Curtis 1204M Manual
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Curtis 1204M Manual

Motor controllers
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C
I
I
URTIS
NSTRUMENTS,
200 Kisco Avenue
Mt. Kisco, New York 10549 USA
Tel. 914.666.2971
Fax 914.666.2188
www.curtisinstruments.com
NC.
1204 M
1205 M
MOTOR CONTROLLERS
© 2009 CURTIS INSTRUMENTS, INC.
DESIGN OF CURTIS PMC 1200 SERIES
CONTROLLERS PROTECTED BY U.S.
PATENT NO. 4626750.
1204M/1205M Manual, p/n 53113
Rev. A: December 2009

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  • Page 1 1204 M 1205 M MOTOR CONTROLLERS © 2009 CURTIS INSTRUMENTS, INC. DESIGN OF CURTIS PMC 1200 SERIES CONTROLLERS PROTECTED BY U.S. PATENT NO. 4626750. 1204M/1205M Manual, p/n 53113 Rev. A: December 2009 URTIS NSTRUMENTS, 200 Kisco Avenue Mt. Kisco, New York 10549 USA Tel.

  • Page 3: Table Of Contents

    Controller Cloning ............21 4. MONITOR MENU..............22 5. DIAGNOSTICS AND TROUBLESHOOTING ....23 6. MAINTENANCE ..............26 EMC & ESD Design Considerations APPENDIX A Curtis WEEE & RoHS Statement APPENDIX B Programmer Operation APPENDIX C 1204M / 1205M Controller Specifications APPENDIX D Curtis 1204M/1205M Manual...
  • Page 4 Curtis 1311 handheld programmer........C-1 TABLES High current connections.............5 TABLE Low current connections ............5 TABLE J4 connector pinout .............6 TABLE Status LED fault codes ............23 TABLE Troubleshooting chart ............25 TABLE D-1: Specifications, 1204M / 1205M controllers ....D-1 TABLE Curtis 1204M/1205M Manual...

  • Page 5: Overview

    In addition to configuration flexibility, use of the programmer offers diagnostic and test capability. Curtis 1204M and 1205M controllers are the ideal solution for a variety of electric vehicle applications, including industrial trucks, personnel carriers, material handing vehicles, golf cars, etc.
  • Page 6 ✓ Rugged anodized aluminum extruded housing meets IP65 environmental sealing standards for use in harsh environments. Familiarity with your Curtis 1204M/05M controller will help you install and operate it properly. We encourage you to read this manual carefully. If you have questions, please contact the Curtis office nearest you.

  • Page 7: Installation And Wiring

    INSTALLATION AND WIRING MOUNTING THE CONTROLLER The outline and mounting hole dimensions for the 1204M and 1205M controllers are shown in Figure 2. The controller meets the IP65 requirements for envi- ronmental protection against dust and water. Nevertheless, in order to prevent external corrosion and leakage paths from developing, the mounting location should be carefully chosen to keep the controller as clean and dry as possible.
  • Page 8 EMC performance complies with applicable regulations; suggestions are presented in Appendix A. The 1204M and 1205M controllers contain ESD-sensitive components. Use appropriate precautions in connecting, disconnecting, and handling the controller. See installation suggestions in Appendix A for protecting the con- troller from ESD damage.

  • Page 9: Connections: High Current

    Low current connections The 1204M/05M controllers have four low-current connections: three 6.35mm push-on terminals ( – ), and one 4-pin connector ( Table 2 Low Current Connections Key switch connection.

  • Page 10: Table 3 J4 Connector Pinout

    Data output to programmer (Tx). Status LED output. J4-4 +15 V. +15 V. Note: When J4 is used for a Status LED, a jumper must be added between pins J4-1 and J4-4 as shown in the basic wiring diagram (Figure 3). Curtis 1204M/1205M Manual...

  • Page 11: Controller Wiring: Basic Configuration

    Standard Wiring Diagram CONTROLLER WIRING: BASIC CONFIGURATION A basic wiring diagram for the 1204M/05M controller is shown in Figure 3. The throttle shown in the diagram is a 2-wire potentiometer; voltage throttles can also be used. (For pump operation, see Figure 9 on page 12).

  • Page 12: Forward/Reverse Wiring

    KSI and the contactors. Forward/Reverse Wiring With 1204M/05M controllers, it is essential that the field be reversed and that the armature be connected directly to the controller’s B+ and A2 ter- minals, because the plug diode inside is connected to these terminals;...

  • Page 13: Throttle Wiring

    – B– M– Throttle Wiring Three types of throttle can be used with 1204M/05M controllers: Type 0, which is a 0–5kΩ two-wire rheostat; Type 1, a 5kΩ–0 2-wire rheostat; and Type 3, a voltage throttle. Throttle Type 0 Wiring for Type 0 throttles is simple: just connect the two wires to the J2 and J3 push-on terminals;...
  • Page 14 Figure 8, and they have varying levels of throttle fault protection. When a voltage source is used as a throttle, it is the responsibility of the OEM to provide appropriate throttle fault detection. For ground-referenced Curtis 1204M/1205M Manual...
  • Page 15 2 — INSTALLATION & WIRING: Throttle Wiring Fig. 8 Wiring for Type 2 Voltage Source throttles. Current Source Curtis ET-XXX Electronic Throttle – Curtis 1204M/1205M Manual...

  • Page 16: Wiring Configuration For Pump Applications

    There are many electronic footpedals on the market; for wiring, consult the instructions that are provided with the footpedal. Basic Wiring Configuration for Pump Applications The 1204M/05M controller models with only three busbars are appropriate for use with pump motors, wired as shown in Figure 9. CONTROL WIRING...

