Curtis Instruments 1232 User manual

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IV #URTIS-ANUAL/3 
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&)' #URTISANDCONTROLLERS 
&)'A -OUNTINGDIMENSIONS#URTISCONTROLLER 
&)'B -OUNTINGDIMENSIONS#URTISCONTROLLER 
&)'C -OUNTINGDIMENSIONS#URTISCONTROLLERS 
&)' "ASICWIRINGDIAGRAM 
&)' 7IRINGFOR4YPETHROTTLES 
&)' 7IRINGFOR4YPETHROTTLES 
&)' 7IRINGFOR4YPETHROTTLES 
&)' !CCELERATIONRESPONSERATEDIAGRAM 
&)' "RAKINGRESPONSERATEDIAGRAM 
&)' 4HROTTLEMAPPINGTORQUECONTROLMODE 
&)' %FFECTOFGEARSOFTENPARAMETERTORQUECONTROLMODE 
&)' %FFECTOFBRAKETAPERSPEEDPARAMETERTORQUECONTROLMODE 
&)' $RIVECURRENTLIMITINGMAP 
&)' 2EGENCURRENTLIMITINGMAP 
&)' 4HROTTLEADJUSTMENT 
&)' 6#,MOTORCOMMANDDIAGRAM 
&)' 6#,CONTROLMODEPROCESSING 
&)' 6#,PROPORTIONALDRIVERPROCESSING 
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ANDMOTORCONTROLLERS
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9OUWILLNEEDTOTAKESTEPSDURINGTHEDESIGNANDDEVELOPMENTOFYOUR
END PRODUCT TO ENSURE THAT ITS %-# PERFORMANCE COMPLIES WITH APPLICABLE
REGULATIONSSUGGESTIONSAREPRESENTEDIN!PPENDIX"
4HE  CONTROLLERS CONTAIN %3$SENSITIVE COMPONENTS
5SEAPPROPRIATEPRECAUTIONSINCONNECTINGDISCONNECTINGANDHANDLINGTHE
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""56AND7
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&IVEALUMINUM-TERMINALSAREPROVIDED,UGSSHOULDBEINSTALLEDASFOLLOWS
USING-BOLTSSIZEDTOPROVIDEPROPERENGAGEMENTSEEDIAGRAM
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s )FTWOLUGSAREUSEDONTHESAMETERMINALSTACKTHEMSOTHE
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(IGHCURRENTWIRINGRECOMMENDATIONS ALLMODELS
"ATTERYCABLES""
4HESE TWO CABLES SHOULD BE RUN CLOSE TO EACH OTHER BETWEEN THE CONTROLLER
ANDTHEBATTERY5SEHIGHQUALITYCOPPERLUGSANDOBSERVETHERECOMMENDED
TORQUERATINGS&ORBESTNOISEIMMUNITYTHECABLESSHOULDNOTRUNACROSSTHE
CENTERSECTIONOFTHECONTROLLER7ITHMULTIPLEHIGHCURRENTCONTROLLERSUSEA
STARGROUNDFROMTHEBATTERY"TERMINAL
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4HETHREEPHASEWIRESSHOULDBECLOSETOTHESAMELENGTHANDBUNDLEDTOGETHER
ASTHEYRUNBETWEENTHECONTROLLERANDTHEMOTOR4HECABLELENGTHSSHOULDBE
KEPTASSHORTASPOSSIBLE5SEHIGHQUALITYCOPPERLUGSANDOBSERVETHERECOM
MENDEDTORQUERATINGS&ORBESTNOISEIMMUNITYTHEMOTORCABLESSHOULDNOT
RUNACROSSTHECENTERSECTIONOFTHECONTROLLER)NAPPLICATIONSTHATSEEKTHELOWEST
POSSIBLEEMISSIONSASHIELDCANBEPLACEDAROUNDTHEBUNDLEDMOTORCABLESAND
CONNECTEDTOTHE"TERMINALATTHECONTROLLER4YPICALINSTALLATIONSWILLREADILY
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NOTBERUNPARALLELTOTHEMOTORCABLES7HENNECESSARYTHEYSHOULDCROSSTHE
MOTORCABLESATARIGHTANGLETOMINIMIZENOISECOUPLING
,UGASSEMBLY ANDMODELS
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-BOLTSSIZEDTOPROVIDEPROPERENGAGEMENTSEEDIAGRAM
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WASHERWITHITSCONVEXSIDEONTOP4HEWASHERSHOULDBEA
3#(./22OREQUIVALENT
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ATOMMDIAMETERTHINWALLINSULATION
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MOTORANDCONTROLLERLOGICCONNECTOR4HESECANOFTENBERUNWITHTHERESTOF
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MANYSUCCESSFULAPPLICATIONSATK"AUDARERUNWITHOUTTWISTINGSIMPLY
USINGTWOLINESBUNDLEDINWITHTHERESTOFTHELOWCURRENTWIRING#!.WIRING
SHOULDBEKEPTAWAYFROMTHEHIGHCURRENTCABLESANDCROSSITATRIGHTANGLES
WHENNECESSARY
!LLOTHERLOWCURRENTWIRING
4HEREMAININGLOWCURRENTWIRINGSHOULDBERUNACCORDINGTOSTANDARDPRACTICES
2UNNINGLOWCURRENTWIRINGPARALLELTOTHEHIGHCURRENTWIRINGSHOULDALWAYS
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 $RIVER 'ENERICDRIVERCAN !UTOMATE?07- 3W?
   ALSOBEUSEDASADIGITAL 0UT?07- 07-
   INPUT(ASLOWFREQUENCY  07-?/UTPUT
   07-CAPABILITIESANDA 
   SLIGHTLYHIGHERCURRENT
   RATING4YPICALLYUSEDFOR
  ELECTROMAGNETICBRAKE
 $RIVER 'ENERICDRIVERCAN !UTOMATE?07- 3W?
   ALSOBEUSEDASADIGITAL 0UT?07- 07-
   INPUT(ASLOWFREQUENCY 3ET?)NTERLOCK 07-?/UTPUT
   07-CAPABILITIES #LEAR?)NTERLOCK )NTERLOCK?3TATE
  4
YPICALLYUSEDFORMAIN  -AIN?3TATE
   CONTACTOR
 )/'ROUND )NPUTANDOUTPUTGROUND 
   REFERENCE
 3WITCH #ANBEUSEDASGENERIC  3W?
  !NALOG SWITCHINPUTORAS  !NALOG?)NPUT
   GENERICANALOGINPUT  -OTOR?4EMPERATURE
  4
YPICALLYUSEDASTHE
   MOTORTEMPERATURE
   ANALOGINPUT 
 3WITCH 'ENERICSWITCHINPUT  3W?
  4
YPICALLYUSEDASTHE
   INTERLOCKSWITCH
 3WITCH 'ENERICSWITCHINPUT  3W?
 3WITCH 'ENERICSWITCHINPUT  3W?

