enhanced plug braking current). Fig. 10 Curtis PMC 1204X/1205X/1209/1221 Manual...
  • Page 22 Throttle Pot Wiring Standard Potbox Wiring If the throttle input to the controller is from a Curtis PMC potbox or footpedal, the wiring is simple: just connect the two wires of the potbox/footpedal cable to the two push-on terminals of the controller, as shown in Figure 8. It doesn’t matter which wire goes on which terminal.
  • Page 23 INPUT SWITCH SPEED REDUCTION RESISTOR APPROX. % OF ORIGINAL TOP SPEED The speed reduction shown in the curve is approximate. The actual vehicle top speed will depend on the motor characteristics and the vehicle load. You Curtis PMC 1204X/1205X/1209/1221 Manual...
  • Page 24 Unlike resistor controllers, Curtis PMC controllers operate efficiently in the reduced speed mode, because little power is lost through the controller. Electronic Throttle Wiring Curtis’s electronic throttle, ET-XXX, is wired as shown in Figure 15. It requires a controller with the optional 0–5V throttle input. Curtis electronic Fig.
  • Page 25 Another problem is that plug braking could not be used without adding external circuitry. These controllers are not recom- mended for use with PM magnet motor systems. Consult your Curtis office for controllers compatible with PM motors.
  • Page 26 Apply the throttle, turn the keyswitch on, and then select a direction. The motor should not run. Release the throttle and re-apply it — the motor should now run. If the motor runs before you release the throttle, recheck the wiring. Curtis PMC 1204X/1205X/1209/1221 Manual...
  • Page 27 If the belly button is pushed while the vehicle is moving backwards (away from the operator), the vehicle will accelerate to full speed but will not change direction. Curtis PMC 1204X/1205X/1209/1221 Manual...
  • Page 28 MAINTENANCE & ADJUSTMENT MAINTENANCE & ADJUSTMENT Curtis PMC 1204X/1205X/1209/1221 controllers and potboxes require only minimal maintenance if properly installed. : The controllers are sealed and NOTE thus are not field serviceable. CONTROLLER Maintenance It is recommended that the following two steps be performed occasionally. First...
  • Page 29 (with a moist rag) as required. Adjustment Curtis PMC potboxes are factory set and rarely require user attention. To test and adjust, connect an ohmmeter to the potbox wires and use this procedure: 1. With the spring holding the lever arm against the return stop, the resistance should be less than 50 ohms.
  • Page 30 If it does not, adjust by loosening the two screws holding the slotted microswitch mounting plate to the stop spacers and moving the plate. Recheck the switch operating point after tightening the screws. Curtis PMC 1204X/1205X/1209/1221 Manual...
  • Page 31 The controllers themselves are sealed and not field serviceable; contact your local Curtis PMC service center if the problem is in the controller. The diagnostic section provides enough detail to enable you to track circuitry problems to their source and repair them.
  • Page 32 16 volts. Refer to the specifications (Appendix C) for other models. Hot Controller If the controller gets hot, it does not necessarily indicate a serious problem. Curtis PMC 1204X/1205X/1209/1221 controllers protect themselves by reducing power to the motor if their internal temperature exceeds 75°C (167°F). Power output will be reduced for as long as the overheat condition remains, and full power will return when the unit cools.
  • Page 33 Check current in controller’s M- (motor field) lead while circuit. If current is high but depressing pedal. 4-D, E motor won’t turn, check motor, if NO Current should be high, and motor should turn. wiring & plug diode. 4-F, G, H, I Curtis PMC 1204X/1205X/1209/1221 Manual...
  • Page 34 If the contactor and KSI terminal are not getting voltage, that’s the problem. Use the voltmeter to find out where it is not getting through. Connect the voltmeter (-) to the controller’s B- terminal and check the following points with the voltmeter (+) lead to trace the flow: Curtis PMC 1204X/1205X/1209/1221 Manual...
  • Page 35 Actuate the pedal and verify that the potbox lever moves from contacting the pedal-up stop to nearly contacting the pedal-down stop. If the mechanical operation looks okay, replace the potbox. Curtis PMC 1204X/1205X/1209/1221 Manual...
  • Page 36 If the voltages are still out of range, the controller is at fault and should be replaced. Curtis PMC 1204X/1205X/1209/1221 Manual...
  • Page 37 If your meter has a diode test function, use it. Curtis PMC 1204X/1205X/1209/1221 Manual...
  • Page 38 • a THROTTLE POTBOX. For controllers with the standard throttle input configuration (a 5 kΩ pot wired as a two-terminal rheostat), a Curtis PMC potbox or any 5 kΩ pot will work fine. For controllers with other input options, use whatever kind of throttle is used on the vehicle.
  • Page 39 F/R SWITCH CONTACTOR FORWARD REVERSE F/R CONTACTOR POWER KEYSWITCH SWITCH POWER SUPPLY (to match your controller) POTBOX (to match your controller’s throttle output) TEST LOAD (to match battery voltage) FAULT SWITCH Setup for bench testing. Fig. 18 Curtis PMC 1204X/1205X/1209/1221 Manual...