  • Page 17: Installation Checkout

    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 1204M/1205M Manual...
  • Page 18 The vehicle should smoothly brake to a stop and accelerate in reverse. I. On vehicles that are intended to have plug braking inhibited, verify that the maneuver in “H” produces freewheel coasting. Curtis 1204M/1205M Manual...

  • Page 19: Programmable Parameters

    3 — PROGRAMMABLE PARAMETERS PROGRAMMABLE PARAMETERS The 1204M/1205M controllers have a number of parameters that can be adjusted using a Curtis 1311 handheld programmer or the Curtis 1314 PC program- ming station. These programmable parameters allow the vehicle’s performance to be customized to fit the needs of specific applications. For information on programmer operation, see Appendix C.

  • Page 20: Basic Parameters

    RANGE DESCRIPTION Voltage 36V / 48V Each controller has two available battery voltage settings. For all 1204M controller models and the 1205M-5601 and 1205M-5602 controllers, voltage can be set to either 36 volts or 48 volts. 60V / 72V For 1205M-6B401 and 1205M-6B402 controllers, voltage can be set to either 60 volts or 72 volts.

  • Page 21: Speed And Acceleration Parameters

    When the throttle is moved from zero rapidly, the quick start feature is activated. The Quick Start acceleration rate then replaces the normal acceleration rate (as set by the Accel Rate parameter). The Quick Start parameter can only be set to values smaller (faster) than the programmed Accel Rate. Curtis 1204M/1205M Manual...

  • Page 22: Throttle Input Parameters

    ALLOWABLE PARAMETER RANGE DESCRIPTION Throttle Type 0–2 The 1204M/05M controller accepts a variety of throttle inputs. The Throttle Type parameter can be programmed as follows: 2-wire rheostat, 0–5kΩ input 2-wire rheostat, 5kΩ–0 input single-ended 0–5V input. Throttle Deadband 5–30 % The Throttle Deadband parameter defines the neutral deadband as a...

  • Page 23: Fig. 10 Effect Of Throttle Adjustment Parameters

    3 — PROGRAMMABLE PARAMETERS: Throttle Parameters Fig. 10 Effect of throttle adjustment parameters. In the examples shown in this figure, Deadband = 10% Max = 80%. Curtis 1204M/1205M Manual...

  • Page 24: Undervoltage Parameters

    The allowable ranges depend on battery size, as follows. 36V battery: 24–36 V 48V battery: 32–48 V 60V battery: 39–60 V 72V battery: 48–72 V. Adjustments can be made in 1V increments. Curtis 1204M/1205M Manual...

  • Page 25: Other Parameters

    For example, the programmer can read all the information from a 1204M-5201 controller and write it to other 1204M-5201 controllers; however, it cannot write that same information to 1204M-5204 controllers. To perform cloning, plug the programmer into the controller that has the desired settings.

  • Page 26: Monitor Menu

    Throttle Throttle request Duty Cycle Controller’s PWM output, as percentage of programmed Max Speed. Motor Open On/Off Status of motor connection. A2 Voltage Voltage on controller’s A2 busbar. Plug Braking On/Off Plug braking feature on or off. Curtis 1204M/1205M Manual...

  • Page 27: Diagnostics And Troubleshooting

    5 — DIAGNOSTICS & TROUBLESHOOTING DIAGNOSTICS AND TROUBLESHOOTING The 1204M/05M controller detects a wide variety of faults or error conditions. Fault information can be obtained in either of two ways: (1) by observing the fault codes issued by the external Status LEDs or (2) by reading the display on a 1311 programmer.
  • Page 28 If not, shut off KSI and remove the J-1, J-2, and J-3 connectors. Check the connectors for corrosion or damage, clean them if necessary, and re-insert them. Curtis 1204M/1205M Manual...

  • Page 29: Table 5 Troubleshooting Chart

    -25°C and 2. Improper mounting of factory-set temperature controller. cutback setpoint. 3. Operation in extreme environments. 4. Thermistor damaged. Overtemperature PWM output disabled. Heatsink temperature 1. Heatsink temperature above below the factory-set the factory-set overtemperature overtemperature limit. limit. Curtis 1204M/1205M Manual...

  • Page 30: Maintenance

    6 — MAINTENANCE MAINTENANCE There are no user serviceable parts in the Curtis 1204M/05M controller. No attempt should be made to open, repair, or otherwise modify the control- ler. Doing so may damage the controller and will void the warranty.

  • Page 31: Appendix Aemc & Esd Design Considerations

    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.
  • Page 32 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.
  • Page 33 ELECTROSTATIC DISCHARGE (ESD) Curtis 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.
  • Page 34 The requirement to mark equipment with the WEEE symbol (the crossed-out wheeled bin) went into effect as of August 13, 2005. As of this date, Curtis In- struments began the process of marking all products that fall within scope of this directive with the WEEE symbol, as shown opposite.
  • Page 35 Curtis firmly believes that the operating environments, safety requirements, and reliability levels required of automotive electronics are directly analogous to that of our speed controller products. As such, Curtis will not be switching to a lead-free solder process until lead-free solder pastes and techniques are available that meet the requirements of the RoHS study groups and ELV Automotive In- dustry bodies.

  • Page 36: Fig . C-1: Curtis 1311 Handheld Programmer

    APPENDIX C: PROGRAMMER OPERATION APPENDIX C PROGRAMMERS Curtis programmers provide programming, diagnostic, and test capabilities for 1212 controllers. 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;...
  • Page 37 — 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. Curtis 1204M/1205M Manual...
  • Page 38 ISTA 2A; electronics sealed to IP65 Weight 1204M: 2.3 kg; 1205M: 2.7 kg Dimensions (L× W×H) 1204M: 174 × 146 × 77 mm 1205M: 199 × 146 × 77 mm Regulatory compliance Safety — Designed to the requirements of EN 1175 EMC —...

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