#URTIS-ANUAL/3 
 3WITCH 'ENERICSWITCHINPUT  3W?
 #OIL2ETURN 4HISISTHECOILRETURNPIN
   AT"POTENTIALFORALL
   THECONTACTORCOILS
 3WITCH$.# )NTHETHISIS  3W?
   GENERICSWITCHINPUT
   )NTHEAND
   $O.OT#ONNECT
 4HROTTLE0OT(IGH 0OTHIGHCONNECTIONFOR
  A
WIRETHROTTLEPOT
 4HROTTLE0OT7IPER 0OTWIPERCONNECTIONFOR 3ETUP?0OT 4HROTTLE?0OT
  THETHROTTLEPOT 3ETUP?0OT?&AULTS 4HROTTLE?0OT?/UTPUT
 0OT7IPER 0OTWIPERCONNECTIONFOR 3ETUP?0OT "RAKE?0OT
   THEBRAKEPOT 3ETUP?0OT?&AULTS "RAKE?0OT?/UTPUT
 0OT,OW #OMMONPOTLOW  0OT?,OW?/UTPUT
   CONNECTIONFORTHETHROTTLE 
   ANDBRAKEPOTS
 $IGITAL/UT !NOPENCOLLECTORDIGITAL 3ET?$IG/UT 3W?
   OUTPUT#ANALSOBEUSED #LEAR?$IG/UT $IG/UT
   ASADIGITALINPUT  $IG?/UTPUT
 $IGITAL/UT !NOPENCOLLECTORDIGITAL 3ET?$IG/UT 3W?
   OUTPUT#ANALSOBEUSED #LEAR?$IG/UT $IG/UT
   ASADIGITALINPUT  $IG?/UTPUT
 #!.4ERM( (IGHCONNECTIONFORTHE 
   #!.TERMINATIONJUMPER 
 3WITCH 'ENERICSWITCHINPUT  3W?
  4
YPICALLYUSEDASTHE
  &
ORWARDSWITCH
 #!.( #!.BUSHIGH 3ETUP?#!.
    3ETUP?-AILBOX
    3END?-AILBOX
    ETC
 3WITCH #ANBEUSEDASGENERIC  3W?
 !NALOG SWITCHINPUTORAS  !NALOG?)NPUT 
   GENERICANALOGINPUT
  4
YPICALLYUSEDFOR
   EMERGENCYREVERSESWITCH
   IFAPPLICABLE 
 6/UT 5NREGULATEDLOWPOWER  %XT?3UPPLY?#URRENT
   6OUTPUT 
 6/UT 2EGULATEDLOWPOWER  ?6OLTS?/UTPUT
  6OUTPUT  %XT?3UPPLY?#URRENT
  