  • Page 40 G. With the controller on and operating in the forward direction, check the controller’s fault detect feature as follows: 1. Move the throttle to full on. The lamps should be at full brightness. Curtis PMC 1204X/1205X/1209/1221 Manual...
  • Page 41 With the throttle still in the ON position, reconnect the wire. The lamps should smoothly increase in brightness to their previous level. Finally, remove the controller from the test setup and check its internal plug diode, as described in Troubleshooting Procedure Curtis PMC 1204X/1205X/1209/1221 Manual...
  • Page 42 A fuse should be installed in the power wiring circuit to protect the motor when using bypass. Curtis PMC controllers are so efficient that the difference in efficiency when operating with and without bypass is negligible. The main advantage of bypass is the additional torque it can provide in overload conditions.
  • Page 43 If the fault has been corrected, the controller will turn back on. Current limiting Curtis PMC controllers limit the motor current to a preset maximum. This feature protects the controller from damage that might result if the current were limited only by motor demand.
  • Page 44 ET-series electronic throttles The ET-XXX is a wigwag-style throttle control assembly, manufactured by Hardellet for Curtis. It provides a 0–5V signal in both the forward and reverse directions along with high side coil drivers for the forward and reverse contactor coils.
  • Page 45 HPD feature. Wiring details are provided in Section 3. A 1 kHz tone may be heard during plug braking. This noise is normal and indicates that plugging is taking place. The noise will stop when the plug braking stops. Curtis PMC 1204X/1205X/1209/1221 Manual...
  • Page 46 PWM (Pulse Width Modulation), also called “chopping,” is a technique that switches battery voltage to the motor on and off very quickly, thereby controlling the speed of the motor. Curtis PMC 1200 series controllers use high frequency PWM—15 kHz—which permits silent, efficient operation. PWM is described in more detail in Appendix B.
  • Page 47 Thermal protection Because of their efficiency and thermal design, Curtis PMC controllers should barely get warm in normal operation. Overheating can occur, however, if the controller is undersized for its application or otherwise overloaded. If the internal temperature of the controller exceeds 75°C (167°F), the main and plug current...
  • Page 48 (Appendix C). Reducing the output to the motor allows the battery voltage to recover, and an equilibrium is established in which the battery supplies as much current as it can without falling below the cutback voltage. Curtis PMC 1204X/1205X/1209/1221 Manual...
  • Page 49 FAULT FAULT INPUT CONDITIONING RELEASE INHIBIT DETECT TIMER Block diagram, Curtis PMC 1204X/1205X/1209/1221 controllers. Fig. A-1 These controllers consist of three sections: (1) a , (2) a , which drives the POWER SECTION LOGIC SECTION power section, and (3) an , which enables and monitors the power and logic sections.
  • Page 50 These pulses become the input to the controller’s main power MOSFET switch via a gate drive circuit that provides the high pulse currents needed to turn the Curtis PMC 1204X/1205X/1209/1221 Manual...
  • Page 51 fixed value. Plug current limit will be at this enhanced level, independent of accelerator position, even if the variable plug option is installed. Emergency reverse plug current level is set to customer specifica- tions during manufacture and is not user adjustable. Curtis PMC 1204X/1205X/1209/1221 Manual...
  • Page 52 (≈10µs) to turn off the contactor driver(s) and then waits approximately 10 ms before trying to turn them back on again. If the coil short is still present, over-current control will keep trying to turn back off and on until Curtis PMC 1204X/1205X/1209/1221 Manual...
  • Page 53 “reverse” and “full speed”. The vehicle is suddenly reversed (if in forward) and the controller goes into enhanced plug braking mode to slow the vehicle to a stop before it accelerates away from the operator in reverse. Curtis PMC 1204X/1205X/1209/1221 Manual...
  • Page 54 The control current ramps up and down as the switch turns on and off. Average current, which determines motor torque, is controlled by the ratio of on/off times. Smooth, stepless control of the power delivered to the motor is achieved with almost no power loss in the control components. Curtis PMC 1204X/1205X/1209/1221 Manual...
  • Page 55 (amps) NUMBER 1204X -12XX 0.35 -14XX 400* 0.25 -42XX 24–36 0.35 -44XX 24–36 400* 0.25 -52XX 36–48 0.35 1205X -14XX 0.25 -16XX 500* 0.20 -44XX 24–36 0.25 -46XX 24–36 500* 0.20 -53XX 36–48 0.35 30-second rating Curtis PMC 1204X/1205X/1209/1221 Manual...
  • Page 56 (volts) (volts) (amps) NUMBER 1209 -46XX 24–36 0.15 -55XX 36–48 0.30 -64XX 48–72 0.30 -6A5XX 48–80 0.25 -72XX 72–120 0.70 1221 -48XX 24–36 0.10 -57XX 36–48 0.25 -66XX 48–72 0.25 -6A7XX 48–80 0.20 -74XX 72–120 0.50 Curtis PMC 1204X/1205X/1209/1221 Manual...

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