 0OT(IGH 0OTHIGHCONNECTIONFOR
  A
WIREBRAKEPOT

).34!,,!4)/.7)2).',OW#URRENT#ONNECTIONS
4ABLE ,OW#URRENT#ONNECTIONSCONTD
    2%,!4%$6#,
0)..!-%$%3#2)04)/.&5.#4)/.3  2%&%2%.#%3

#URTIS-ANUAL/3  
).34!,,!4)/.7)2).',OW#URRENT#ONNECTIONS
4ABLE ,OW#URRENT#ONNECTIONSCONTD
    2%,!4%$6#,
0)..!-%$%3#2)04)/.&5.#4)/.3  2%&%2%.#%3
 3ERIAL48 3ERIALTRANSMITLINEFOR 3ETUP?3ERIAL
   DISPLAYORmASHUPDATE

 3ERIAL28 3ERIALRECEIVELINEFOR 3ETUP?3ERIAL
   mASHUPDATE

 !NALOG/UTPUT ,OWPOWERLOWFREQUENCY !UTOMATE?07- 07-
   n6ANALOGOUTPUT 0UT?07- !NALOG?/UTPUT

 %NCODER! 1UADRATUREENCODER  -OTOR?20-
   INPUTPHASE!  -OTORSPEED!

 %NCODER" 1UADRATUREENCODER  -OTOR?20-
   INPUTPHASE"  -OTORSPEED"
 3WITCH 'ENERICSWITCHINPUT  3W?
  4
YPICALLYUSEDASTHE
  2E
VERSESWITCH

 #!.4ERM, ,OWCONNECTIONFORTHE
   #!.BUSTERMINATION
   JUMPER
 #!., #!.BUSLOW 3ETUP?#!.
    3ETUP?-AILBOX
    3END?-AILBOX
    ETC
0INNOTCONNECTEDONCONTROLLERS

#URTIS-ANUAL/3 
&IG "ASICWIRINGDIAGRAM#URTISMOTORCONTROLLER
).34!,,!4)/.7)2).' 3TANDARD7IRING$IAGRAM
#/.42/,,%27)2).'"!3)##/.&)'52!4)/.
!BASICWIRINGDIAGRAMISSHOWNIN&IGURE4HROTTLEANDBRAKEARESHOWNIN
THEDIAGRAMASWIREPOTENTIOMETERSOTHERTYPESOFTHROTTLEANDBRAKEINPUTS
AREEASILYACCOMMODATEDANDAREDISCUSSED IN THEFOLLOWINGTHROTTLEWIRING
SECTION
4HEMAINCONTACTORCOILMUSTBEWIREDDIRECTLYTOTHECONTROLLERASSHOWN
IN&IGURETOMEET%%#SAFETYREQUIREMENTS4HECONTROLLERCANBEPROGRAMMED

#URTIS-ANUAL/3  
).34!,,!4)/.7)2).' 4HROTTLE7IRING
TOCHECKFORWELDEDORMISSINGCONTACTORFAULTSANDUSESTHEMAINCONTACTOR
COILDRIVEROUTPUTTOREMOVEPOWERFROMTHECONTROLLERANDMOTORINTHEEVENT
OFVARIOUSOTHERFAULTS)FTHEMAINCONTACTORCOILISNOTWIREDTO0INOF
THEPINCONNECTORASSHOWNTHECONTROLLERWILLNOTBEABLETOOPENTHE
MAINCONTACTORINSERIOUSFAULTCONDITIONSANDTHESYSTEMWILLTHEREFORE
NOTMEET%%#SAFETYREQUIREMENTS
.OTETHATTHEBASICWIRINGDIAGRAMISDESIGNEDFORGENERICAPPLICATIONS
ANDMAYNOTFULLYMEETTHEREQUIREMENTSOFYOURSYSTEM4HESECONTROLLERSHAVE
VERYmEXIBLE)/ANDWIRINGCONlGURATIONSYOUMAYWISHTOCONTACTYOURLOCAL
#URTISREPRESENTATIVETODISCUSSYOURPARTICULARAPPLICATION
37)4#().0547)2).'
4HEFOLLOWINGINPUTSAREDEDICATEDTOSPECIlCFUNCTIONSWHENTHEPARAMETER
SETTINGSAREASSHOWN
3WITCH %MERGENCY2EVERSEINPUTIFTHE%-2%NABLE/N
AND%-24YPESEEPAGE
3WITCH )NTERLOCKINPUTIF)NTERLOCK4YPESEEPAGE
3WITCH ,IFTINPUTDEPENDSON6#,PROGRAM
3WITCH ,OWERINPUTDEPENDSON6#,PROGRAM
3WITCH &ORWARDINPUTIF4HROTTLE4YPEnSEEPAGE
3WITCH 2EVERSEINPUTIF4HROTTLE4YPEnSEEPAGE
4(2/44,%7)2).'
)NTHISMANUALTHETERMTHROTTLEISUSEDINTWOSENSESASANOTHERNAMEFORTHE
DRIVETHROTTLEANDASAGENERICTERMCOVERINGBOTHTHEDRIVETHROTTLEANDTHE
BRAKETHROTTLE7IRINGISTHESAMEWHETHERTHETHROTTLEINQUESTIONISUSEDFOR
BRAKINGORFORACCELERATION
6ARIOUSTHROTTLESCANBEUSEDWITHTHECONTROLLER4HEY
ARECHARACTERIZEDASONEOFlVETYPESINTHEPROGRAMMINGMENUOFTHE
PROGRAMMER
4YPE WIREKΩnPOTENTIOMETERS
4YPE SINGLEENDEDn6THROTTLESCURRENTSOURCETHROTTLES
WIREPOTENTIOMETERSANDELECTRONICTHROTTLES
4YPE WIREnKΩPOTENTIOMETERS
4YPE WIGWAGn6THROTTLESANDWIREPOTENTIOMETERS
4YPE 6#,INPUT6#,?4HROTTLEOR6#,?"RAKE
4HETWOTHROTTLEINPUTS DRIVE THROTTLE AND BRAKE THROTTLEAREPROGRAMMED
INDEPENDENTLY

#URTIS-ANUAL/3 
&OR POTENTIOMETERS THE CONTROLLER PROVIDES COMPLETE THROTTLE FAULT
PROTECTIONTHATMEETSALLAPPLICABLE%%#REGULATIONS&ORVOLTAGETHROTTLESTHE
CONTROLLERPROTECTSAGAINSTOUTOFRANGEWIPERVALUESBUTDOESNOTDETECTWIRING
FAULTSITISTHEREFORETHERESPONSIBILITYOFTHE/%-TOPROVIDEFULLTHROTTLEFAULT
PROTECTIONINVEHICLESUSINGVOLTAGETHROTTLES
4HROTTLETYPESnUSETHEFORWARDANDREVERSEINPUTSSWITCHESANDIN
ADDITIONTOTHETHROTTLEPOTINPUTTODElNETHETHROTTLECOMMANDSEE&IGURE
PAGE4HROTTLETYPESANDDONOTUSETHEFORWARDANDREVERSEINPUTS
7IRINGFORTHEMOSTCOMMONTHROTTLESISDESCRIBEDINTHEFOLLOWINGTEXT
ANDSHOWNINTHEACCOMPANYINGILLUSTRATIONS)FATHROTTLEYOUAREPLANNINGTO
USEISNOTCOVEREDCONTACTTHE#URTISOFlCENEARESTYOU
4HROTTLE4YPE
&ORTHESEWIRERESISTIVEPOTENTIOMETERSSHOWNIN&IGUREFULLTHROTTLEREQUEST
CORRESPONDSTOΩMEASUREDBETWEENTHEPOTWIPERPINANDTHE0OT,OWPIN
).34!,,!4)/.7)2).' 4HROTTLE7IRING
&IG 7IRINGFOR4YPE
THROTTLES
"ROKENWIREPROTECTIONISPROVIDEDBYTHECONTROLLERSENSINGTHECURRENTmOW
FROMTHEPOTWIPERINPUTPINORTHROUGHTHEPOTENTIOMETERANDINTO
0OT,OWPIN)FTHE0OT,OWINPUTCURRENTFALLSBELOWM!ATHROTTLE
FAULTISGENERATEDANDTHETHROTTLEREQUESTISZEROED.OTE0OT,OWPIN
MUSTNOTBETIEDTOGROUND"
4HROTTLE4YPE
7ITHTHESETHROTTLESTHECONTROLLERLOOKSFORAVOLTAGESIGNALATTHEWIPERINPUT
:EROTHROTTLEREQUESTCORRESPONDSTO6ANDFULLTHROTTLEREQUESTTO6!VARIETY
OFDEVICESCANBEUSEDWITHTHISTHROTTLEINPUTTYPEINCLUDINGVOLTAGESOURCES
CURRENTSOURCESWIREPOTSANDELECTRONICTHROTTLES4HEWIRINGFOREACHIS
SLIGHTLYDIFFERENTASSHOWNIN&IGUREANDTHEYHAVEVARYINGLEVELSOFTHROTTLE
FAULTPROTECTION
7HENAVOLTAGESOURCEISUSEDASATHROTTLEITISTHERESPONSIBILITYOFTHE
/%-TOPROVIDEAPPROPRIATETHROTTLEFAULTDETECTION&ORGROUNDREFERENCED
n6THROTTLESTHECONTROLLERWILLDETECTOPENBREAKSINTHEWIPERINPUTBUT
CANNOTPROVIDEFULLTHROTTLEFAULTPROTECTION
4OUSEACURRENTSOURCEASATHROTTLEARESISTORMUSTBEADDEDTOTHECIRCUIT
TOCONVERTTHECURRENTSOURCEVALUETOAVOLTAGETHERESISTORSHOULDBESIZEDTO
PROVIDEAn6SIGNALVARIATIONOVERTHEFULLCURRENTRANGE)TISTHERESPONSIBIL
ITYOFTHE/%-TOPROVIDEAPPROPRIATETHROTTLEFAULTDETECTION

#URTIS-ANUAL/3  
).34!,,!4)/.7)2).' 4HROTTLE7IRING
&IG 7IRINGFOR4YPE
THROTTLES
 #URTIS%4888%LECTRONIC4HROTTLE
 6OLTAGE3OURCE
 #URRENT3OURCE
 WIRE0OTENTIOMETER
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#URTIS-ANUAL/3 
7HENAWIREPOTENTIOMETERISUSEDTHECONTROLLERPROVIDESFULLFAULT
PROTECTIONINACCORDANCEWITH%%#REQUIREMENTS4HEPOTISUSEDINITSVOLTAGE
DIVIDERMODEWITHTHECONTROLLERPROVIDINGTHEVOLTAGESOURCEANDRETURN0OT
(IGHPROVIDESACURRENTLIMITED6SOURCETOTHEPOTAND0OT,OWPROVIDES
THERETURNPATH4HISISTHETHROTTLESHOWNINTHEBASICWIRINGDIAGRAM&IGURE
FORTHEDRIVETHROTTLEANDFORTHEBRAKETHROTTLE
4HE%4888ELECTRONICTHROTTLEISTYPICALLYUSEDONLYASADRIVETHROTTLE
4HE%4888CONTAINSNOBUILTINFAULTDETECTIONANDTHECONTROLLERWILLDETECT
ONLYOPENWIPERFAULTS)TISTHERESPONSIBILITYOFTHE/%-TOPROVIDEANYAD
DITIONALTHROTTLEFAULTDETECTIONNECESSARY
4HROTTLE4YPE
&ORTHESEWIRERESISTIVEPOTENTIOMETERSSHOWNIN&IGUREFULLTHROTTLEREQUEST
CORRESPONDSTOKΩMEASUREDBETWEENTHEPOTWIPERPINANDTHE0OT,OWPIN
).34!,,!4)/.7)2).' 4HROTTLE7IRING
"ROKENWIREPROTECTIONISPROVIDEDBYTHECONTROLLERSENSINGTHECURRENTmOW
FROMTHEWIPERINPUTPINORTHROUGHTHEPOTENTIOMETERANDINTO0OT
,OWPIN)FTHE0OT,OWINPUTCURRENTFALLSBELOWM!ATHROTTLE
FAULTISGENERATEDANDTHETHROTTLEREQUESTISZEROED.OTE0OT,OWPIN
MUSTNOTBETIEDTOGROUND"
4HROTTLE4YPE
4YPETHROTTLESOPERATEINWIGWAGSTYLE.OSIGNALSTOTHECONTROLLERSFORWARD
ANDREVERSEINPUTSAREREQUIREDTHEDIRECTIONISDETERMINEDBYTHEWIPERINPUT
VALUE/NLYn6VOLTAGESOURCESANDWIREPOTENTIOMETERSCANBEUSEDAS
4YPETHROTTLES4HECONTROLLERINTERFACEFOR4YPETHROTTLESISTHESAMEASFOR
4YPETHROTTLESSEE&IGURE4HENEUTRALPOINTWILLBEWITHTHEWIPERAT
6MEASUREDBETWEENPOTWIPERINPUTPINAND)/GROUNDRETURNPIN
4HECONTROLLERWILLPROVIDEINCREASINGFORWARDSPEEDASTHEWIPERINPUTVALUEIS
INCREASEDANDINCREASINGREVERSESPEEDASTHEWIPERINPUTVALUEISDECREASED
7HENAWIREPOTISUSEDTHECONTROLLERPROVIDESFULLFAULTPROTECTION
7HENAVOLTAGETHROTTLEISUSEDTHECONTROLLERWILLDETECTOPENBREAKSINTHE
WIPERINPUTBUTCANNOTPROVIDEFULLTHROTTLEFAULTPROTECTION

&IG 7IRINGFOR4YPE
THROTTLES

#URTIS-ANUAL/3  
).34!,,!4)/.7)2).' 4HROTTLE7IRING
4HROTTLE4YPE
4HROTTLE4YPEPROVIDESADIFFERENTWAYOFSENDINGTHETHROTTLECOMMANDTO
THECONTROLLER4HISTHROTTLETYPEUSES6#,TODElNETHETHROTTLESIGNALTHAT
WILLBEhINPUTvINTOTHETHROTTLESIGNAL CHAIN SEE&IGUREPAGE4HIS
THROTTLETYPECANBEUSEDFOREITHERTHEDRIVETHROTTLEORTHEBRAKETHROTTLEBY
USINGTHE6#,VARIABLES6#,?4HROTTLEAND6#,?"RAKE(OWTHE6#,PRO
GRAMISWRITTENWILLDETERMINETHESOURCEOFTHETHROTTLESIGNALMAKINGTHIS
AVERYmEXIBLETHROTTLEINPUTMETHOD6#,CANBEWRITTENTOUSETHETHROTTLE
POTINPUTSSWITCHINPUTSOR#!.COMMUNICATIONMESSAGESASTHESOURCEOF
THETHROTTLESIGNALS)FYOUHAVEQUESTIONSREGARDINGTHISTHROTTLETYPECONTACT
THE#URTISOFlCENEARESTYOU
3ETTINGTHE4HROTTLE4YPETO4YPEALSOALLOWSTHETHROTTLEANDBRAKE
POTINPUTSTOBEREDElNEDBYA6#,PROGRAMFORUSESOTHERTHANTHROTTLEOR
BRAKEINPUT4HEVARIABLENAMESTHAT6#,CANUSETOINTERFACEWITHTHESETWO
INPUTS ARE4HROTTLE?0OT?/UTPUT SEE PAGE  AND "RAKE?0OT?/UTPUT SEE
PAGE
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